SAFARI

GEAR BOX G-76

ASSEMBLY OF GEAR BOX

Place shifter fork assembly 1st/2nd and Reverse/5th

over main shaft assembly at its proper place, keeping

notches towards coupling flanges side.

Place shifter fork 3rd/4th (123) alone without shaft at

its place over main shaft sleeve such that its collar is

facing outwards.

Keep counter shaft assembly aligned with main shaft.

Insert two Nos. ball (138a) in holes of shifter shaft

bore in housing. Use grease for keeping them in

position.

Fig. 94

Hold and place main shaft assembly along with

counter shaft assembly and shifter fork assembly in

position in the housing - Rear.

Fig. 95

While inserting shifter shafts in the housing,

ensure

that interlocking balls are not displaced.

Fit interlock pin - 12.8 mm length (146) in shifter shaft

3rd/4th (118). Insert shaft through the shifter fork.

Align shaft with hole of fork and then press spiral pin

(124).

Fig. 96

Place 3 Nos. ball - 8 mm dia. (138) and detent spring

in holes of housing. Detent spring (142) is to lock

1st/2nd & 3rd/4th shifter shafts where as short and

stiff detent spring (141) is to be used for Reverse/5th

shifter shaft.

Fig. 97

Fix gasket (139) to detent cover (140) and tighten

hex. screws (144) along with spr. washer (145). Fit

rollers 4 Nos. (113) over pins (114) of selector shaft

(112).

Fig. 97

Fig. 96

Fig. 95

Fig. 94

Sectional View

Inter lock

balls

138

138a