GEAR BOX 35 NOTE If replacement is required, always replace the synchro sleeve and hub as a unit. Inspect inside of synchro cone for wear. Inspect the synchro cone teeth. SUB ASSEMBLY OF ENGAGING GEARS 01 Engaging Gear 02 Shifter Sleeve 03 Interlocking ball and cage assembly Identify all the gears and needle bearing cages. The gears are to be assembled in pairs of 1st / 2nd, 3rd/ 4th and reverse / 5th. Keep gear such that dog teeth are facing upwards. Fit proper synchro cone. Fit proper engaging gear over synchro cone, fit other pair of gears. NOTE While assembling 1st /2nd engaging gear the single groove on the sleeve should be towards 2nd gear side. Locate strut 3 nos. in slot of engaging gear with help of grease. While assembling 3rd / 4th gear, the shifter sleeve without groove to be fitted with broader side towards 3rd gear. In Reverse/5th gear assembly, fit double groove side of shifter sleeve towards reverse gear. ASSEMBLY 1. Hold the main shaft vertically keeping the coupling flange end upwards. 2. Slide reverse gear subassembly on main shaft along with needle roller cage and engaging gear keeping engaging gear upwards.
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