Steps to be followed:
- Once the gearbox as been separated from the engine.
- Overhaul of Synchromesh Gearbox
- GEARBOX—SYNCHROMESH
- GEARBOX OIL PUMP
- Remove and refit
Removing
1. Remove the speedometer drive housing. 37.25.09.
2. Withdraw the oil pump complete.
3. Withdraw the joint washer.
4. Retain the shim for the layshaft bearing.
Refitting
5. Prime the pump with clean gearbox oil.
6. Smear a new joint washer with Hylomar PL 32/N jointing compound, Rover Part No. 5342~.
7. Reverse 1 to 6 ensuring that the oil pump drive is aligned.
GEARBOX MAIN CASE
Removing
1. Remove the gearbox. 37.20.01.
2. Drain the gearbox oil.
3. Remove the speedometer drive housing. 37.25.09.
4. Remove the gearbox oil pump. 37.12.34.
5. Remove the selector shafts. 37.1 6.31.
6. Remove the bolt and retaining plate from the reverse gear idler shaft.
7. Withdraw the shaft.
8. Remove the fixings securing the bell housing to the gearbox main case.
9. Position the gearbox upright on the bell housing.
10.Push the reverse gear to one side clear of mainshaft first gear.
11.Withdraw the gearbox main case.
12.withdraw the bell housing joint washer.
Refitting
13. Smear the joint face of the bell housing and the gearbox main case Hylomar jointing compound.
14. Place a new joint washer in position on the bell housing.
15. Place the reverse gear.in position in the main case.The lead on the gear teeth must be towards the front of the gearbox.
16. Lower the gearbox main case on to the bell housing 12 & 14 while keeping the reverse gear pushed to one side.
17. Locate the main case to the bell housing with two bolts, but do not fit the nuts at this stage.
18. Fit the reverse idler shaft.
19. Fit the retaining plate, engaging the slot in the reverse IRC 27 /idle shaft and secure with a bolt only (no washer).Torque: 1,0 kgf.m (8 lbfft).
20. Fit the main case to bell housing fixings. Torque: 7,0 kgf.m (50 lbfft).
21. Reverse I to 5.
GEAR CHANGE SELECTORS
Removing
1. Remove the gearbox assembly.
2. Drain the gearbox oil.
3. Remove the speedometer drive housing.
4. Remove the gearbox oil pump.
5. Remove the gearchange shaft housing.
6. Remove the reverse light switch complete with its mounting bracket.
7. Remove the seal retaining plates.
8. Remove the retaJning plate, joint washer and detent springs.
9. Withdraw the rubber plug.
10. Pack grease into the three selector spring location holes to retain the three bails.
11. Remove the gearbox top cover complete with the selector balls held by the grease.
12. Remove the balls and grease from the detent spring location holes.
13. Withdraw the interlock plungers.
14. Screw a slave bolt (10 UNF) into the reverse selector guide rod and withdraw the rod.
15. Lift out the reverse gear selector fork and shaft.
16. Lift out the two remaining selector forks and shafts together, taking care that the shoes fitted in each fork do not fall into the gearbox.
17. If required, remove the forks and seals from the selector shafts.
Refitting
18. If the forks and seals have been removed, refit them with the smaller diameter of the seals towards the forks.
19. Fit the first/second and third/fourth forks and shaft assemblies. Ensure that the shoes locate their respective synchromesh unit.
20. Fit the reverse fork and shaft assembly, locating the reverse gear.
21. Fit the reverse selector guide rod.
22. Move the seals along the selector shafts to clear their grooves.
23. Fit the interlock plungers.
CAUTION:
Do not damage the bell housing gasket when fitting and removing the gearbox top cover.