gearbox and overdrive - bristoloda.org · the gearbox at joint 'a' which will leave the...

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Gearbox and Overdrive

List o f Contents

SPARES ILLUST RATIONS.

Type 404, Remote Control Gearbox Cover and Casing

Type 404 Clutch Casing, Gearbol< Extension and Speedometer Drive

Type 404 Mains haft _ Gearbox

Type 405 Clutch Casing and Overdrive Unit

Type 405 Mainshaft _ Gea,-box

Type 405 Sel ec tor Shaft and Layshaft. ..

GEAR130X eWeR7 - TYPE 404

GEARBOX eWeR!! - TYPE 405

DESCRIPTION ...

REPLACEMENTS

REMOVING AND REFITTING ruE GEARBOX TO TI-iE CAR

SERVICING 11-IE GEARBOX . "

DISMANTLING niB GEARBOX

La yshaft ".

Main Driving Shaft ..

Drive Shaft

Frecwhc"l. ..

Reverse Se lector Mechanism

Gearbox E xtension ...

Rem ote Control Gear Change

INSPECTION OF PARTS PRIOR TO RE_ASSeMBLY ...

RE_ASSEMBLING ruE GEARBOX ...

Layshaft ...

Main DriVIng Shaft .. .

Freewheel ...

DrIve Shart

Checlung Drive Shaft and Main DrIVIng Shaft

Reverse Selector Mechan tsm

F INA L ASS EMBLY OF GEA RBOX ...

Clutch Casing ...

Gearbo. E.tens ; OO1 ...

OVERDRIVE

Overdrive Contac t Switch and Reverse S WlIc h ...

Sect ional Vu:w."

Pans Index

Page

2

3

• 5

6

2

8 &. 10

9 & 11

13

13

13

13& .. .. .. 15

15& " 16

" " "

17 6. 18

20 &. 21

21

21 &. 22

" " 23

23

23

,. ,.

,. 25

27 - 31

List of Contents

OVERDRIVE ICont,)

DO:llcription

Ca ,'e and Lubricllt!on

Checking Cea ,'box and Overdrive Oil Level

Draining and Refi ll ing Cearbox and Overdrive,

Pitti ng a Replacement Ove,·drive .. ,

Diagnosis and Ro:c llfic:uion of Faults ...

RemOVI ng and Refi tting the Overdrive Unit

St ripp ing and Rebuddin8 the Overdrive

Page

33

33

33

33 &. 34

34

34 _ 39

39

39 _ 43

•

•

• Gearbox and Overdrive

•

-.-

Po .. No. ",m

, .,"" , 1Gi.S8S,n , ~ . 4S4540 3

• t:"l 4OS/L S

- , :'I 454510 1

N 455120 • :'<I 454770 , 1'1 45~ 560 " N.45WiO » N.4545;0 " N. 45USO

" N.4538l10 .. N. 455110 )S

N.70411B " 1'1 4 S~070 " N.453920 " N,4S4620 " 1",454030 20 1" 454530 " N. ~ S3?90 " l\ 4545.;0 " :".45-1.520 ,. N 45S3Q(l 1S No 015114 TO " N 45Zl.>O -

N 4S!>SSO

, """" K 4ill70 -

'"'''''' " N 452270 "

TYPE 404 . REMOTE CONTROL

O"c';p' ;.,n No.oif ~rcar

n:..... (\lo'l 1 J(ft d ••• Spr . ng W ... l",r " " .. • Spl.l P ,n l/16 ft d l. " - 1""11

, 5f l6' IN'. Sloltf!d Nul , 5{l6 ft Plain W .. h~. )

Selector t' , nger , Ib:I"", Sh.ft tiHt , .. , , Go .. o..n8" ..... er , B .... "" c..,

, Sp.,n/j: , fio,u'RU'Il l'ln .. , Cltd II' , D..u f",du:.ler , aur Le • .,. Knob , Pope. "as)",' )

Q,.". PIu., , Stoo - Ge .. l".e. L"""tion )

Stud - Turr~t eo .... , """,,,te Ge • • Q"lnge Turret , "'-, )

Jo,n t 'Nu"', 1 PO", )

C..rbox c...~r )AlI 40. Car. )

JT)'P<! 405 c. •• , I;,:-ctar Iloll tillt l ector n.ll u"t - Rove • ..,h", to o.u.i . I

(""' rI""d '11') , .",

r...r-box c..ver )Type 405 ~rs

Sel...,to. a.ll u,>t ) u"ed on .nd

Selector Bo il u"t - Il.o. .... ..,)(, ... o...u ,. (M.rk<! n' , , 4137

Set.., ...... - !\e.er ... Plunger Sp.II'8 - !\o.er..., PI...ger

, . -.'!~ , ~'-

,

<lH -.;;... ---- --

.:cJ - , .

. ", ." , .-

lf

)

) , , )

)

GEARBOX COVt:R ,"0 CASING.

Pa" No. I . ~ .. No. 011 , Oucrip' i.,n p~ru r

''''''''' " Re .... .., Vl~. ,

~ . 4 5 1 880 30 Oi l f>1I .. . VI"6 , T ~po 404 , f1f>.52O " Ifu",". , Cm , N 452SSO - O' ... d ..... c..nlacl S.ncb - ,

T". "" '-•• 5ISSOO-45 ,

Cm ,

", .... - $h,. 'Jut...r , .... eqd .

N. 4511ZO 32 "'" , • N. 4S0600 33 lA .tone .. 'os",". - So:I~ .... r Pin" ,

N. 450570 ,. DlItOllC<' Tub~ " Sel"" ..... Pllt" ,

N.4SOS'il0 " Tabw .. ",". ,

fN . 104/1. 36 Nut )(- 1&' , N.45309O 31 Stud _ 51>0"- _ Golrbox c.. .. ". 6

N. 4S3<l60 38 St.ud - 1..:.", " Gu.box Cc.". , N. 455340 " Stud - I..:.ng - Cl utch Casing • N. 45536O .. Stud _ snort _ CLutch Cas i ng , N. 455310 "

Sl.ud _ $hort " ~'.xt"n.;on BrlOCket , N, 455350 " Stud - l"ng - En .. n.ion Br lOCket 3

N.4SS380 " StuJ _ Short _ Extension Uncket ,

N.455260 " Stud - !.on! _ F...t~n, i on B.IOCket ,

fl*\.J79/t6 " "'~, ,

N 452730 " Ge.rbo~ Casing - OfCaid~ , . )

N.45274.0 " C..rbox Cuing - Nearside 1 P.tred )

I N. 452S40 .. PO", , ms.SIT .. lI'u",",

, N.4Sl110 " Lout'ng Uo l t , rn. 105/ 160 " ",. , Ht IOSf 4311 " .".

, I m . lOS/ 490 " .". ,

m . losf 4ill " &,. ,

m . losf 4Sl1 " "" ,

fN 105fL

" NIIl S/ l6r' 1&" 10

!Gi. 58:.1E 51 Sprins W • • her 10

N.45I080 " ..... "" 3

11'1 ·455710 - .......... r _ to ~ uaed wnh t"" n-d Nut 3

• ,

•

TYPE 4 0 4 CLUTCH CAS ING GEARBOX EXTENS I ON AND S PEEOOMnn~ DRIVE .

P. " No. he m Ors<:,lpo.;otI No. 011

Po" No. he m [)<'s<:';po.;Oft No. olI

f-~CO , pe, e.,

N ~2760 I Clut~h c.s ontS I N.4S1890

" Co.er (Speed" In 1Iedn. Sirftfd I

N. 450010 , .Io,ot Washer (Geor Ilo~ Frond I ~ . 4S4230 17 "'- I "5. lOS/ lOO , Seu~.-- 5/ 16 ~!SI' I ""~l lSO

" Gelr (Spooll!do> lu lledn . Iki ... n) I

"I. 106/ 2:!D , Bo l t 3/ S" RSl , N . ~ 2600

" '"' I

~ . IO~/l. , Nut S/ 16" 1l')tto" • ~ . 450400 " Thrust P.d ( ~Dri.,,) , tGS. seS/E ,

Spr .. " ' · .. he r S!16 ~ • !'I . ~1 J1 0 " Gear 00. £.rcteu i on ~il I tU. IOS/ 21D 7 Bolt 5/ 16 " (SI' • ~ . ~ I I90 " Jo,nt Wulrer (Gear 00. Rear> , "11'5 . 105/ 1"11) • Seuc rew 5/16" IN' , !'I 450960

" Joint Wuher ( fad Phte) I

Jt:i106/l. , Nut 3/ S"lJ5'/I' (St.ute r l , IGS S8SJ1) " SprintS Wosher • • .oGS. seS/f" iO Sp r one: "uher 3/8" (Stul"d , N.-I50890 " &Id Plo te I

N t j 17S(J 11 Inlpec tion Port Conr I t"S. I04/70 " Set.crew I( " IN-" • tGS 58510 12 Spro "g " .. I,,,r

, N. 31 1290 27 Rur ~ting Blod: , "IIS. 1OS/ 3Il 11 So!Ucr"" 1(" (9' , lID. lOS/ SI) " fult S! 16 " 1.1'51-' • N.451010 19 lYIion (~ Dr; .e) , 1GS. 585! E " !c;,ring , 'uhe r 5/ 16" • N. ' 54240 15 Goor (Speedo 2nd fledn. Dri.~n) I FN .1OS/I . '" Nut Sl16" •

o o .. o

co o

0= •

P ~ rt No. ['em

N. 453660 1

N. 45081O , N. 452390 3 N.4S3670 , r., ~ S2720 5 N,45ISS0 6 N. 453650 7 N. 453,"0 • N. 45l68O , N. 453210 10

N.455SOO n N. 45361O 12 N. 453020 13 N.453030

" N. 453600 15 N. 45381O_7 16 N.453810 _8 · N, 453570 !7 N,45093O IS N.4Srmo " .

" N. 453800_7 · N. 45:>8oo_8 · :oi 453800 _9 · N453800_10 · N 45:>800 II

N,453800· 12 · N.453000 _13 · N. 4538oo-H

N. 453OOO _15

N. 453800 _16 · N 453800 17 N. 453800 18 N 45242(1

" 22

N.4S3800_1 · N,453800·2

I : :oi 453800 _3

TYPE 404 MAINSHAFT GEARBOX

Desctiption

!learing Retain>ng Nut T&h "" s h~r _ Driv~ Shaft

I llearing - Front Drive st..ft Distance Piece _ Drive Shaft

Circlil' Ilearing _ Drive st. . ft

Ihstance Washer - Drive Shaft

Gm Drive Shaft

Woodruff ""y Synchroni ser Blocker Ring

Slidi"" Ifub 3r<l and 4th

!\eu ining Ring Shifting Plat e

nub Fixed 3rd and 4th

1hr""t W •• her . 100 thick Thrust .... her . 000 thick

nub Free 3ed Gear

Lock,,~t - Mo i Mh.ft Front

T..h"uhe r Thru~t \I'uh~r _ Front _ c.,ntr~ Mainshaft

Il.,.ring

Thr "" ~ Woo""r 19S thi ck Thrust W ... he r . 19Q thick

ThrustWuhH . 185 thick

Thrust. W ... he r · HlO thick Thrus t W .. he r . 175 thick

Thrust Washe r . 1701 thick

Thr\l3t ''''""her · 165 thick lbrus t Washer . 160 t.h i ck

'Thrust 'II'~ s h e r · ISS thick

'Thrust Wuher · ISO thick Thru5t Waaher 145 t hick

11u-UlIt ''''a.her 140 tnick

Boating - Gentr. ",,"in Staft

Thr"M W .... her _ flear u,ntre MaiMhaft

Bearing 'Thrust ,,,rasher · 225 thick 'I'hru,t "/I'ashet . 22(1 thick

Thrust ...... her 215 th i ck

No. off petc. t

I

1

1

2 1

1

2 1

1 1

I

3 I , 6

I

I

· I

I

I , ·

· ·

· · ·

I , ·

·

P." No. l' ~m

N. 4S3OOO-4

NAS3800 _5 · N.4S3SOO-6 N. 4-'i 3800_ 7 N.453900-8 N.453800_9 · N.453800_)0

:oi,453800-11 ·

N.453540 " N. 4S3S50 " N.452840 25 N,453590 26 N.452900 27 N,452690 28 N.45282<1 '" N,452670 30

N. 450 63O " N.451260 32 N.451300 33

K. 451230 " N. 4512S0 35 N.453710 36 N. 4S 1630 37 N. 450 52(1 38 N. 453000 39

N.453360 ~

N. 452410 " N. 4S3380 " N.~SI910 " N. 453370

" N.4S322<1 " N. 4S1730 " N.450790 " N.451180 " N,450330/

" """" N.452620 50

N.480021 51 N.70 4112 " N. 451600 53 N.451610 S<

31 " 0 32

l3 c

De .• ctip<ion

Thrust W .. . her . 210 thick Thru. t WMher . "'5 thick lbrust Wa..her .wo thick

Thrust 'j" & ~ her . 195 thick

Thrust \I'uher '''' thick

Thru..t '''' asher 185 thick Thrust Washer . 180 thick Thrust Wad",r 175 thick

nub Free 2nd Gear

Sliding Ihob - Lot O1ld 2nd Thrust W".her Il,b fixed 1st and 2nd

Distance Washe r

1h,ust W.s her

Ge Rr - F re~ .. " ee l Mainshaft I n Fr~ ~ \lhee[ nu .. - Mainshaft I n

Spring - he""hM l Plunge r f reewheel

!\el le .. - Free" hee l fuller Retaining PI.t e

Hetaining Ring

Freewhee l Assembly

!lush Ileacing kcation Need l . fuller Bearing

~h i n Dri.ing Shaft L'n.it

Di s tanc e Pi ece

Needle full e r

Dis tance Pi ece

Ci.rclip - Main.haft

Distance Pi""" Woodruff Key

T.rr..ashe r

Nu~ !\e ~ aini ng ~"' in . haf t

Retaining RillS

Iklb , Re.eue , &. Speedo Lni .. Se l~c ti . e

As ... """,ly

Fle or ing flet a ini"g lung

Key

~anion Flange Tab ... h.,

Nut _ u.upling Retaining

I~~O I b ~o " "

40 42 43 44

CD" CD 0 (] Orn5

0 ~ 50

3

~@~ ii I MJI 49 52 ' 5]

4S 'O 45 =

39

No. off

P~tC " t

·

· · ·

· · 1 • I

I

I

I

I I

I

" 8

8 , I

1 1

I

I , "0

I

I

1

3

I I

I

I , I

I

I

I

•

TVPf 40 5 CLUTCIl CASING AND OVERDRIVE UN IT .

Pall Ne>. ' .m O" .~ ';pti"" No.cll po:, uJ" V." No. h e .. o...c"", ioft

No.off perc a,

N.4SS6JO , O ll\.(:h Cuing Unit. , f1(;S. S85/D n Spnng ""ashe. l( ~ di • . ,

lU . l~ n lD , Ibl t 5/ 16" "hi t. 2. 5/ 8" \Oflg • '!IS . 104/]) " SelllCre.,l.( " ~ il 3/ 1\" '-

, .oG:l, saS/E , Sp.;"" W .. her 5/]6" di • . a :-; .451S60 " fille r Plug

, IIN . IOS/ t. • NUL 5/ 16 H

.... hi t. . • mS.S20 '" Wu h" • • Fille!' Plug , '1111. lOS/riD S ful l5/l6 "'IIhit 21/8" long , N.45S170 "

Ilol l _ RUT F",s, ne ~ut\ting , u.., 00 ,

fill l OS/ lOO 6 Iblt 5/ 16" Whi t. UI" 10016 , N 455240 22 T.bwoo. loc . , a... .... ,

• MJ 106l m , Boil 3JS- 'llha "' · I""S , N <t5S160 " Meh lul i~ M.o:t.<one MO ... l i ng) 4001 to 4 1 8 ~

, ,lG<; . ~IF • ~rin8 ..... her 3/ 8 " .I ... 2 4O~1 -20 158 " Set.., re'lO • ~ .I 06!L , Nul 3/e" MIl t , · " 5/16" S,uep roo f '11" .. "". • N. 441000 " Goaer , N 455660 " Jloll , U ... 00 2

N.440990 " G..i ler - ~nling k! 'er , · " li .. dil. Plain Wuhe. ) 2 .

" No.6 I' K. SeT"" Type

, '", "" 5/ 16 " 10flg " N. 455670 '" 1);1 SIlield ) , 2

. " . "' Pl.in D,pper " .. he ' J6 N. 45569O ,.,

11 ... . ~ine ~tI"I! ) 0. ... . . 4 1115 2

1\ 4SOO l0 " JO.H - G...rt.o" - rroo.~ , N 455700 " I'cbo-.l ".shor ) ,

N 431190 " Jo. n~ _ G...rbox " .. , · "

7 / 1 6 ~ 11 S. F "t,, 1 id .. NuL ) ....... , N.46I7$O " Inspecu,,", P Q r ~ c..er , 1( 454400 " o.erdri.e lmi~ <: ~le\.e

,

, O .

. , "\'

" ~ ~~ I

~" , " : ~ :=:

--- ~ ;;

. ,

-

• =<) , .

. ,.

Part No. 1, ,, ..

N -\.53660 , 111.450810 , N. 45239O J ti 453670 , N.45272O , III 4SISSO , N.4$3650 , '11.453440 , III 453660

I l~ N.453210

'II.455SOO n N 453610

" N 453020 I " tUS303(l ,. N.453600

" N. 4S:lfIlO_7

" N.4SlS10_A -N. 453570 " N 4:.o<l:J.O " ~ 45092(1

" - 20

N 45.'lI'IOO _7

N 45l8OO ,6

~ 451ilOO Q

N 45l8OO 10

N 453800 11 'I 45J8())_12

~ 4Sl8OO·l l -N 4S3ftOO_14

N 45l8OO· 15 N 45liJ)O 16 N. 4-S38OO _ 11 -N 4531100·18

to 452420 " " N 453800 _1 -N 453800· Z -N 4.'.l8OO_ 3 -~ 453800_4 -N.453800 5 N 4 ~_6

.'U538OO· 7 -

TYPE 05 MA 1NSltAtI , - GEARBOX

I ~""rip<i"" No,otf

I'<"~.' Pan No. h ... o....,,,,,, ioo

lIu,"'4I l1cu ' '' " \ff Not , N 4 ~·8 - Thrl'S~ , ........ . .190 ~h l du ... !.~

Tobwa.t", • • IX •• " Sh.ft , 111 . 453800·9 - TI" 'lAt 11.".",,-, . ISS th, ew ..

llo:.u'''S f ront Or .. " Shdt , N. 4S3800 _IO - Thrldt Wuher 180 t hi"lu.,., .. D,Uan.,. 1'. """ . o,.ue Sh.o f t , N 453800· 11 - Thr .... t "11 .. "" . 17S thicJu.., ..

Co...:!>p , !'I . 45li4O " lIot. - Free · 2nd. Gea. 0.."l1li . Or i .uhdt & ),I", ... h.£t ,

N . 4S~ ,. S hdll'6 llW • 'at ..,d 2nd

O'.t...., ....... ""-, . Ori", Sbarl ,,"" N 452840 " ll' .... l ""nhe. Go • • - Or .. ., Shaft , N. 453S90

" lIub • • ' ixed lat and 2n.I .

1\- , ... Sbooh , ,.",.,

" Din.nce "'. ),e r Woodruff Key ,

N . 4 ~ " ThU8t . .. he.

Synchron i ..... Ill"""". 11, "11 J N.4!>2620 " Gur • fr ~.t..:" L • Mo. i nshd t lo t. Shd "lfI Ihob 3. d .ne! 4th , N . 4 ~670 30 .-._10 .... 1 I ~ ob • "'- iMhoft l&t.

l\o:hln,,'I!' Ru,!! , N.450630

" Spr inc - h ........... l SI"fu'lll' P I . l ~ , '11 451260 32 1'1 ",,«,,' - rr ......... el llub - Fi xed 3rd a"d 4~h , N.451300 33 l\ollu - f ruwhoel "Thru.st '/1",.., .... . 100 ~ hi <: k",, ~. ,

N, ~ 5 1 230 " !\oil e r 1"Io~ . ini"f!: Pi ne Tht\l$l W. $her .060 ~ h itk"e u N. 4S1250 35 llo=uin inc Ri,.. llulo _ ~ ' r u 3rd Gear , IU537\O 36 F.H ..... I Aalerrt.l y

Lo" k",, ~ - M.'Mhaft - front , N. 4S1830

" lIush - B..rins Locuio" Tab • •• l",. , N. 45052O 38 Needl e Iloller llo:ari''II' ' n' r U $~ 'II' •• her - f ront - Genu., ""'",sh.ft 'U53OOQ ~ M" in Or,.i" 8 ~.f~ Unit IJ,..ri"ll , N. 4S3J60 .. Di .tance Piece

Th"11l W .. I",. 19S thlckne .. - l'U52410 " Nee<l l e 11011e.

Thr"' l '/I'ashe. . 190 tb.cknesl N 453380 " n.-unce P" ,ce Thrust '/I'une. ISS lh,ci"",u N_45191O

" Clrclip _ Mo iMhah

Th.Wlt ..... ho. 1110 tll1ck"" .. - N.453370 ~ m.la""", Piece

Th ..... t " . . ..... 11$ thlCk ...... - N. 45322O " \ItOodruf( ~y

11,r".l '/I'.&her- 170 tn.cl",,, .. - N. 4S01JO " , ..

Thr ... t "'.aM. 165 tn,ckne .. - N 45 1730 " Tolw .. ..". Th.uot W ....... 160 tlu e ~ ...... - N 4507<10 .. Nut - l\ot.in,,'6 ' Mlllnah.rt

11>r ""t "nhe. 155 lhl ckne"" - N 451180 " r"'t .. n i llf! 1I,,'fI

11"",,< lI'uhe. . ISO th lcknesa - N 455040 SO G"" 11>. ""t * .. he r . 115 duck"" ... N.4S4 120 " I l'4'tIt Sh. r t 11> .... t 1I'uhe. 140 th ,ck""u - fN. I04/L " Nut "~69'"

Bo . .. "S - c"ntn: - M"'n . ... r t , - 53 " "he . ,, ~ ~ > 1 1t Sp. i ns

11> .... t "uhe. _ n •• r - Gentre !<I.,naho ft N 454410 " " ... o.lCUIft , N. 454080 SS U •• ""S Ile u i ....

11>run " .. he r Z25 t l .. ekn" .. N.454370

" IJo II n. ~e

Th., .. t W .. he r .220 thICIrne .. - N 454 150 57 C,.cl.p Thrust ".shoo. 2U th . c ~ ""u - N. 4541JO·l

" rA n lnce Piece 097 thi cb ....

Th. ""t "·I.her . 210 t hiclmcoa - N.454130_Z - DIn.nee Piece 101 t hI ckne ..

l br ... t ' · .... he r . 205 th lc"""" - N.454130· 3 - Dinl"ce I' iece 105 th iclmc ..

Thrust "uner ,,.,

t h.ekneu N.454130_ 4 - Duunce Pi ece . 109 th ickne n Thtll l~ W ...... r . 195 ~~ i elu ", 1S - N. 454090

" Ci . cl ip

uJ =~==rn !C : !I01'O(t@/rlw oo @ ~

It ~ 15 I1

" (0

,

mo •

45 .,. 45 = 45 "'"

"

No,offl

pcr.::..-

----, , , , , • , , , , • , , , , , , , ,

"" , , , J , , , , , , , • , , , , , --,

•

TYPE 4 0S SH[CTOR S IIAFT AND LAYSHAFT -

Pal< No. h~ .. I 001lC1;P<'<KI No • .,,1

POrt No. he .. Ouc,ipt;on INo.Ofl ",,,ca, 1-

p~tur

"<~ 515500- 45 , "".er." L'8h s.,. lch , N. t 55610 s., l~cl.O r Shdt lot &. ) TYJ'" 405 Co.u

:" 452WJ , '11'0 .1>.. • • Ile ."rae Light s.. itch , '"'. ) U...,d on and ft ... , N. 4SI)SBO 3 u, iru, Bl <>ek , N. 4SSS 10 - s"l""tar Shaft - 3ed " ) Cl"", • •• 4137

K1S 585!D , Spr; 1lj( ,.....,h.:r , 4th . , , N. 452780 ; s.:ucre_ 1( " IN" ,

• ;<1,450560 6 SoleClo. Pl ate Uaed up t o o..ui & tl36 , N.45231l.O " fork (Selecto' L.t .nd 2nd) , u..,d ~ u. O' ... i . 4136 ;<1451720 " Toob. uhe r

, :-4. 4SSS20 Sel«tor I'l.le , N.450670 '" Nul ' t'crk n"' ta .n, ,,,,)

, Used on and fro. o.u. ,. 41 37 N. 45053O " f ork (Seh'Cl.Or 3rd .nd 4th)

, N.452660 1 lh.u"",,, ...... he . '11""k"", •• 020 · N 450301 " L..y.ho h

, (Se lector fork ) .~'" , ""'" " «, ,

N 452670 - [hs u nce " ...... . 1)""k ...... .1)3(1 . J'i. 450400 " Taboouhe. ,

(Selector Fork) m'" N.4S0l2O " ,., ,

N 452680 n .. l.""" 'fu her "\luck""u 0"- N.452aO " Circl1p ,

(Se l ector Fork ) I .eqd N.45IS311 " Ilo,or;ne; (f rond ,

N , ~ 511XlO B Spmdle (l\e oe r oe Ge u Idl ~r) , N. 450690 " D. .unce Pi ece <.hord ,

N, 451160 • IIe.en" Gea r (Idle d wi~h Bush , N.4S0700 " Di stance Piece (1 0"6 )

, r">'.4S0750 W Du . .. (1'<:0" • .., Ge .. idl " rl , N.~ 5 3HO '" Spo.c ;ng Wuhe . 2

rU50360 " .'ork St lecLO I' (1'." ,, '0,, ) , N. 453730 " I"Iol l"r fle.rin8 _ c" nLre ,

N,450860 " P ,vot P ,n , N. 452440 31 a n ri "@' . r... .. r , N,4520c,0 " T.u..uh" .

, N ~3 4 30 33 Our (LaYB~.r t J)r 'Vl I\II) ,

N.450430 " ,~ lc rl _ Uo:>e' (~o~ne) , ,,""" " ("",or (Lo.ysh.ft 3rd ) ,

1'1 450190 " Selecto. Sh.rt (n.. vern) , N.450270 "

«., (Layohlr ft 2nd ) ,

N 453630 " Select' .. Sh.rt • Q lot" )AII TYP'" 404 c.. .. N . 4 ~ " «., m •• e . ae) ,

'od lTYP'" 40S c.rs ... , 1'1,453640 n Selector Sh"rt - 3.d" ho o.a .. , . 4136 ,

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• Fig. 12 . Gearbox and overdrive BWC R"

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Arrangem ent of !!carhm< w itho lU overdrive

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A rr anJ;c rn c nt of g-carho x w;11o ovenJr;vc

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Gearbox

Description The gcar"box fined to the Type 404 Cat' is .. hown in

P lg.!)l and is 8ultnpcd Bw.eR? followed by i t .. serI al nllmber.

The gearbox an ti ove rdrive ullit fined to the Type 405 Car is .. hown In Fig.52 and is stamped I3W.CR ll followed by its ",crial number.

Basically the gearbolt portion fO " ward of i ts "ca r fac e is Ident ical in both ca r s but on Type 405 C a rs the gearbox CllIcn,lIon is ...:placcd by an overdrive unit.

Type ..... ... ........... ...... 'Bristol' Wilh Barg_Warner Synch romesh, constant mes h helical gcars.

Nu..,ber of Spccds ....••.. F ou r fo rward _one reverse. (Type 405 has Overd ri ve used in conj unc t ion with Top Gear only).

Synch romesh Ln ••••••••••• 2nd .. 3rd . , and 4th. Gears.

Is •. Gea r ............... .. .. Fn:cwlu:cl.

Replacements

Typc 404.

A complete nW.CR7 gea r boll is availa ble as <I recondllionea excha nge unit from Ihe works .

Type 405 Car.

The ge arboll por tion only is available as a reconditioned ellchange unit from the wo rks.

The overdri ve unit is a separate component, Bnd is alllO available aa an ellchange reconditioned unit from the workll.

In all instances e xc ha nge units are s upplied subjec tto lhe r elUrn ana inspe c tion of the rcmoved unit.

Removing the Gearbox from the Car

Dra in the oil r '·om the gea rbox and refit the plug •

Remove the bonnet 10 enable the li ft ing sling 10 be used.

Remove the se3UI ana floor covering.

Remove the clu tch and brake peaal pads . s lac ken rhe accelerator pedal clamp scre w and awing it clca r o f thc lOe-board .

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Remove the four aom ed nutS attaching thc rcmote cOnlrol to the gearbox cover alld Irh this poruon clear of the stuas.

Rem ove the ge arbox tunnclling. rhe floor-boards and t he toe_boara.

D isconneCt the s peedomcte r nexible d .-i ve from rhe gea r box a nd the elect rical connect ions 10 the reverse lIght s witch (and overd ri ve s witch).

Disconnect thc companion fl ange at the rear of the gear box or overdrive .

Fil the engine slmg and take thc weight of the engine. (see Removm8 the e llgine).

Remove The mountIngs sec unng the gearbox o r overar,ve to the ch a!l", i l!< .

Remove Ihe ",I Orter m Olor.

S uppor ting Ihe gea r box, remove the remoining bohs securing rhe cl utch cos ing to the engine.

Remove the brac ket f rom the e xhaust pipe clips and the clutch pull _off spri ng anchor brac ke t.

Withd raw the gearbox reorwanis keeping It in line wllh the t r onsm ission toavo,ddamage to thecIulch dri ven plate. When clear li f t the georbo. from the cor.

To Refit the Gearbox to the Car

Before ,·cfin ing the georbox, en .. u r e tha t the joining fa ces a r e c1eon and undamaged and that the locat' ng dowels a l·e posiuoned cor rectly.

Reverse the operati on .. of the removing procedure and fina lly r efi ll with oi l.

Servicing the Gearbox

The most com m on rea sons fo r strippin.': the 'Bristol ' Gearbox a rc, noi",y races, dropping out of gear a nd the f r acture of the 1st. CFree whee l) Gellr .

T o enable the ball races 10 be rep laced without undue delay Fig . 53 will indica te the bearings used In the georboll fined to the T ype 404 Car and F ig.54 the bea nngs fi nea i n the gearbox /l nd ove r drive of the Type 405 Cor.

Dropping OLII of ge a,·, invllt·iabl y 3 .. d. Gear, con be caused through insufficient o r WOl"O meshing of the dogs. iI is not ad vi",ab le to t r y to cor r eCt th,s by packing the

Fig. H. Gearbox bea.ing diagram

seieClOr forks o r sc rewing in tbe scle c lOr ball units. New parts and the co,' reel spacing by selec live thrus t washer!! is necessa r y. This i8 deal! with in detail.

The fracture of the ht . Gear lFreewheell c an be c aused by violent acc eleration when in 111[. Gear causing the rollers in the f "ce whecI la s hoolout agains[ the inner wall of lhe gcar. Cont inuation of this will resul t in c rac king the gear. Whe n thi a is s us pec ted the integral meshing gCIl" of the lay" haft " hould also be inspected .

Dismantling the G earbox

Remove Ihe cl utc h operating leve r and il" fulc rum brac ket Fig. 55 and n: Jeue the 9;X nu tl;l accuring the clutch hous ing to the front fa ce of the gearbox.

T ype 404 Car". ,

Rem ove the Iluts secu ring the gearbox extensiontothe rear face of the gearbox and withd r aw the extens ion un1l c omplete with liS s haf!.

T ype 405 Ca rs.

Refe ,·r.ng to Pig.56 det ach the ove rdrive u .. itfrornthe gca r box a t J oint 'A'.

Procced on both t ypea 8 8 fo llo wa:

Remove the nuta aec uring the ge arbox cover and lift

off the cover.

Lift out the reverse aelee tOr shaft.

Remove the .. ut llo and bolts s ecuring the two halves of the c asing a nd note where they are positioned as aome ac t as c10ae fining loc ating bolts.

Separate the c ps ing and lift Out the selector s h afts .

Re move the Layshaft aSlle mbly Fig. 57 .

Lift out the drive shaft and main driving s haft groups and wit hdraw the m ain driving ah aft from the r ear er;lQ of the drive shaft. Remove the needle roller r ace from either the from s pigOt of the main driving shaft or the recess in the drive II haft.

Dismantling the Layshaft Fig.58.

Re lease the tabwashe rs a nd remove the rctai ning nuts at e ach e r><!. of the s haft .

Refe r rtng to F ig.59 press the fronl bea r ing. s ho r t d ista nce piec e ar><!. gear f rom the ahaft . Remove the key and r e move the long d is ta nce piece.

Press off the 3rd . tays haft gea r in a s im ila r manner then rem ove the key and de ta ch the fron t spacing washe r .

Using the split bush T F N 8699 press the 2nd. layshaft gear, rear IIpac ing was he r and the centre bearing f r om the s haft as desc ribed fo ,' the lays haft driving ge a r , ,hen

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"emove the key fr om th e s h aft .

Reverse the la yshaft in the p ress and us i ng the drift T 178322 and the split bush T17832 1, p ress the shaft ca r efu ll y un t il the rear be a ring comes into eomact with the key of the reverse gea r . Now press the bearing bac k 10 Its original posll ion leav ing a gap between the bea r mg and the reverse gea r. F it the split bush T 188283 Lnto the gap and prcss off the gear. Remove the key from the shaft and p res!io off the r ear bearing.

N . ~lJI>O - ,~ ,. ... UXl ,.1"'- UlSG

= = L,

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.... Sl?lO IIWLRJ2S

000

~~

the r e ma ining s h iftin g pla le ret a inmg ring from the fixed hub.

Re lease the ta bwashcr and remove the specia l bolt f r om the rear end oftheshaft, Fig. 62,then using the d r ift T 1783 16. base T176317 and spli t bus h T176318 wi thd r a w the r eve rse gear a nd hub. Remove the key and locate the a88em bly in a press wi th Ihe s pli t bus h T17831~ beneath the f,'oOl fa ce of the I sl. gea rthen pres8 off the hit. ge ar and it s hub and the bea r ing loca ring bus h comple te w,th the bea ri ng.

~ =

I .... S2400 Nti010

"' .... J.;>O II ~ .. LJ, 'lG ~o

Fig. H . Gearbox and ovcrdrh'c bearing diagram

Dismantling the Main Driving Shaft Fi g.60.

During the di6m andi ng procedure, label the synch r o mech anism and ~y ...!. hrust washer s for 20l1itlon . This wi ll considerably Simplify re _assembly.

Lift out [he 4[h. s peed bloc ker ring and withdra w [he sliding hub. The three s hifti ng p lates will s pring out as they a r e r eleased. Remove the exposed reta ining r ing from the r eeess III the fi xe d hub .

Rele ase the tabwa she r at the forwa rd e nd of the sh aft and r emove the locknut. Fig. 61

Locate the s plit bu sh T FN 6699 in the r ecess in the 3rd / 4th fixed hub and press the hub from the s haft. Lift out t he 3rd . speed blocker ring then r em ove the key. Ma ke provision to catc h the needle r ollers alld s lide the 3rd . gear hub fr om [he shaft follo wed by the d is ta nce piece and the cent re bea ri ng fro" t thrust washer. Rem ove

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Refe rri ng [ 0 Fi g. 63 withd raw the l s tl2 nd s peed sl iding hub: the three s h ifting p lates will s p ri ng out .'" the y a r e released.

Remove the re t aini ng r i ng from the r ece ss inlhc fi xed

hub.

Loc ati ng the split bus h TFN 86 99 in the r ecess of the h ub. press the hub f rom the s haft . Lif[ou t the 2nd. s pe ed blocker ring rhe ll r e m ove the fixed hub key. Taking p r e e sutions to preve nt the I06S of [he Ileed le rolle rs. s lide the th rust washe r and 2nd . gea r hub f rom the sh aft. Re move the needle r olle r dis tance piece and the Cent re bea ri ng rea r thru,, [ washe r.

F inall y pres s the ce ntre ball bearing off of the s haft.

Dismantling the Drive Shaft

Referring to Fig.64 relesse the t abwashe r lInd remove

the bearing retaining nut. Posit ion the s plit bush TFN 8699 as shown in Fig. 65 and press off the front bearing. d,stance p'ece and rear bea"ing and the gear.

Should it be conside red ,hat "emoving the gear is unnecessary. remove the front bearing using "plit bush TFN 8699 . Take off the di"tance piece and press off the rear bearing using the s pin bush T178320.

C 6 0$

Fig. jj. ClUTCh casing and rele~se mechanism

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Fig. H . Layshaft assembly

Dismantling the Freewheel

Referring [0 Fig. 66 remove the ci rclip and the retain_

ing plate .

Ease Qut the freewheel mechanism until the rollers can be pushed down clear of the spring loaded plungers. then push the gea,' clear of the hub.

R everse Selector Mechan ism

Referring to Fig. 67 lift out the reverse fulcrum lever and. if necessary. release the tabwasher and un"Crew the pivot pin bolt.

Unsc rew and remOve the reverse light s witch. Slide Out [he reverse idler gear together with the fork selecrer .

IYf~ e 4 04 Cars.

SHAFT ASSt toA BLY"

O IL PUMP

oPERATIN G CAM

4 NUTS I SPRING

WASHERS TO RE MOVE

AS!)E toA BLY

Fig. S6. D j'm"ntling Ihe overdrive unil from Ihe gearbox

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FRONT BEARING SPAC ING WASHERS REVERSE GEAR

DRIVING GEAR 3,oGEAR

/ 2- ' GEAR 1'" GEAR

--'-

tr ~ ~

JI - IT . , . . .

"" .

" '" -" "

E::J; ItGJi l ,

:....-...J C 398

DISTANCE PIECE DISTANCE PIECE

SHO T R ) (LONG) CENTRE BEARING L , REAR BEARING

Fig. SS. General arrangement of layshaft

Fig. S9. D ismant ling ~he !ays h af~

Dismantling the G earbox Extension

Referring to Fig. S8 remove du· sCreWs securing the end_plate and withdraw the extension sh af ~ from the casing.

Release the tabwasher, remove the nut and wi thd raw the companion flange from Its taper onrheshaft. Remove ~he beanng locating circlips and press the be aring from the s haft.

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Unsc r ew the speedometer drive union from the front face of the c asing and withdra w the 2 nd. reduction speedometer driven gear.

Unscre w the cover and withdraw the 1st . reduction s peedometer driven gear complete with the worm gear.

If necess ary the WOrm ge ar c an be pressed off.

Dismantling the Remote Control

Unscrew the gear lever knob. Remove the rubberdusl excluder protecti ng the gear leve r ball joint. followed by the circlip. spring retainer. spring and bearing cup. then lift ou~ the gear lever.

Remove the dome nuts securing the COve r plate and if necessary remove the s peci a l stud which provides locati on for the gear lever. Th is is sc rewed into the casting. See Fig.69.

Remove the plug (,·om the mher end of the casting and remOVe the spin pm. nut and washer from the end of the roc king shaft and detach the selecwr finger located by its ke y. The r ocking shaft can then be withdrawn.

Inspection of Parts Prior to Re-assembly

Carefully examine all components and check for wear on thei r essendal loc ations . Pay particular a ttention to ,he mating splines of the fixed and sliding hubs and the dog teeth of the gear wheel hubs.

Excessive wear at these locations will res ulr in ac cumulated and undesirable ba c klash.

Clean all bearings thoroughly in paraffin. spin by hand to test for running and if the y are acceptable lub6cate them lightly pending rc-assembly. Renew bearings where harshness is not"d or exc "ssive wear.

The 2nd. and 3rd. gear wheel s ar" a splined fit.

4'"AND J·· SPEED

SUDING HUB

JU SPEED

RING 2"" SPEED

BLOCKER RING

2·· AND I" SPEED

SLIDING

REVERSE

GEAR

4"'SPEED

BLOCKER RING J"SPEED I" SPEEO I " SPEED

PLATE

THRUST

WASHER

RETAINING

RINGS

SELECT IV E

GEAR

HOB SHIFTiNG

PLATE

Fig. Go. General arrangement of main dri,· in/! shaft

RETAINING

RINGS

GEAR SUDING H UB . J RD SPEED BLOCKER RING.

/ r U

RETAINING RINGS

SHIFTING PLATES.}

~

THRUST WASHER

JRD GEAR HUB.

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, -THRUST

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WASHE R.

DI STANCE PIECE .

lRD/4TH SPEE D

F I XED HUB.

" NUT ~ ~

LOC KWASf-IER .

Fig. 61. Dis mantling the main dri.-ing s haft Stage I

PI ECE

C6BS/A

EE WHEE L

fInally pt""t""!1ed to thelr re spectlVe hubs, noattt""rnptshould be made to sepa n"t"" them .

Chec k the freewheel gear fo r any SIgns of crac kmg "SIng a magna nu x tt""st where possIble.

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DISTANCE PIE CE .

DrS TANCE \ PIECE .

CIRCLI P, _

T H RUST WASHER .

RE AR BEARING .

1ST. GEAR HUA .

REVERSE AND

SPEEDO HUB .

KEY --<'"7 It Jl\\ ~'f~SPECIAL OOLT .

TABWASHER .

Fill'. 61. Dism antl ing the main driv ing shaft Slage 2

~ THRUST _ , ~

WASHER ~ ~J)

DISTANCE PIECE.

2NO SPEED HUe .

TH RUST

WA SHER .

'- - K Ey

2 NO. SPE EO BL OCK ER R IN G .

r--_ ...... ~ ) , ""'--I'-C601

F ill" 63. D i~rnanlling the ma in driving shan Stage 3

.,.

2 NO AN O 1ST .

SPEEO FIXED HUB . 2ND. ANO

I ST. SPEEO SLIDING HUB,

LOCKWASHER FRONT BEARING . REAR BEARING .

BEAR ING RETAIN ING

~ \

DISTANCE PIECE . GEAR

KEY. --"-:ilJ

C602

Fig. 64. Dismantling the drive shaft

Fig. 6,. !'rruing component8 fro m d . ivr sh3ft

Re-assembling the Gearbox

If the gear change lever mechanism .n the gearbox cover has been dIsmantled. rebudd It as follows .

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Fig. 66. Dismantling .he f.eewheel

Fi t a key to the r oc king s haft, and poaition the shaft into the remote control caS ing. Fit the selector finger to the shaft and key, fit the washer and nut, tighten and s ecure with a split pin . The plug c an now be fitted to the front end.

If the s peci al stud, providing location for the gear change lever has been removed, refit the s tud . Fi! the loi nt and the cover pla!e, fit the spring washers and dome nuts a..d IIshten.

Check that the gear leve r is a good fit In the bearing cup and If not lap the part s together until a r:oocI bearing surface ia obtai ned. This opera tion will eliminate gear lever vibrati on.

Fit the lever followed by the beanng cup, spnng,

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rc(aln1ng plate and circlip. Finally fit the rubber dust excluder.

C61.3fA REVERSE FORK SELECTOR .

Fig. 67. Re"crsc selector mcchanism

Fig. 68. GCllrbox extension

Fig. &). Gear lever locat;on special stud

With the joint washer In position. fit the remote control over the studs of the gearbox cover and secure with the spring washe,'s and dome nuts.

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Fit a distance piece over each of the selector plate scuds in the gearbox COver and position the selector plale, complete with its guide blocks, cut_awa y edge to the front of the cover Fig.70. Fit a distance piece to each stud and secure with rabwashers and nuts.

u,,~ "N~ ","c','",'c',',":',' , LOC"'ION - o

~ tv~qSt GtAR '". ' NGLool>(D PW NGt"

Fig. 70. ScleclO. plate assembly

Layshaft Fig.58.

Where the original gears are being refitted it is important to re_fit the gears the correct way r ound to

mate the established tooth bearing surfaces with those of

the opposite gears.

Fit the 2nd. Gear key and using the drift and base T178296 press the shaft into the gear. Fit a spacing washer with its full face to the gear then press on the inner race of the centre roller bearing and fit the outer rac e. Fit the second space washer with the relieved face to the bearing, then fit the key and press on the 3rd . gear.

Slide on the long distance piece, fit a key and press on the layshaft driving gear usi ng the drift T178297. Fit the short distance piece followed by the front bearing with its circlip towards the gear. Fit the tabwasher, tighten the nut and lock.

Using the ba se T1 78298 and the drift T.178297 press the rear bearing into position , fi t the key and press on the reverse gear. Fit the tabwasher, tighten the nUt and lock.

Main Driving Shaft

See that the 3/32 inch diameter dowels are in position

on each side of the cemre bearing location .

Locate the centre ball bearing in the base T178300 and using the drift press the mainshaft in(O position . It is important that the bearing is centra l with the raised portion of the shaft.

Fit Ihe COI"'C,",t thruS! walShe l' 10 thc 10llg cnd of the "haft. loc3lLn~ n .... 10[ over the dowel. Well g r e ase the shaft suffic Ient TO r etain the needle rollcrs and posIl ion 40 roller .. next 10 ,he thrU$1 washe,·. fit the shon dUHance piece followed by a fu rther 40 neeJI(' rol!e l·s .

Slldc the 2nd. ge ar hub. gea ,: whee l finit . over ,he rollere.. fIt the ,hr",,' wa" he .· 10 the recess in ,he 2nd . gea,· hub and then in sert ,he fix ed hub key.

1'1( ,he 2nd. speed blocker nng on ,heconc face of , he 2nd. Rear hub.

Fn a n:ta.mng nng 10 ,he front recess of the fixed hub sO Ih~u onc 100,~ue of the nngengages onc of the SIOlS for the shlftlnj2. plates . the other tongue I'Csl "'g agaInst the recess In the hub.

F,! the fixed hub ovcr ,hc shaft. ahgnthe kcy and key • ... a ~ and usinR the splIt bush TFN8699 and thc d,.,f\ P"css the h ... b OIl until it abuls thcthrust washc,·. p,t the cirelip IntO the ~roove and aga,n USing spI n bush TPf\8699 press the hub back against the cire[ ip to give the ncccssa,'y

clearlln .... '·

Pit ti, .. · .nd reta imng n ng to thc rca ,' rccess of the f.xcd hu b r> , nbure that the tong~ the ri ng does nQ! en~aij!e the " ,",,, ,e shi fllt1g.platc slO[ as the front rinf ' Fit an temror,l' Ir re(ai n by hand (he th"ce ",lll ft ing pates . turnin~ the 2"d, speed bloc ker r ing as necessa,'y s o that thc s hift ing pl~le notchcs III the blocke,' nng e ngage thc ends of the "h,f(,ng plates , Press ,he 9h'(I,ngplates down into tllci,' SIOIS .n the fixed hub and fit the sliding hub. lon~ end (,rSt, over ,hc assembly and ccntrlllt s e i,. 11le CCnlr1l1 posr.uon can be felt by the sh,fl1ng p[ates locaung In the ,nlerna[ groove of the ", lt ding hub.

Assembling the Freewheel

Refel'r",/! 10 Fig. 66 ft( (h e spr ings and p lunge,'s and fit the hub pan .a1l y ,nto position in the gco ." Inse rt the rollc,'s push the asse mbl y ,'.ght In and fll the reta,ning plat ... and c.,'cl,p,

To com"' ... e with the main dnv.ng s haft assembly, fit the "H. specd d,stance piece IntO thc ,'ccess of the fi xcd hub. mal1ng the nOlche,. to the ends of the s h lft.ng platcs, Pu thc 1st, ge a r thrust washer over (hc c " ,cl ip. Crease the shaft and fit tWO roWS of 40 """die: ,'01lers, as prev;· ously descrIbed. wnh the long d's tance p'ec e between tkem, Ihcll slidc the 1st, Preewhec! gea,· asse mbl y. dog [eeth {1t'St. over the rollers.

Press the bea"in~ location bush 1111 0 the rear bea ring with the ,·ctaintng ring ill ,hc OUler racc located adjllcen[ 10 the f1an~e: of the bush. P,'css ,heaf;semblcd bearrng lInd locallng hUbh. flange fi,'sl, on to the shaft us ing thc hase and dnft of ' I 001 178300 . Th,s comp[ctell the rear end of the shaft fo,· the ume be"'g.

Comm"'.lclng wtlh the (rom cnd of the shaft fi t [he

cor ,'cct thrust washe l' loc a rms ItS groove ovcrthedowel. Crease the s haft and fit 40 ,·ol [ers. followed bv the d ,st ance p,ece "nd a funher 40 r o[lers . Sltde on th~ 3rd gea,· h ub over the rolle r s and dis ta nce piece. F il the dlruSt washer into the reecs", of the gear hub.

TIl e 3 nl/4th. s pced fi~ed hub ha,; a s lI ght eoumc,·bore un o l1 e face onl y of the sha ft bor e. ' 1111 .'1 mu st fa ce th.e c entre be .. nng, Pit a r""t"iOlng ringtolh i!! s ide of the hub so thal one tongue of thc nng engages onc of thc slots fa,· the s h,fl1ng plates , the othe r longue ,'es{Jng aga,nst the rCCe!;s .n the hub. Fn ,he key to the sh aft and uSIng ,he ",pi n bus h TFN,8699 and a ",u n able d nft prcss on ,he hub and secure u wilh us tabwas her loc knut.

Fit the " hifting plate!; ancl the f r ont retaming ring then fit the s bdlng hub as des c nbed fo" the 1s, and 2nd s pee d ", 1id,ng hub.

Reve ' ·lIe the sh aft and ( 11 the key . nto the cnd. With thc Revcrsc gea r assemblcd with 118 hub and rc[alnlng r\llg, pn.'SIl thiS assembly on to thc shaft and secure it wnh the labwasher and specia l bolt.

Drive Shaft Fig,64 .

If thc ge ",· has heen removed. fil the kcy to the shaft and uSing the spin bush TFN.8699 beneath the gea r. P"CSS Ihe ",hllft into pos illon.

FII thc was her or wa sbers to the gear face and us,ng , hc d,' ,fl 1"17 8299 press on the drive s haft rear bearing Cll'cl ip to the fl·on,. Fit a needle roller bearing eithe,' 1'0

th e s pi/!Ot of the main driving bhaft 0,' into the re ces s of the dnve s haft.

1"11 the 4th . s peed blocke r nng 10 the dn ve sh aft ,hen Ilssemble Ihe s ba{[ assemb!t e8 logether. T ,' ;a [ filthem into , be left·hand ha lf of the gea l'box cas,ngtoens"re that the hea" Ing clrclips locate cor r c e tl y , ntO the grooves , If the aSlOctll Dly has been assem bled WI th ,IS corr ec t posit ioned orig.nal pans this s bould locatc solt sfacrorily . If not some adp'st me", may be neeess(l,'y to the washers located b.! tween th e drive s haft gell t' nnd the rea,' bea n ng .

Whcn Ihis loc at,on ha ", been determined. part the

a ssembltes. "lode the d ist"nce pIece on 10 thednve shaft and press on the front bc armg,

F I\ the tlIbwas hcr, ,,)?h[en Ibe nu, and lock.

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Checking Drive Shaft and Main Driving Shafl

Aga In assemble Ihe II h af ~ assem blies toge ~ h er a nd locate them inlO Ihe lefl hand side of Ihe gearbox cas ing. ens un ng Ihal Ihe notches of the bloc ker enga ge the cnd ,. of the s hifting plat es and tha t th t: bearing circlips arc sc ating in the gr oove s of ,hc C09 1ng,

F it the s electo" fork ond ils o"i g inal washers 10 the 3 ,'d/4 Ih, speed s c!eclol' s haft , fi , a lock washer and secu re ,empor a r ily with the fo rI< ,'c ta lntng nut , Ihen posit ion Iht: sha ft and fo rk III the gea r box casing, F it the gea r box cover 811sembly c ompl!!'!!!' wllh the ,'em ote COJl(rol lIl ec ham llm and secure 11 w"h Ihe castng s lUdll,

Ope r ate ~he ge ar cha nge leve r to engage the 3rd , and 4t h, s peeds .n (Urn and check the e ngagement. Ihe n add 0 1'

re move dis tance wa s ht: r s bt: twee n the s elec to r fo,'k and the e<c!ector fork and the col lar of the s elector II haf!. a.s neeell9a r y . to equa li se tht: e ngagement. Fig.7l, Whe n sa ll sfae tory loc I< the nut with tht: tabwa~ h er .

"'OJIJST "''''SfEIlS TO E; OU"'~I$f; OI~ENSK)NS 'ci . '1'+:

Fig. 71. E"Iu:ali " in~ ,he !ld ee' o, for k ]oc,,,ion

Fi t ,he 1s t12nd speed selector s haft In a si milar man "er and enSure ade'1u are e n g ~ ge ",ent of the s liding hub with the 2nd. ge ar hub . Full engagement with the fi rs t gea r hub is the n' ass ured, T he se le ctor shaft in thi s lostance wi ll nOl ha ve ils fult loca tion which is partiall y In the right hand .. ide of the c asing .

Remove Ihc gearbox cove,' allse m bly. follo wed by the drtve s hafl/m a ln dr,vl ng shaft assem bly when these engage ment checks have been completed,

Reverse Selector Mechanism

T he s pl1ldl e for the rt:ve ,'se id ler gea r is a slid e fit In the cas ings be ing ,'etained by onc of the gc ~ rbox c a s ing bolts . T hi s s pindle and th e b"':l h of the gear s hould be e xamined fo" wea" be fm'e I'cll,!.sembl y and r"ne wed if worn bad ly.

The phosphor br on ze bush III av a d a ble as a s pa re and Ihe o ld onc should be pressed out a nd a ne '" bus h pressed m . The three 10/8" meh dlamel<:r holes s hould then be d r dled Ihrough the bush f rom the gear and the n Ihe bor e shou ld be s i zed 10 , 782 ~ .0005 Inc h.

T o assem ble the r evel'se gear m echanism Flg.67 s lide the CuI away end of the Id ler gea r s pIndle llllO the "' ght hand SIde of the c asl" g. F il Ihe for k of lI. e selector In ~ o

the g "oove of Ihe ge a ,' and sltdc the sdector and gea ,' "'to the ir ,'e s pect ive !oclll ions .

Fit the rabwa ~ h cr a nd pivol from the On rhe ins ide fit the fulc rum lever engaging its lowc r t: nd in the Blot in s elec tor ,

Final Assembly of Gearbox

out si de und loc k, to the pivol pin . th " rcve nlt: fork

F t! the dnve s haft /main d ri ving s hafl asscmbhes m posiIJon in ,he right hand half of the gearbox cas ,ng 10 ' Clll "'S Ihe be aring c i rci ,ps in the groo"es.

P it !hc Ia ysha ft aSllembly 10 the c a s ing. m eshing liS

m ating gears and locat ing the .. ireI ,p of the fr ont bt:aring In the g r oove of th e CI1 !H ng,

Fit the 1st/2nd. and 3,·d/4t h. se lec tor s haft a nd fO"k ass embli es in ~ o Ihe lilidlllg hubs ignori ng Iht: groove loc ati ons unti l Ihe clls mgs are filled loge lhe ,' ,

Apply a Ihi n coalms of 10' nt,ngeompoundtothe matmg gearbox joint f aet"~ and a~~em bl e Ihelwoha lvcstogethe r . ens uring thal Ihe bea r ing c , re[ ips a r e correct in the groove s . F I! the securing bolts was hers and nulS and Iighten!O a !Orque [oadl ng fig u,''''' of 7 !O 9 [b,fl .

Overtighlenin g ca n ca use di lito l'tion and mi s ali gnm ent of the bearings r esultin g in noisy raCes .

Positi on the 1s t/ 2nd . and 3rd / 4th , s e lec tor s hafts and PUt them in t he neutra l pOli ll ion, F lI the ,'everSe selec lo ,· /:Ih aft and e ngage " with the upper end or Ihe revt:rse fulcrum le ver .

Before fitl1 ng the gea r box cover alle lllwn s hould be g tven 10 Ihe s elector ball unllS , T here arc IWO typell filled as ",hown in F ig.72 the e a rl ier t ype s ha ve no p05-ilive depth location whde the la ter type a re tden ll cal except . ha t the sp ri ng and ba ll housi ng IS shouldered. The re verse ba ll se lec lor of each lype ha s It d lffel'en t s pring teosion and is st a mped 'I{' for idem ification, It s loc ation is o n the ri ght hand s ide of the gearbox ,

First c hec k each uni t to /:lee that the ball will ,·espolld and s eat it s elf with its s p ri ng p ,'e sllure,

Scre w therll 11110 the gea l'box cover unlil thc ba ll on ly p "otrude s in to Ihe half round s e le e!Or s haft locallonsand the ba ll hous ing IS juS! dca " , F r om th 'll pa..it ion they ca'l be fi nally ad jus ted ba ck but they m us t nm be "c ,'e wed do wn otherwi s e they will foul Ihe s ha fl and d am age Ihe hOUSing thus preventIng the ba ll f r om s e ali ng .

If an overdri ve cont a ct s W1l eh IS fined to the cove,'

remove ;t al t hi e< 9 ta ~e .

T o continue with th e a sse mbly, apply a thin CO Ut of jointing c ompound to the fa ce" and assemble the gc a rbox cover 10 the c asi ngs and liecure with spring was herll and nUls .

Check the gear lever , n ils e ngaged POSlllonS and tf harsh o r hea vy the s elCClOr ball UOlI " hould be ca l'd ully unscrewed unll l CO'TeC!. Peen as 1:o hown ill Ftg, 72 ~o fI nally lock them 11>10 p06l1lOfl.

SHOWING METHOD OF PEENING

FOR LOCKING

Fig. 72. Selector ha ll units

Clutch Casing

'Ihc leather galt,,!·s at the clutch operating Icverslots and nlso the timing aperture are only to be found on later cars .

To fit the clutch casing to the gearbox casing, fit a new Joint washer to the front facc, llsin~ jointing compound and a~semblc the clutch casing over the end of the drive shaft, locating the drive shaft from bearing imo its housing. Secure the casing to the gearbox with the nulS

and sp "ing washers.

Fa the clutch (u le"urn bracket to it.s correct position, right hand ,;id., for RH drive and left hand side for LH d,-;ve, and fit the tabwashCl" , rightcn and SClscrew and lock. Inser! the clutch lever, fit the fulcrum pin and secure with a split pin.

Fi! the c1U1ch release the fork of thc Icver retamers.

I ype 404 Cars.

bearing and and secure

cup assembly into it with its s pring

Gearbox Extension Re-assembly

Fit the key to the 1st. reduction speedometer driven gear and fit the WOrm gear, theninsertthc gears into the extension casing with thc lowcr end of the gea,' against lis th "ust pad. Sercw the cove " into position.

· 24 '

Fit the 2nd. reduction specdo driven gear to (he drive union, thcn scre w the union intopositionensuringthat the teeth of the gear and worm mesh cOt·rec dy.

Fit the ball race to the extension shaft and secure it with the circlips. Fit the end plate to the shaft then fit the key and companion flange. Fit the tabwa"her and nut, tighten the nU! s ec urely and lock.

Fit a new Joint wa" her tothe rear end of the extension, then insert. the el<1.ension shaft and secure the end plate with the four set bolts and spring wa"her".

Finally assemble the extension unit to the rear of the gearbox by fitting a ne w joint washer, using jOinting compound , then taking ca,'e that the teeth of the extension s haft engage in the hub and that the speedo gears mesh correctly, attac h the extension unit to the gearbox and SeCU!'e it with the nuts and spring was hers.

Overdrive Contact Switch and Reverse Switch

These switches, Lucas 515500-45 at'e identical.

The rcverse switch has a po"itive washer when it is fined to the side of the gearbox. while the ovet'drive switch in the gearbox cover is controlled for height by "hims. In this way the switch is smoothly operated by the selector shaft when Top Gear is engaged.

Both s witche" can be fitted and checked when the gea,·box is in the car, but before the floorboard", tunnelling ctc .. are refitted .

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11 I

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1 1 @ "'-"-"'_8 U70 _

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Sectional view of overdrive

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Laycock Pare Number Desc ription No. per UniL

XN.24 Valve Plug 'Wa s her 2

XNA40 Va lve Spri ng 2 XN.36 Ball Va lve P lunger 2

XN.378 Dra in Plug I

• XNA06 Drai n P lug Wa s her I

XN.479 Welch Was her I

XN.536 Pu mp Plunger Spring I XN.6 14 Plug for Valv e 2 XN.620 Plug for Pump Body I

XN .621 Fiher Bolt I XN.629 Thrus t Wa s her I XN .631 Thrust Wa s her I XN.634 Thrus t Washer I

XN.649 Operating Valve I

XN.657 Spac ing Wa s her in the following sizes :- I

XN.657E .146" ! .0005 thick XN.657F .15 1" .:!: .0005 thick XN.657G .156" .:!: .0005 thick XN.657H .161" ! .0005 thi ck

XN.657J .166" ~ .0005 thick

XN.663 C am I

XN.664 Stud 2

XN.667 Thrust Washer in Ihe following s izes :- I

XN .667A . 113/.114" thi ck XN .667B . 107/ 108" thick XN.667C .101 / .102" thic k XN.667D .09:;/.096" thick XN .667E .089/ .090" Ihick XN.667F .083/ .084" thick XN.667G .077/.078" thick XN.677 S"d 2 XN.679 S"d 2 XN.704 Br idge P iece 2 XN.712 Valve Opera ting Shalt I XN.723 P ump P lunger Gu ide Peg I

XN.807 Stud 3 XN.B13 Operat ing Valve Serting Lever I

XN.8 14 Operating Pi s ton Ring 2 XN .814 Accumulator Piston Ring 2

XN.B 19 Stud 4 XN.823 Side Cover P late Joint I

XN.845 Pump Body I

XN.879 Operati ng P iston 2 XN.888 S. "d I

XN.1058 F ilt er Di s tance Tube I XN.1082 Speedo Bearing Locking Screw I

• XN.1085 Slon ed Nut I

XN.1090 Cou pli ng Fl ange I

XN.1099 Speedo Drive n Gear I

XN .4010 Uni-Di rect iona l CIUl c h Inn er Membe r I XNAOl 1 Uni -Directional Cl ulch Cage I XNA059 Spring for Uni -Directiona l Cl ut ch I

·27·

Laycock

Part Number

XN.40S1 XN.4246 XN.4266

XN.4283

XN.4370 XN.4372 XN.4373 XN.4429 XN.4486

XN.4804 XN.4941 XN.4970 XN.5024 XN.5025 XN.5026 XN.5027 XN.50BB

YN.21 28 YN.2161

REF.131/5 REF.6024 REF.6127 REF .9003 REF.91OS REF.921O REF.9802 REF.9809

AT.20I02 AT.20201 AT.20202 AT.20301 AT. 20301 AT. 20306 AT.20401 AT.20402 AT.20501 AT.20601 AT.20603 AT.20701

Description

Accumulalor Housi ng Acc umulalor Pi s(on ThruSI Washer Solenoid Stop Breather Solenoid Lever Collar for Va lve Operat ing Shaft Stone Guard '0' Ring Filler Was her for Locking Screw Accumulator Spring Ball Bearing 50 :.:: 90 :.:: llm / m Ball Bearing l~ x 2* x 1l / 16" Ball Bearing 30 x 60 :.:: 16 m/ m Torrington Bearing B.7S So lenoid

Brake Ring Front Cover Plale Joioc

'0' Ring 1* " dia. Spi ll Pin l / S" x IX" Taper Pin No.OOO 1/16" x S/S" Seegar Circlip 1. 7/ S" dia. Seegar Circlip 90 m/ m Oil Sea l Steel Ball x." dia. Stee l Ba ll 5/16" dia.

Boh ~ " BSF Setscrew No. 10 Cheesehead Setscre w 5/16" N.F. 2" x 1~" Plain Washer 3/ 16" di a. Plain Washer ~ .. dia.

Plain Wa s her * " dia . Hexagon Nut ~ " UNF. 2. Hexagon Nut 5/16" NF2. Hexagon Nut ~" BSF Spring Wa s her Spring Wa sher Tabwas her

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No. per Unit.

I

2

3 I

I

I

I

I

2

I

I

I

I

I

I

6 I

I

I

2

I

2 I

I

I

I

I

I

4 2

I

I

I

4

9 I

5 5 4

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Bris tol

Part Nu mber Desc ription No. per Unit .

N.4)0330 Hub--Rev erse Gear 1 N.4)0790 NUl -Ret a ining Mai ns hah 1

N.45 11BO Reta ining Ring 1 N.4) 1l9O J oin( -Gearbox-Rear 1

• N.4)1730 Tabwas her 1 N.4)3220 K,y 1 N.4)4080 Bearing Retainer 1 N.4)4090 Circlip 1

N.4 ) 4120 Input Shaft 1 N.4)4130-1 Distance Piece .0975 )

N.4)4 130-2 Distance Piece .101 5 ) Selective 1

N.4 ) 4130-3 Distance Piece .1055 )

N.4)4 130-4 Distance Piece .109) )

N.454 140 Adaptor Casting 1 N.4)41)0 Circlip 1 N.4)4370 Ball Race 1

FN. I04 / L ~" BSF Nut 4 N.4)44 10 Stud 4 N.4))040 Gear 1

Selecli ve Assemblies

Pum~ Plunger Assembl):: S P.20002 Laycock P art No.

XN.828 Pump Pl unger 1 XN .4) 4) Roll e r 1 XN.829 Pin 1 REF.6302 Mill s Pi n 1/ 16" x W' 1

Cl ut ch Thrust Ring Ass embly SP.30004

XN.S I6 Thrust Ring 1

XN.S17 Pin for Clutch Spring (long) 4 XN.SIS Pin for Clutch Spring (s hort) 4 XN.830 Pin for Thrus t Ring 4

Cl ut ch Sliding Member SP.30005

YN .78 Sliding Member 1 XN .62) Cone Cl utch Inner Lining 1 XN . 1092 Cone Clutch Oute r Lining 1 XN.72) Rivet 24

• Sunwhed Assemb ly SP .30907

XN.4 194 Sunwhecl

XN.4213 Bush for Su nwheel

·29·

Laycock

Part Number Description No . per Unit.

Planet Carrier Assembly SP.30008

YN.21B5 Planet Carrier 1 XN.4400 Planet Wheel 15 teeth 3 XN.799 Planet wheel 21 teeth 3 • + XN.5027 Planet Bearings-Torrington B.78 6 sets

XN.4399 Planet Bearing Shaft 3 REF.6388 Mills Pin 3/32" 1" 7/16" 3 XN.654 Key for Planet 3

+ XN.4266 Thrust Washer 3 + XN.631 Thrust Washer 1

Annulus Assembly SP.30009

YN.2052 Annulus 1 XN.637 Bush 1 XN .651 Uni-Directional Clutch-Oueer Member 1

Accumulator Piston Assembly SP.30011

+ XN.4 246 Accumulator Piston 1

+ XN.814 Accumulator Piston Ring 2 sets

+ XN.40Bl Piston Housing 1 + REF 131/5 '0' Ring 1~" dia. 2

Spacing Tube & Washer Assembly SP.30012

XN.4245 Tube for Piston Housing 1 XN.4 244 Washer 1

Clutch Spring Set SP.30014

XN.687 Clutch Spring-long 4

XN.107I Clutc h Spring-shore 4

Stee 1 Roller Set. SP .30015

REF . 135/ 1 Steel Rollers 3/8" x X" 12

Speedo Bearing Assembly SP .30020

XN.1081 Speedo Bearing 1 XN.1083 Speedo Drive Screwed End 1 XN.1087 Speedo Bearing Oil Seal 1

Solenoid Bracket Assembl~ SP.30028 • YN.2l18 Solenoid Bracket 1 XN.4097 Pi n 1

+ XN.4283 Solenoid Stop 1

-30-

Laycock

Part Number Description No. per Unit.

Rear Cas in& Assembll SP .300H

WN.I84 Rear Ca s ing I + XN.819 St "d 4

• Speedo Drive Assembly SP.30048

XN.I08 1 Speedo Bearing I XN.IOB3 Speedo Drive Screwed End. I XN.1087 Speedo Bea ring Oil Seal I

+ XN.1099 Speedo Drive Gear I

Front Casing Assembly SP.30063

ON.1267 Front Casing I XN.616 Sc rewed Plug B XN.617 Screwed Plug 2 XN.821 Sc rewed Plug 2 XN.632 Bus h 2

+ XN.479 Welch Washer I

+ XN .712 Valve Operating Shaft I

+ XN.BI 3 Valve Seuing Lever I

+ xN.6n Stud 2 + XN.807 Stud 3 + XN.664 Stud 2 + XN.679 Stud 2

+ XN.888 Stud I

+ XN.723 Guide Peg-Pump Plunger I XN.785 Cam Lever I

+ XN.6 127 Taper Pin No.OOO 2

+ XN.4486 '0' Ring 2 REF 990 1 No.2 Parker Ka lon Dri ve Screws 2 XN.768 Name Plate I

It ems marked thus + are al so s upplied separate ly .

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The Laycock de Normanville Overdrive Unit

The Overdrive Untt IS a standard fitment to the Type 405 Car being fitted \0 the rear of the Gearbox. It is self contaIned and in conjunction with the gearbox top gear provides an extra high gcar when circumstances permi t. Th,s exu'a gear permits afaslcruisingspcedto he rnain~ tamed. whde the engine revolutions are reduced, thereby reducmg engine wear and petrol consumption.

The overdrive is operated by a solenOId fitted to the left_hllnd side of the unit and IS controlled by a plunger type switch fitted to the gearbox cover immediately for_ ward of the gear change turret assembly. A magnetic relay switch is situated on the offSIde of the instrument panel.

When top gear is engaged. the plunger type switch comes Into operation allowing the current from the ignItion switch IQ connnue to the magnetiC relay switch on the panel. This laner"witchi"underthe control of the driver and may be operated when it is desired to engage or disengage the overdrive. The magnetic relay switch will automaticall y s wi tch 'off' when top gear is disengaged.

It is recommended that the overdrive is not brought imo use at s peeds below 4 0_45 mph.

Care and Lubrication

The oil In the Overdrive is eommon with that in the Gearbox.

Recommended grades of od IQ use are;

MOBILOIL A. ESSOLUBE 30 ENERGOL SAE 30 SHELL X_lOO 30 CASTROL XL.

T he oil capacity of the Gearbox and Overdrive is 3.112 pints.

Checking Gearbox and Overdrive Oil Level

Set the car on level ground. LIft the c arpet in front of the right hand front seat to e xpose the panel in the side of th .... front Ulnnel. Reiease the sCrews and remove the Panel IFig.73l. Clean off any dirt in the vicinity then remOve the fdler plug from the overdrive unit. If the oil IS Iow fill until it is visible in the filler neck allOWIng suffi CIent time fo r the ot! to find its level throughout the gearbox and overdrive unIt.

F ig. 73. Checking gearbox and overd rive oil level

Draining and Refilling Gearbox and Overdrive

To dram the unit it is necessary to remove the drain

plugs from both the gearbox and o"e "drlve umt Fig.74 but refilling takes place through the overdrive on ly.

Fig. 74. Gearbux and ovet(hive unit drain plugs

After refilling drive the car a short dislance then again lOp up with oil. ThIS IS necessary because some of the oil will be taken into the hydraulic system of the ove ,·d "i ve.

Never run a car without oil in the unit s ince air ma y

enter thIS hydraulic system .

Cleanliness is essenlIal and the smallest partIcle of dirt o r 'fluff' from a wiping cloth which find s its wa y IntO

a valve or the overdrive mechanism will cause a great deal of unnecessary trouble, Make sure th~t the oil used for rilling is perfectly clean.

Fitting a replacement Overdrive Unit to a Gearbox.

The Laycock de Normanvi!!e overdrive is adapted to the gearbox of the 13 ,'istol Car by an adaptor cas tmg and a selecti ve Input Shart assembl y. T hese parts aI'" pecu!i a r to the 'Bristol' Car. The adaptor casti ng is Interchange_ able with the gearbox but the splines of the Input shaft which locate in the Keverse Gear of the geat'boxes at'e not Interchangeable consequently the whole Input shaft assembly must at all times be kept with the gearbox .

To ,'eplace a complete Overdrive Unit the following procedure s hould be used.

Using Figs.75 & 76 dismantle the overdrive unit from the gearbox at Joint 'A' which will leave the "everse gear r'rmly in position on the rear race of th" gearbox f,'om wh"re it can only be "emoved by the complete d,smantling of tne gearbox,

o

JOINT A

o

scre wdriver Cl' simtlar bar until they a"e both in line. I t will be noted that rotat,ng the coupling nange at the rear does not alter the relationship or the two sets of rear splines so tha t when they arc initially lined up they will remain so.

Locate the overdrive oi l pump operating cam (cam inward,,) on the input s haft and insert the shaft into the ove,'drive. Press down the sp ring loaded oil pump plunger to allow the roller to locate on the ca,n and locate the four holes i n the al"minium bearing reta iner on to the stud9,

Holding the input shaft. {CUrn the coupling nange on the rear of the overdrive until the rea ,' splines locate and push the shaft in to the bearing retainer face. The four spring washers and nuts c an then be positioned and tightened.

Couple up the splines of the input shaft with the reverse gea I' of ,he gea rbox and finall y tighten the overdrt ve to the gearbox at Joint 'A'.

Diagnosis and Rectification of Faults

SHAFT ASSE M BLY

OIL PUMP

OPER"TIN G CAM

4 NUTS .. SP~INC;

WASHER S TO I'<EMOVE

ASSEMBLY

Fig, 75 Dismantling the overdrive unit fmm the gearbox

Next, from the front of the overdrive unit remove the four 114" Nuts and Spring Washer9 and rake out the Input shaft assembly, ThiS is a selective 'Bristol' assembly compriSing the ioput shaft. bearing housing. ball race selective distance piece and circJips and it should not be dismantled except for obvious repair or renewal of the ball race. The overdrive oil pump operating Cam will either be on the front splines of theinp,,! shaft when it is withdrawn or left as a loose piece in the front of the overdrive.

Th,s removed assembly should noW be fitted into the rcplac"ment overdrive unit by the follO Wing method.

Vis"ally check the s plines at the rear of the bore in the oven!";ve which mate with the input s haft. Th ere arc tWO sets of Identic~I splines here and th" rearsplines can be freely moved in an anti_clockwise direction wah 3 long

· ,4,

Five symptoms a"e numercially given and each has items for finding and rectirying the fault in the quickest manner.

The teStS are arranged in progressive order so as to avoid any unnecessary dismantling,

(1) OVERDRIVB DOES NOT ENGAGE.

(~l Insufficient oil in the unit.

The overdrive unit must be filled to the level of the filler plug.

(bl Electrical Control System (Fig.77

When the e lectrical circ"i!is working correctly the solenoid can be heard to 'click' in and out when top

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gea r is engaged. the ignmon s witched on a nd the overdrtve (dashboard) s wi tched moved [0 the ' on' and 'off' pos iuons. When the ge ar lever ;8 moved inw any othe r gea r the C l r c ... 1I s hould becom e 'dead '. , hat is. no 'clicki ng' of th e solenoid s hould be hea rd .

T o c hec k th is seu ing s witch on the ignition, engage top ge ar and s wilch the overdrive s witch 111 '0 the 'on' p06ition . This s hou ld operate the solenoid and m ove the val ve operating shaft to the overdrive pos ition . The hol e In the sclti ng lever s hou ld now be

" 'V'"SE GEAR TO STAY IN POSITIO N

INPUT SHAFT ASSEM8L Y

CO~PR I $j NG -

INPUT SHArT

BEARING RETAINER. CALUt.4INIUM) eALl QACE

CIRCLIP (ON SHAFT)

CIRCUP (O N BEARING)

DISTANC E PIECE (SElEC TIVE)

Fig. 76. D i.mantling the overdrive unil fro m the gearbox

It has been found Ih al mO~lIop e .. ati onal fad u .. es a .. e due to eo .... oded term inal,. 811d fa ulty wi ri ng. so make 3 point of c hec king ove l' the winng and eonnectlons fi r st.

Check ,he bauery.

Chee k that volnge appears a t the overd rive s wi tch on Ihe ge a" bo~ cover when the igllition is s witched on. If so. apply a 6h ol'l c ircui l le mporarily 10 Ihe gea .. box s wi lch and ~ w itc h on Ihe ignit ion. If the c i" c uit !lOW opcnHell . e ith e .. the s witch is fa ult y 0 .. i ts height ill Ihe ge a rbox Ileeds adju sting by me ans of thc shims fittcd bcne ath it.

If the c . rcuit aull fai ls 10 operate when the ove r _ drive (dashboard) switch is used loc a te the a nal' connec to r adjacent 10 the overdrive solenoHi and pul l out the WI I·e. Check fo r c onl inu it y between the wire from the SWItch 10 ch aSSI S when the ove r d ri ve (d ashboard) s witc h is oper a ted. If the r e is no continuity the overdr,ve (dashboa rd) s witch i .. fa ulty. If c on tinui ty exillt!! the !!oIenoid s witch is faulty .

(c ) Solenoid Le ver nOI lI et co r·ree dy. Pigs .78 & 7(l

On the opposite aIde of the o ve rdrive t o Ihe sole n_ oid will be scen a valve lIel1ing le ve r (A) an 3ched to the valve Ope l'8tLng ahafl (B). In the oute r cnd of the lever i .. a 3/ 16 Inc h d ia . hole (Cl wh,ch must I.ne up wnh the sa rne d iameter hole (D) in the overdrive c as.ng when Ihe leve r is in thc corr e ct pOSH,on.

in line with the ho le in the ove rdri ve calling and it should be possible to insert a 3/ \ 6 inch di a . pin or d rill s hank (E) into the IwO holes .

If the ho lell do nOt line up . the sole noid leve r m ust be r eset usi ng the follOWi ng procedu r e.

Sl ack off the cl a mp ing bolt IF) in t he solenoid leve r.

Ene" gis e the solenoid as alre ady described and ins e .. t the 3/16 inc h d in. pin through the hole in the valve sett ing le ver into the hole in the casing.

Hold the solenoid lever IG) downwa rds so that it be a r s lightly agaln!!t the solenoid s top (H I and t ighten Ihe clamp ing bolt (P).

Ma ke lI ure tha t there is no end Ooat III the va lve operaung s haft by p ress ing the va lve sClli ng leve r a nd th., solenoid lever inwa rds sI m ultaneous ly whe n ti ghten ing the lIoJe noid lever bol t. This expand!! the oi l se al s at eith c r endofthe sha ft and p revents oil leakage .

Re m ove the pi n fr om the setting le ve " andopcrBle the s o lenoid seve r al tim e s by SWi tching the ignition on and off (top gear engaged and the ove r drive s witch 'on'l.

• Check Iha t the hole in the va lve sen ing lever corres ponds wi th Ihe hole in the cas ingby inserling the p m agll lll .

E

AMMETER @ ,---''''-------,

@ IGN. 5WITC"I

COr'\,T"<Oi,.. BOx.

~AI-0 - F

, , \

I="USE U N IT , ----------- _ . /

@

J I---:: ~ ~ : ;;:::;;~ ;;:]l ~ 1 ~~~g;~V E r11 ti l.L .......... SWITCH

U OVER DRIVE SWITCH

ON "-OPOF G~AR90X ,.

OVERDRIVE

O"E.RATING SOLE.NOID

Fig. 77. Electrical control system

A

B

the Valve Seat Fig.SO

The ope,·ating valve plug is situalcdallhctop t"ighl hand side of the overdrive casing almost over the valve setting lever.

Before attempting to remove this plug it is very important to release all oil pressure from the svstem by ope,·ating Ihe valve settingleverbyhand about ten (10) limes.

On removing the plug (J) and the spring (J ) and pltlnger (K) the sleel ball 'L' will be "een in the bOl!om of the valve chamber and a small magnet could be used to extract the ball. To remove the valve (M) a short length of wire 3/32 dia. should be in"erled into the hole in the centre of the valve, which can ,hen be lifted out.

Fig. 78. Setting the operating valve

Clean thoroughly and e xamine the seating" and if necessary 'grind_in' Ihe ball seati ng of the operating valve using a spare 5116 inch dia. steel ball and a fine grade grinding paste. Clean off all traCes of the grinding paste and re_assemble.

(d) Opet·ating Valve leaking due to foreign matter In

The steel ball can be assisted in its resealing in the overdrive casing by lightly tapping on to its seat

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\hling ~ soft cOPP"" drift.

(e) No Oil P ressu re.

If the unit s till rail s w operate and the openHing valve is seating and working corre c tl y. chec k that the oil pump is working.

Jac k up the rear wheels of the ca ,', operat e the valve senins..!rrer about te_" (]O) times to release an )::...o il prcssu"e f r om the sr.Stem and then remove the operating valve plug.

G

Fig. 79. Setting the solenoid lever

Start the engine and engage top gear with the engi ne dcking over s lowl y and nore if any oil is being pumped into the valve chamber. If none appears. then the oi l pump is not working probably due to foreign m aner onth" se at of the non-rewrnvalv" . 11 flow of o il into the val ve chambe!' does not in_ dicate tha t the P" es!l ure is cort'eC! and th is s hould be checked .

An adaptor r an N o. 7H 5899 s hould be sc rewed in to the casing. in place of the operatitlg valve plug, and an 800 Ib.pel' s quareinchpress ure gauge sc rewed into the 1/8" BSP. thrcad of the adaptor.

S tat'[ up the engine. engage top gear and s wit ch On the overd,.,ve. T he p n:ss ure gauge s hould read 500 p. s . i. :!: 10 p.s.i . Low pressure indi c ates le akage and to r emedy this fau lt proceed as follows:

k.emove the drain plug (E) Fig.81 and allow tne

,37-

oil to drain. Remove the solenoi d . Slacken off the clamping bolt o f the solenoid lever and "e m ove the solenoid lever and the distance collar. The solenoid brac ket is s e cured by tWO (2) 5/16"

dia . s tuds and two (2) 5/16" dia. bolts the heads of whi ch are painted RED.

J

L

o Fig. So. The "P<'tating va lve

Remove the tlut s, washe",. and stone guard from the s tuds before touching the bolrs .

The two (2) bol ts s hould now be s lackened off LO

gether "c1easi ng the P"essure on the internal accumu lator spring .

The pump valve plug 'A' Fig.81 can noW be re_ moved with a box s panner followed by the spring. plunger and ball.

Clean th e valve s cat and if necessary r e-seat the ball by tapping it gently on to its seat using a copper drirt.

Fig. 81. s.,ction vi"w of oil pump showing the non-rcturn vah"c

Re-a sse,nblc rhe valve and ensure thar the valve plug is well rightened on to the soft copper washer which should be replaced by a new washer if dam_ aged in any way,

Rc_assemble the solenoid brackel and parts the reverse of the above procedllre and ensure that Ihe accumulator spring is located on ils spigol al the back of Ihe 901enoid bracket. After re_assembly it will be necessa,'y to reset the solenoid leverlo the procedure already given.

(2) OVERDRIVE ON ALL GEARS.

(a) E le ctncal Comrol System.

If overd rive is obt:ainable on all gears tbe overd,';ve SWLtch on the gearbox cover could be stuck .

(b) Solenoi d lever not set correctly (descri bed previo_ llsly),

(3) OVERDRIVE DOES NOT RELEASE,

If this happens do not tr), 1:0 revers e the car as thi" may rcs ult in unnecessary damage.

(a) Blockcd RC9trictor Jet In the Operating Valve (Pig.SO)

The operating valve should be removed as already desCf'ibed and the restricto" let (M) should be cleared,

(b) Electncal system not operating correctly.

If the unll remains in overdrive after the ignition ha s been switched off thcn Ihe electrical circuit. is nor at fault. If however the unit cuts in and out with the ignition switc h a shon circuit in thc Wlrtng or a faulty relay should be looked fo".

(cl Solenoid lever not set cm·recdy orSolellOldPlung_ er sticking,

It is very unlikely tbat an)' mal-adjustment of the

lever will develop 1:0 prevent tbe overdrive from ,'cleasing, The setting and working of the valve setll ng lever, however, s hould bc checked and cort'ecled if necessary.

(d) Sticking Cone Clutch.

This fault has becn known to occur as a ,·esult of heating up on a long run on a new unit before the

linings arc fully bedded in, The clutch invariably releases itself when it has cooled down a litde, 0'" it can be released b)'givlngthccasinga sharp blo,:" with a hide hamme" over the brake ring between the body of the overdrive and the r'ear cover .

(e) Damaged parts within the unit necessi tating removal and dismantling of rhe unit for inspection,

Internal damage however is very unusual and it is ,·ecommended that all tests should be re_cbecked befor" deCiding to remove the unit.

(4) CLUTCH SLIP IN OVERDRIVE.

(a) Insufficient oil in overdrive and gearbox,

The correCt oil level must be maintained .

(b) Solenoid lcver not set C01T"Crly,

Check the setting as already described,

(c) lnsuffici"nt Hydraulic Pressure,

Probably due to for"ign matter on the bal l seat of the pump v~ I ve or ·operating valve . Ch"ck tbe pressure with the adaptor and gauge as already des_ cribed and clean and reseat valve if required.

(d) Worn or burned out COne clutch Outer lining,

This is not experienced even after ver)' large mileages unless the c ar has been driven forq long time in overdrive with the c1utcb slipping due to causes, a, b, and c given above, Removal of the uni land ,'eplacem"nt of a cone clutch rnernbe I' would be necessary in this case.

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( [» CLUTCH SUP IN REVERSE OR F REE ,<VH EEL CONDI TI ON 0.\1 OVEHDRiVE .

(a) I\[oc ked ,"e,lInCCOr lel .n , h I'" ope r a l ing va [ve caus. ng

s[ uggls h n::,u '-n m ove"'e'" of the cone cl u tch .

Clean , he r cstrictor le, as a l read y described .

To Obtain Access to the O verdri ve Unit for Testing and Rectification' of Faults

Remove ,he IWO fr om seats and Ihe c arpets .

DCltl cll .he tu ,','C' gc a r cha nge by r e moving the fou r (4 ) dom ed nlII S und hfllng cle a r of ,he ,;""d". This wi ll a llow t he from , unne lll11g '0 be ,"cmoved .

Re m ove .he n oorboa f"(j s ,

R e~a n oc h ,he t urre , ge,1r change ,

Removing and Refitting the Overdrive Unit On ly

Remove .he t wo f ron t se 3t l:l and ,he ca'"pet .. ,

De'llch .he ,u,"re, gea r c hang .. - by removing t he four (t) domed nullI and l ifting clea r of , he st ud s , 11" s wi ll .1l1aw .he front ,unncl hng ,a be removed"

R("OIove , he noor bo(lrds.

U'\>'C"ew the d "a m plugs ( F ' g .74) a nd d r a.n the ge a r~

box and ove rd ri ve unll. Refi t ,h(" d ram plugs.

D.sconnect the prope llor " hafl a , the ov(" rdnve c nd only and s b de the cnd back to dea ,",

Remove .he t wO (2 ) rea r m ounl1 ng bo lts a nd d ll' ~

conncct ,he "peedometcr d ri ve"

T u ,'n thc fa n b lades of ,he eng.ne to the ho r izont 31 POSItlOO It o avo.d brea kage when Ii hing ) then li f , and support ,hc e llgme Dnd ge a rbox s uffiCiently only to all ow dIe ove ,"dnve " "it to be withdrawn. Removc the nuts at J Olll ' 'A ' (P' g.75) secunn g ,he o~erdriv e to the gearbox 3 nd m anoeuvre the ""'t c lear" of the car.

T o I"efit .").n o ve rdrive unit. revers" the abovc procedurc . ensllnng th at Ihe 'npUt s haft s piines mesh cor,"ec rly i ll the revc,"se gea l""

Stripping and Rebuilding the O verdri ve

Removi ng and Refittin g the Oil Pump (P'gs . 8 1. 82 & 83 .)

Remove the soleno,d b r ac ket as 1)l"evlOus l y desc ri bed

and I. f l out Ihe accumu lato r " p ,". ng and tu be to g ive acccss 'a ,hc 011 pump non ~r ct ul"O valve" Remove t he oil pum p non_retu,"n va lve plug l A) spnng. 181 p lunger (C) and ba ll (01. Hemove ,hc d ,"aon p lug (El , Removc the fi lte l" bolt IF) II nd , he o d fiiter IC)' T ake ou t the plug (H) f r om

, he od pump body and renlove the ' wo s mall "C '"C"-" . L:song Ihe od pum p e xt raCtor tool (Chu r c h,[ l L. 183) sc ,'cw the ", xt r aClor bolt "" 0 Ihe o il pump bod y']} p l llce of Ihe rcmoved sc ,"ewcd pl ug. T u .... all the ...... ng nu t whic h WI ll w!!hdnlw Ihe Pelm? body .

_. E xtracting the pump hody from thc casing us ing

9pccial 1001 Ch ureh ill LI83

T o r c pl ~ , c c:h e o il pump body which i s a" imerfc,"ence fit in the c as .ng us e two (2) numbe r 10 UNF Stud s about 3" long a s guides li o IOC.").te the sere w ho les ) and drive the p um p bod y hom e with a suitable brass dnf, or use " pee ia! tool (Ch","chdl L.184)which incorpora,es the 'wo gUldc8 .

Fig. S,. Fill;]}/<:" the oil pump body us ing ChutchilllOol LI84

The pump plunger is preven,ed from rotation, when in p rnl illon, by a gu ide peg In the front casing. It is possiblc to gu.de It pa st the guide peg by means of a se rewdrtve,' i"se r,ed through the s.de of the ca s ing ,

Removing and Refittin g the Accumulator Piston ana its H ousing

Remove the s o leno id brac kct as previous ly deSC ribed and [i f I oul the accumu la to r s p r ong and s pring tube. The acc umu lator P' Ston hOUl. ing is a push fit into the unit c as ing and , he o t! tightness of ,h(" housing i .. ens ured by

the two rubbel" nngs .

The hou ... og c an be exu"ac ted eastly toge ther wilh the pIStOl). by Ihe use of a s pec ial 1001 which fits 10tO the bore of Ihc hous .ng IInd has a rubbe r riog whi ch e an be ex· ra ndI'd by fa r m ng the t Omm y bar.

To use the eXU'a ClOr first remove th., ope ra ting valve plug (Fig. SO) to admit a,r to the ,'ea" of the housing. intlert the no"e of the extractor as fa" alii It wdl go into the bore of the houlil lng. tighten the rom my bar and pull (F'g.S4)

P ISTON

Fig. 84. WithdrAwing Ih., pislon housing ~hnw ing

CXtT~ctOT 1001 Churchil l L.8z in po~ition

Examine the bOI'c of the housIng (or !ligns of wear ~uch as a ridge Or !lcormg. ThIs .,xanllnation should be car,.,.,d out WIthou t removing the piston from the housIng.

The accumulato t· pUHon IS fined "'to the housIng with 11 s pecIal ventun tube (Churchill L.179) to enSu re that th~ p,ston rings donot scrll\"C as they enter the aluminium hou",ng. Therefore do no! remove the plllton from the hllu",ng unless !! IS considered neceSSllt·y. Should the p,ston be removed WIth no venturi tool IIvailable to insert it then it should be Intlerled at the fr ont of the housmg ... s lng a s mall P'tlton nng cl amp to compress the ring" a" the piston enters.

T o reass emble the ho"' '''''g and p,StOO assembly Into the c a " lOg use either the withdrawa l tool or push On the t nner piston otherwi se this piston may blow out backwa rd!! a~ the housiog goes mto thc casing.

Dismantling the Body and Gears

FIrst remove the adaptor casllng whI ch c onnects the overdrive unit to the 'BrIstol ' GearDox. It will be noted that tillS is bolted together by foul' (4) short studs and two (2) long s tud ... Remove the nut s and wllBhel'9 from rhe s ho rt studs before touchmg the long swds . The nuts on the long 9tuds shmdd then be unscrewed sl!llI11taneously a few tu rns on each to rdease the compr.,ssion on the Irlner clutch r et ... r n s prings.

LIft rhe cl utch thrust "prmgs from the supportmg s tuds . Ne~t rem ove the nut9 from the SII. St uds whic h

hold the c asings together and the front c a s "'g and rear c a s Ing Can then be sep ar3ted. Note the two (2) th"u"t wa s hers between the bush in th" front c asIng and the sun wheel splined e~tenOlIOn.

Remove the brtdge p'eees frolll the f ron t of the oper_ aung pistons and withdraw the cone clutch.

Wnhdraw the tWO (2) ope ra ting pistons .

Remove the small Cl rcl,p secunng the ball beanng to the c one clutch extenSIon and remove the COne clutch from the ball beanng and 'n,rust Ring a ssembly.

Remove the larger ci r e hp reta ' nlng the ball bearing m the Thrust Rmg assembly and presll OUt the bearing.

· ~ o·

Us ing 11 h,de faced hammer tap e venly around the cas t 'ron brake ring and remove.

T he remova l of the solenoid cover and valves ha" bee n dealt WJlh Pl'eVlOUllly In the fault fi nd!llg.

Sun Wheel, Planet Carri er and Uni-direct ional Clutch

Lift out the su n wheel and remove the thrust wa .. hers between the sun wheel and the plllnct carrier. Thcn remOve the planet c arrie r.

Withdraw the un_direc riOlla l clutch using the a .. sem bly r ing (Chu r chill L.118) to reta in the rollers and then hft out the thru." washerll.

Dismantling Rear Casing and Annulus

Unscrew the set screw securing the speedomete r drIve bush and withdraw the bush and gear assembly.

Grip the coupl ing nallge, withdraw the .. pht pin and remove the s lotted nu. and wallher. Withdraw the nange.

The annu lUII. which can now be dnfted OUt easdy from the rear will take the front ball bearing with it and leave the rear ball bearing in the cas Ing.

Extract the rear ball beanng and the oil Ileal.

Inspectio n

Prom Casing.

Exami ne (or c racks or damage, od leaks from the plugged ends of the oi l passages 0" from the welc h plug beneath the acc umulator bore. E ~ amine the bronze "upport bushes in the c emre bo re in which the "'put " haft s hould be a close run1llng {It . Sce that the opc r aling piston bores are free from scratc hes or scon ng and at the s ame t' me c heck that the operat"'g Piston .. and nnga are not damaged.

The Gears

In''pect the tecth of the 8"ars for damage. Exsmlne the bronze bush In th., sun whee l whIch s hould be a c lO6e rllnnlng fH on the malnshaft, and examIne the planet whee ls wh tch should be a clos., runmng fit on the planet p imons.

Cone Clutch Sliding Member Assembly

E xamin., the clutch linings for blll·ni ng. wea,' 01' enlbedded foreign matte r. Sec also that the cone clutch s lides freely on the spitnes of die s un wheel extells,on. Make su r e tha t the P"''' for the clutch springs and bridge piece" a r e nvetled t iSlul y into the clutch thrust nng and that the Ihrus t nllg ball bearing IS in good eondHion .

Clutch Springs

Examine for distortion or collapse. pree length oflhe outer springs should be 4.112 inc hes and the f ree l.,ngth of the inoer sp rmss 4.1 / 4 inc hes. Replacement springs arc s uppl ied tn sets.

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Uni-directional Clu tch

Sce that the rollers are not chipped or damaged and that the inner and outer members of the roller clutch arc nO! damaged. Sce that the spring is not distorro;d or broken.

Replaccment rollers are supplied in sets .

Ball Bearings

Sce that the ball bearings for the annulus arc in good condition and free from any roughness when rmating slowly ..

All T hrust Washers

Ins pe ct for sco,·ing.

O il P ump

Examine the pump for signs of WeaT·. The pump plunger s hould be a close s liding hyaraulic fit in [he pump body and the plunge ,' roller should rotate freely on the rolIer PI" With no s lackness . E xamine that the pump valve seat and ball arc fre e fT'om ni c ks and scratc hes .

Operating Valve

Sec th a t the ball searing, and ball aq: free from nic ks and SC !'atches and the res trictor jet clea ,·. Make sure tha t th .. valve slides freely ini tsborein the front cas ing.

Re-assembly of Overdrive Unit

First build up the Rea r Case assembly.

Drive the front ball bearing on the annulus and then press th" annulus right home in the !'ear c asing .

A sclective spacing washer mu",t now be fitted which should give an end floa t of .005 inch to .010. inc h (sce Fig.8S). Y.'hen a su itabl e washer has been dec ided upon fit this 10 the shaft, drive on the coupling. fit "nd tighten the slotted nut . The end float of the annulus must now be mea s ured preferably with a dial indicator or measured f"om the fa c e of the front casi ng to the fac e of the annulus . It is very important that nO pl'e_load should develop on the annulus bea rings when the unit warms up in use. If the cnd float does not conform to the correCt l im its. the slotted nut and coupling flange must be r emoved and anothcr spacing washer s elected. When the end float is c orreCt_remove the nut a nd flange and press home the oi l se al with the lip of the seal inwards. Finally press on the coupling flange, tighte n the s lotted nut and Jock with split pin.

ASSEM BLE ll.,E FRONT CAS ING in the follOWing order:

Assem ble the oi I pump wi!h valve etc . , th.c ac cnmulator housing with piston, aceum ulal.Or spring, tube and sole no id brac ke t as previously desc ribed.

Next fi' the two ope"ating pi sl.Ons using a small piston ring elasp t o a s "lst assembly or s peci a l tool (Churchdl L.179). The operating ball valve, plunge",sp"ingandpJug s hould nOW be fined.

-4 1-

_I- m

f/ "~ ""' .... u ~"s - "',~ 5 ..... ~f

('.

~\\ll\\\ ! P l\ 'il '"'",:" """" "",,

\ y /C ?

"'~~ .. co.s, ..... / \,,-,, S57 ..,.,c , "' ~ W~SHE:F<

[S~_EC f'~ J

Fig. 85. Sele<: tion of washer for annulus end final

Finall y dnve home the c ast 'ron brake nng us,ng a hide hammer (Fig .S6l. The brake ring is splgotted to the main c asing and i s a light imerferer1ee fit.

BFlAI<£

Fig. 86. Fitting thc brakc ring

THE SLIDING CLUTCH M E M BER s hould now be a s sembled.

Pr"ss tho; ball bearing into the hOUSing in the thrust ring and sec ure wi!.h the eXlernal ci ,·clip. T he thru st ring and bea ring is then pn~ssed on to the cone clu1.ch member and secured with the imemal c irclip.

Assemble the Uni -directional Clutch

Fit the spring and centre member of the c lutch 1.0 I.he c age, loc ating the spring to cause the rollers (whe n fit1.ed) 10 "i se up the incli ned face of the ce ntre member.

Pos ition the r oller ass embly ring (Churchill L.178)

to c age and inner members then feed the rollers II'W

position (Fig. 87!' Mount the rear cas ing flange down_

ASSEM SL.Y CL.U;CH

CAG E.

Fie;. H7. Assembly of uni_directional roller clutch in assembly ring- Churcbill Lq8

wards in a s uitable support. Fit the correct washe.· to the n."cess in the anm,lus. With assembly ring still in position to n.",ain the rollers . nt the uni_directional clutch (open side of the c age inwards) to the annulus ( Fig.SS) and withdt·a .... the assembly ring.

~L!f'l. CLUTCH

"'SS£M BLY , ,,,

RI"'G

XN 6~4 THRLlsr W A Si~~ ,

Fig. 88. Fining "ni-dite<:tional roller clutch to annulus

Assembly of Gears

With the rear cas ing held vertically by its coupling fla nge.

P lac e the th'-ee thrust washers for the rcar of thc s un wheel into positi on inside th" planet carrier with the steel thrus t wa sfler between the two bronze ones .

_42_

0 ~ c

@ , ,®-,

Ill)))))) [((((((( ,

"y~

, , 0 0

<

, , @l

Fig. 89. Positioning the puneh marks on the planet wheel.

One tooth On each planet wheel is ccntrc punch marked and the planet wheels s hould rotate in the carrier so that the punch marks are radially outward" as shown in Fig .. 89. The "un wheel should now be inserted into the planet carrier and. with the punch marks s till outward. the planet carrier should be placed into the annulus .

A dummy input shaft (Churchill Tool No.185l should now be inserted and left in place until the a"sembly is completed .

The neJ<l operation is to dt:termine the correct amount of end float fo'· the sun wheel which must be bet .... een .014 inch and .. 020 inch.

Place the bronze thrust washer (fixed sizel over the dummy input shaft. A s teel washer (selective) whic h is fitted between t he bronze thrust washers and the central bush in the main casing serves als o to make this adjustment and is s upplied in seve n thicknesses to s uil the assembly.

Gauging the end noat of the sun wheel can be ca'Tied Out wi th feeler gauges u"ing the following procedure.

With the bronze thrust washer and a s tee l thrust washer in position on the dummy input shaft and locating on the face of the sun wheel extension. place another steel washer of known thickness on the shaft (Fig.90).

The c one clutch assembly should be left out while the thrust washer is being se lected .

Locate the f r ont c asing on the s haft and press down on the face of the thrust wa s hers . The fac es will nOt join bec ause of the gap made by the additional (known size! thrust .... ashe,· and the distance between the two casings should be measured with feeler gauges.

The width of the gap subtracted from the thi c kness of the known was het· will gi ve the amount of end float when that pa '·ticular wa sher i s removed. If the end nOat is found to be too much or too little a suitable washer from

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TkRuST

FOR TE.ST ~U~POSES

SELECTIVE.

W ASH~

)(oN 667

XN 629

Fill' ')0. Selecting ~ suita ble thrust washe r for 8U n wheel end fl oat

·4~-

the seven (7) selecuve sizes can be deternnned by calc ulation.

Wh en the cnd float of the sun wheel has been dctcr_ nu ned the assembly c an be cOfTlpleled .

Fi t the cone clutch a .. sembly into the front casing. Jam

the two casi ngs together. fil the spn ng washers and nuts on 10 the studs and [lghten evenly •

The bndge pIeces fo r the operallngp,Stons can now be posItioned with tabwa shc r s and nuts and ttghtened and locked wi th the tabwaahe r s.

The clutch springs s hould now be p Ol.li1.loned with the four (4 ) longer s prings on the outside pegs and the four (4 ) .. horter one s on th.e inside pegs.

Pit a pape ,· )omt to the front face of the from casing ;Htd fit the adaptor CII..r ing over the st'uds . Locate th.e clutch Otp l'inga on to thei r respective spigots on the Inside face of the c al:lting.

Tighten the adapt o r cas ting by sc rewing down the nul6 evenly on the t WO longest studs and fina lly lighten by means of the four (4 ) remaining studs.

The ove rdri ve unit is then "eady for use or if fo r 'torag!. the fron t face should be covered.

The assembly of the input s haft is s elective (0 e ach gearbox and is cove r ed by its own procc.:!ure pre vLousl y gLven .

gearbox and overdrive - bristoloda.org · the gearbox at joint 'a' which will leave the...

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