Removal of Selector Lever

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





Disassembly

NOTE: When dismantling the gear change mechanism the gear change shafts must be in neutral position.

1. Place the gear change mechanism in a screw vice with protective jaw faces.




2. Tap out the clamping pin for the gear change lever's shaft
3. Tap out the shaft and remove the selector lever.

NOTE: The catch balls fall out of the selector lever during dismantling.




4. Place a finger in front of the seat of the catch ball and pull out the reverse gear shaft.
- Put all catch balls and springs in a safe place.




5. Remove the other shafts with their balls and springs in the same way.
- Start with 5th gear's selector shaft.

NOTE: There are extra catch balls between the selector shafts (catch balls in the double positions).

- Then remove the 3rd/4th gears' shaft and finally the 1st/2nd gears' shaft.
- Do not lose the two pins in the 5th and 3rd/4th gears' shafts.




6. If forks and actuators need to be replaced, tap out the clamping pins and remove the forks and actuators.
- Note the positions for reinstalling.
- Clamping pins should always be replaced when reinstalling.
7. Check the condition of all parts as regards wear.
- Replace worn or defective parts.

Assembly
1. Install the forks and actuators on their shafts if they have been removed.




2. Start with the 1st/2nd gears' shaft.
- Insert the spring and the ball in the bearing support.
- Press down the ball with a drift and insert the shaft to its neutral position.
3. Insert the catch ball for the double position mechanism in the 3rd/4th gears' shaft.




4. Insert the spring and ball.
- Install the pin in the 3rd/ 4th gears' selector shaft; check that it runs easily in the shaft.
- Press down the ball with a drift and insert the 3rd/4th gears' shaft to its end position.

NOTE: The 3rd/4th gears' fork should be threaded over the 1st/2nd gears' selector shaft during assembly.




5. Insert the catch ball for the double position mechanism on the 5th gear's shaft.
- Then insert the spring and ball in the 5th gear's selector shaft.
- Install the pin in the 5th gear's shaft and check that it runs easily in the shaft.
- Press down the ball with a drift and insert the shaft to its neutral position.




6. Insert the catch ball for the double position mechanism in the reverse shaft.
7. Insert the spring and ball for the reverse shaft.
- Press down the ball with a drift and insert the shaft to its neutral position.




8. Place the selector lever with its springs and sleeves in the bearing support.
- Press in the shaft and tap in the clamping pin.