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SYNCHROMESH GEARBOX

Triumph TR 6 Manual. AKM 3529.

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SYNCHROMESH GEARBOX

SYNCHROMESH GEARBOX OPERATIONS. . . . . . . . . . . . .onstant pinion assembly.verhaul 37.20.34. . . . . . . . . . . . . . .ountershaft.verhaul 37.20.29

. . . . . . . . . . . . . .rive flange.emove and refit 37.10.01

. . . . . . . . . . . . . .ront oil seal.emove and refit 37.23.06Gearbox assembly.verhaul . . . . . . . . .. . . . . . . .- remove and refitGearchange lever.heck and adjust . ..emove and refit . .

. . . . . . . . . . . . .ear extension.emove and refit 37.12.01. . . . . . . . . . . . . . .ear extension.verhaul 37.12.04

. . . . . . . . . . . . . .ear oil seal.emove and refit 37.23.01Speed omete r drive pinion assembly.verhaul . . . . . . . .. . . . . . .- remove and refitSynchro units.verhaul . . . . . . . . . . . . . .Top cover.verhaul . . . . .. . . .emove and refit

Triumph TR6Manual.AKM 3529 .

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- -- - -

SYNCHROMESH GEARBOXR E A R EXTENSION- Remove and refitService tools : RC4 21Removing

Drive the vehicle o nt o a ram p and raise the ra mp.Remove the exhaust intermediate pipes, s i lencer andtail pipes.Remove the propel ler shaft 47.15.0 1.Using tool RC 42 1 to retain th e drive flange, unscrewand remove the n u t and washer .Remove the drive flange.Unscrew and remove the peg bol t and washer.Withdraw the speedometer drive cable and pinionassembly.Using a ramp jack, support the gearbox and removethe rear mount ing p la t form a t t achment bo l t s and nu t sRemove the two m ount ing bo l t s and nu t s .Swing the s teady s t rap forw ard and clear of the rearex tension.Raise the gearbox and remove the mounting. Lowerthe gearbox .Place a drip t ray under th e gearbox.Unscrew and remove the bol ts .Withdraw the extension housing, thrust washer andgasket .

Refi t t ingClean the mating faces of the gearbox casing andextension housing and fi t a new gasket .Refi t the extension housing assembly and thrustwasher.Fi t and t ighten the extension housing bol ts .Refi t the speedometer drive cable and pinionassembly.Locate and t ighten the peg bol t .Refit the drive flange.Fi t the nut an d washer.Using tool RC42 1 to retain the flange, t ighten then ut t o 9 0 to 1 l O l b f f t ( l 2 . 4 t o 15.2 k g f m ) .Refi t the mounting.Ref i t the two mount ing bo l t s and nu t s and s tead)strap.Fi t and t igh ten the four mo unt ing bo l ts and nu t s .Refi t the propel ler shaft .If necessary t op u p the ge arbox, with oi l .Ref i t the exhaus t sys tem.

Triumph TR6 Manual. AK M 3529.

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SYNCHROMESH GEARBOXDRIVE FLANGE- Remove and refit 37.10.01Service tools: R C42 1

Removing1 . Drive the vehicle on to a ram p and raise the ramp.2. Remove th e propeller shaft 47 .1 5.01.3. Using tool RC42 1 to retain the drive flange, unscrew

and remove the nut and washer.4. Remove the drive flange.Refitting

5. Thoroughly clean the mainshaft and drive flangesplines.

6. Fit the drive flange.7 . Refit the washer and nut.8. Using tool RC421 to retain the flange, tighten the

nut t o 9 0 to 110 lbf f t (12.4 to 15.2 kgf m).9. Refit the propeller shaft 47.15.01.

m riumph TR6Manual. AKM 3529.

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SYNCHROMESH GEARBOXT OP COVE R

5 4- Overhaul 37.12.19Dismantling

Remove the reverse lamp switch and overdriveisolator switches (if fitted).Remove the screwed plug. distance plece, sprlng andplunger - reverse detent.Remove the screwed plug, sprlng and steel ball --3rd / top de ten t .Remove the screwed plug, sprlng and steel ball -l s t / 2 n d d e t e n t .Remove three "wedglok" bolts - one f rom eachselector shaftMove the three selector shafts Into their neutral Lposltlons. LW~ thdraw he l s t /?n d se lecto r shaf t .Remove the l s t i2nd se lec to r fo rk and d~ sta nce ube .W~ thd raw he reverse selector shaftRemove the reverse actuator and d~stance ube.W~ thdraw he 3 rd l top se lec to r shaf tRemove the 3 rd / top se lec to r fo rk and d~ sta nce ube :/T 0833ARemove the Interlock plunger and mterlock balls.Unscrew t wo setscrews and remove th e cover plate.Remove the sealing rings

37.12.19 Sheet 1 Trlumph TR6 Manual.AKM 3529. l@i

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SYNCHROMESH GEARBOXREAR EXTENSION- Overhaul

1 . Remove the rear extension 37.12.01Dismantling2. Prise out the oil seal.3. Drive ou t the bearing.

Reassembling4. Drift the bearing into th e extension.5, re& a new oil seal into the extension.6. Refit the rear extension.

TOP COVER- Remove and refit 37.12.16Removing1. Remove th e transmission cover panel, see 76.25.07

(includes gear lever removal 37 .16.04).2. Disconnect the reverse lamp and overdrive isolator

switch leads. Release steady strap f rom t o p cover.3. Remove eight bolts.4. Lift off the top cover assembly and th e gasket.

RefittingApply grease to the ab utm ent faces and fit th e gasket.Place the selector shafts in the neutral position and fitthe t op cover assembly. Ensure tha t th e reverse leveris corre ctly engaged.Secure the top cover with the following bolts, eachfitted with a lock washer:a. Two bolts - 67 mm long - o frontb. Two bolts - 73 mm long - o rearc. Four bolts to sidesConnect the reverse lamp and overdrive isolatorswitch leads. Connect th e steady strap.Refit the transmission cover panel, see 76.25.07(includes refittin g gear lever 37 .l 6.04).

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SYNCHROMESH GEARBOXRefit the reverae deten t plunger, spring distance pieceand screwed plug.Refit the Istl2nd detent ball, spring and screwedplug.Refit the 3rdltop detent ball, spring and screwedplug-Check the pull off loads using a spring balance.1s t /2nd and 3rd / top - 32 t o 34 lbf (14.5 to 15.4kgf)Reverse - 26 to 28 Ibf ( l l 8 to 12.7 kgf!Insert shims or grind springs to ad just.Refit the reverse lamp switch and overdrive isolatorswitches.Refit the t op cover assembly.

37.12.19 Sheet 3 Triumph TR6 Manual. AKM 3529. ia

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SYNCHROMESH GEARBOXReassembling

Fit a sealing ring int o each bore.Fit the cover plate and secure with two setscrews.Fit the interlock plunger into the 3rd/top selector,shaft.Fit the 3rd/top selector shaft, distance tube and forkinto the top cover. Push the shaft into the.neutra1position.Locate an interlock ball in-between the 3rd/top andreverse shaftbo res and retain with grease.Fit the reverse selector sh aft, distance tube an dactuator into the top cover. Push the shaft into theneutral position.Locate an interlock ball in between the 3r d/ to p andIst/ 2nd bores and retain with grease.Fit the lst/2nd selector shaft, distance tube and forkinto the t op cover.Secure the forks and actua tor to the shafts using new"wedglok" bolts.

m riumph TR6 Manual. A K M 3529. Sheet 2 37.12.19

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SYNCHROMESH GEARBOXGEARBOX ASSEMBLY- Remove and refit 37.20.01Removing

Drive the vehicle o nt o a ramp and isolate the batt ery.Remove both f ront seats 76.70.04-05Remove transm ission side trim panels 76.1 3.0 6Remove the fascia support bracket 76.46.09Remove the gearlever 3 7.16.0 4.Kemove the carpet and the transmission cover panel.76.25.07.Disconnect the propeller shaft from the gearbox driveflange.Disconnect the speedometer drive cable.Unscrew and remove the mounting bolts and nuts,noting the position of fixings for the steady bracket.Remove the exhaust support bracket.Remove the mounting plate bolts.Unscrew nine u pper enginelbellhousing attachm ents.Raise the ramp.Disconnect the clutch slave cylinder push-rod fromthe cross-shaft lever.Position a ramp jack unde r th e engine and raise theenginelgearbox sufficient to remove the mountingplate assembly.Remove the remaining (seven) enginelbellhousingattachments.Lower the ramp and lift o ut the gearbox.

37.20.01 Sheet 1 TriumphTR6 Manual. AKM 3529. &a

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SYNCHROMESH GEARBOXGEARBOX- Overhaul 37.20.04Service tools: RG.421, S4235A -2, S314 , S4221A -15A, S67A,

S167 .1. Remove the gearbox 37.20.01 and drain the oil.

DismantlingUnscrew and remove eight bolts.Lift off the t op cover and gasket.Remove the clutch release mechanism 33.25.12.Take ou t fou r setscrews and washers.Tape over the constant pinion splines and remove thefront bearing plate and gasket.Remove the peg bolt and withdraw the speedometerdrive pinion assembly (If overdrive is fitted, performoperation 40.20.07, remove the overdrive cam andadapto r plate and continue from para. 13).Using tool No. RC421 to retain the flange, unscrewthe nut .Remove t he flange.Unscrew the bolts.Remove the rear extension and gasket.Remove the thrust washer.Take out tw o screws.Remove the co untersh aft fro nt plate and gaske:.Take o ut the cross recessed head screw.Remove th e retaining plate.Withdraw the countershaft spindle and allow thec lus ter to drop to the bo t tom of the box.Using tool No. S4235A-2 withdraw the constantpinion assembly.Fit th e abutmen t tool No. S314.

37.20.04 Sheet 1 Triumph TR6 Manual. AKM 3529.

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SYNCHROMESH GEARBOXRefitting18 . Check the alignment of the clutch splines, move the

clutch throwout bearing to the rear extent of itstravel and engage top gear.

19 . Manoeuvre the gearbox into position, if necessaryrotating the drive flange to align the input shaftsplines with those of the clutch.30 . Fit the upp er (nine) engine/bellhousing attachments.

21. Raise the ramp and using the ramp jack, lift theengine.

22. Refit the low er (seven) engine/bellho usingattachments.23. Place the mounting assembly in position and lower

the ramp jack.24. Refit the cl utch slave cylinder push rod to the cross

shaft lever.25. Lower the ramp.26. Secure the mo unt ing plate to the chassis frame.27 . Refit the exhaust support b racket.28 . Refit the two bolts and n uts and the steady strap.29. Connect th e speedometer cable to the gearbox.30. Connect the propeller shaft to the gearbox drive

flange.31. Refit the transmission cover panel and carp et.

76.25.0732. Refit the gearlever 37.16.04.33. Refit the fascia supp ort bracket 76.4 6.09 .34 . Refit the transmission side trim panels 76 .1 3.0635. Refit both front seats 76.70.04-0536. Re-connect the batter y.

W TriumphTR6 Manual. AKM 3529. Sheet 2 37.20.01

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SYNCHROMESH GEARBOXReassembling ,131 . Refit the reverse lever with fulcrum pin, washer and

nut t o the gearbox.NOTE: Posit ion th e lever on the pin so that two screw

threads (a pp rox ) are visible between the gearbox andlever. Replace the reverse idler gear and s haft.

3 2 . Using heavy grease to retain the thrust washers inposit ion, f it th e countershaf t c luster.

33 . Align the thru st washers and fit the spindle.34. Check the countershaf t end f loat . The end f loat

should be 0 .007 to 0 .012 in (0 .18 to 0 .30 mm) .Adjust by selective use of thrust washers or ifnecessary remove metal from the steel backing face ofthe thrust w asher . Withdraw the spindle.

35. Check the end f loat of the 1st . 2nd and 3rd gears ontheir respective bushes. End float should be 0. 00 4 to0.008 in (0 .1 to 0 .2 m m) .

N O T E : i Interchange of 1st and 3rd gear bushes ispermissible to obtain these figures.

i i I f necessary reduce the b ush leng th to reducethe end f loat or f i t a new bush to increase theend f loa t .

3 6 . Check the total end f loat of the 2nd and 3rd gearbushes on t he mainshaf t.U. Temporar i ly f i t to th e f ront end of the

mainshaft in order:i Adjustment washer .i i Bush - 2nd gear....m. Thrust washer ,iv. Bush - 3rd gearv. Thrust washer - fit reversed.ir.. Sectioned washer - it reversed.b. Inser t the deeper port ion of a discarded circl ip

in its groove in the mainshaft to retain theitems.

c. Measure the bush end f loat on the mainshaftusing feeler gauges.

d. End f loat is to be withln 0 .00 3 to 0.00 9 in( 0 .08 t o 0 .2 3 mm) .

e. Adjustment of end float is to be made byselection of the adjustment washer (3 . i. ) ofappropriate thickness listed as tbllows:

Part No. Colour in * 0.001 Thickness mm 2 0.25129941 Metal 0 .1 19 3 .0212994 2 Green 0 .122 3 .1012994 3 Blue 0 .125 3 .17129944 Orange 0 .128 3 .25134670 Y el low 0 .133 3 - 38

! Remove the items from t!le mainshaft butsuitably identify selected adjustmeni washer forassociat ion w ith 2n d gear .

37.20.04 Shee t z Triumph TR6 Manual.AKM 3529.

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SYNCHROMESH GEARBOX20 . Remove the centre bearing circlip, washer and snap

ring.21. Using tool No. S4221A-15A , withdraw the cen tre

bearing. Remove To ol S3 14 .22. Remove the mainshaft assembly through the top

aperture.23. Remove the 3r d/ to p synchro unit and cups.24. Remove the washer, 1st gear and bush, washer,

lst /2nd synchro unit and cups.25. Using too l S67 A remove the circlip.NOTE: The sectioned washer behind the circlip has three

lugs that fit in alternate splines, the longer prongs ontool S69A fit in the splines between the lugs.. Rotatecirclip to ascertain position of lugs. Position circlipwith ends on adjacent prongs of tool. With tool inposition, gently prise between 2nd and 3rd gears topush circlip away from slot.Remove the sectioned washer, 3rd gear and bush,washer, 2nd gear and bush, and washer.Withdraw the reverse idler spindle, reverse gear, leverand pivot.Remove the countersh aft rear thrust washer.Remove the countershaft assembly.Remove the countershaft front thrust washer

m riumphTR6Manual. AKM 3529. Sheet 2 37.20 .O4

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SYNCHROMESH GEARBOX

a. I s t /2nd s yn c l~ ro ni t f i t t ed wi th synchro cups .b. Adjustment washer .c. Assembled I st gear and b ush (see 39 Not e) .d. Thrust washer .

WARNING: IT IS RECOMMENDED THAT SEVERALWINDINGS OF CORD ARE LASHED AROUND

4 1 .

4 2 .4 3 .44.

45 .46 .

4 7 .48.4 9 .SO.

51 .

MAINSHAFT TO REAR OF THE 1st GEAR TOP R E V E N T I T S M O V E M E N T , T H E R E B Y ,AVOIDING AN Y POSSIRILITY OF PER SON ALDAMAGE WHEN FITTING THE MAINSHAFT.Enter the rear of the mainshaft through th e top coverand rear aper tures of gearbox, respectively, andmanoeuvre mainshaft assembly into posit ion.Fit tool S 31 4 to th e gearbox and engage themainshaft spigot in the too l .Fit th e snap r ing t o the bear ing.Fit the bear ing to the mainshaft an d gearbox. ToolS314. Remove the tool .Remove tool S3 14.Fit the washer and circl ip to the m ainshaft .Protect the rear end of the mainshaft (hard brassblock) , then tap on the rear end unti l the inner faceof the m ainshaft bearing is in close abutm ent w ith th ewasher an d circlip.Fit the to p gear synchro cup.Fit the constan t pinion assembly.Prior to engaging the countershaft gears, free thesynchro cups with a screwdriver .Carefully invert the gearbox to engage thecountershaf t gears - rotat ing the mainshaft andconstant pinion shaf t as necessary.Align the countershaft gears and thrust washers thenpress hom e countershaf t spindle.

37.20.04 Sheet 5 Triumph TR6 Manual. AKM 3529.m

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SYNCHROMESH GEARBOX37. Check th e end float of the 1st gear bush on the

mainshaft .a. Temporarily f i t the rear of the mainshaft inorder:

i. Adjustment w asher.ii Bush - l st ge"ar.iii. Thrust w asher.iv. Ball bearing To ol S 3 14.v. Washer.b. Insert the deeper portion of a discarded circlip

in i ts groove in the mainshaft to retain theitems.

a Drift the bear ing in to c lose abutm ent wi th thewasher an d circlip.

d. Measure the bush end f loat on the mainshaftusing feeler gauges.

e. End float is to be 0.003 to 0.009 in (0.08 to0 .23 mm) .

J: Adjustment to end f loat is to be mad e byselection of the adjustment washer (a. i .) ofappropriate thickness given in preceding list(36e).

g. Remove the i tems f rom the mainshaft bu tsuitably identify the selected adjustmentwasher for association with the 1st gear.Bearing extrac tor tool S 422 1A-15 A .

38. Assemble each sync hro cu p on the respective gear andmeasure with feeler gauges the clearance between thegear and c up. S hould the clearance be less than 0 -0 30in (0.76 mm) renew the cup.

3 9 . Assemble the fron t of the m ainshaft in orde r:a. Adjustment washer.b. Assembled 2nd gear and bush.c. Thrust washer.d. Assembled 3rd gear a n d bush.e. Sectioned washer.J: Circlip-Tool S 176.g. 3rd/4 th synchro unit f i t ted wi th synchro cups(short boss innermost).NOTE: Ensure correct assembly of bush and gear (b and d )in that bush a nd gear oilways align.

40. Assemble to the rear of the mainshaft in order:

Triumph TR6 Manual. AKM 3529 . Sheet 4 37.20.04

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SYNCHROMESH GEARBOXSYNCHRO UNITS- Overhaul 37.20.08

1. Remove the synch ro units 37.20.04 (1 - 23).Dismantling

2. M t h n the walls of a small bo x to prevent loss ofcom pone nts, carefully push the synchro hub throughthe sleeve.

3 . Collect the three steel balls and springs.Reassembling

Trial fi t the sleeve to the hub. The f i t should be freesliding.Assemble three springs and steel balls to th e hub .Fit the sleeve.Test, using a spring balance, the axial release loadwhich should be:- s t /2nd - 21 to 26 lbf (10.1 to 12.5 kgf).- rd/ top - 14 to 19 lbf (6.7 to 9.1 kgf)If the release loads are below these limits, use newsprings. If abo ve, grind d ow n the springs.Refit the synchro units, see 37.20 .04, instructio ns 39to 62 .

Triumph TR6 Manual. AKM 3529.W

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SYNCHROMESH GEARBOXRefit the retaining plate, secure with cross recessedhead screw.Apply jointing compound to the front cover plategasket, fit the plate and gasket and secure with twoscrews and copp er washers.Refit the mainshaft rear thrust washer and locate therear extension and gasket (if overdrive is to be fittedrefit the adaptor plate and cam and continue from59).Secure the rear extension, six bolts.Refit t he drive flange.Fit the washer and tighten the nut t o a torque load of9 0 to 110 lbf ft (12.4 to 15.2 kgf m) using tool No.R421 to retain the flange.Refit the speedometer drive pinion assembly andsecure with the peg bolt.Refit the front bearing plate and gasket - 4 NT2888Bsetscrews.Refit the clutch release mechanism 33.25 .l 2.Refit the top cover assembly and gasket - scmrewith eight bolts.Refit the gearbox.

m riumph TR6 Manual . AKM 3229 Sheet 6 37. 20 .O4

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SYNCHROMESH GEARBOXCONSTANT PINION ASSEMBLY

Service too l: S422 1A-15A1. Remove the constant pinion assembly, see 37.20.04,instructions 1 t o 1 8 .

Dismantling2 . Remove the mainshaft spigot bearing.3 . Remove the circlip and washer.4. Remove the snap ring.5. Using tool No. S4221A-15A, withdraw the bearing.6 . Remove the oil thrower.

Reassembling7 . Fit the oil thrower over the shaft.8. Using tool No. S4221 A-15A fit the bearing ensuringthat the oil throw er is centralised.9. Fit the washer and a new circlip.

10. Refit the snap ring.11 . Refit the mainshaft spigot bearing.12 . Refit the constant pinion assembly, see 37.20.04,

instructions 48 t o 62.

Triumph TR6 Manual. AKM 3529. B@

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SYNCHROMESH GEARBOXCOUNT ERSHAFT CLUSTER- Overhaul 37.20.291. Remove the countershaft cluster, see 37.20.04,instructions 1 to 23 and 28 t o 30 .

Dismantling2 . Separate the 4th constant gear, spacer, 3rd and 2nd

constant gears from the h ub.3. Remove the circlip.4 . Extract the roller bearings and backing washers from

the hub.Reassembling5. Refit th e backing washers and roller bearings.6. Refit th e circlips.7 . Assem ble the 211d a nd 3rd co nst ant gears, spacer and4th constant gear to the hub.8. Refit the countershaft cluster, see 37.20.04,

instructions 32 t o 62.

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SYNCHROMESH GEARBOXSPEEDOMETER DRIVE PINION ASSEMBLY- Remove and refit 37.25.09Removing

1 . Drive the vehicle onto a ramp and raise the ramp.2 . Disconnect the speedometer cable from the gearbox.3. Unscrewthepegbo l t .4. Withdraw the pinion assembly.

Refitting5. Refit the pinion assembly.6. Locate and tighten the peg bolt.7. Connect the speedometer cable to the gearbox.

SPEEDOMETER DRIVE PINION ASSEMBLY- Overhaul 37.25.13

1 . Remove the speedometer pinion assembly 37.25.09.Dismantling2 . Withdraw the pinion from the housing.3. Remove the '0' ring.4. Ext rac t t heo i l sea l .

Reassembling5 . Press a new oil seal into the housing.6 . Refit the '0 ' ring.7. Refit the pinion.8. R ef i t thep in ionas s emb ly37 .25 .09 .

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SYNCHROM ESH GEARBOXREAR OIL SEAL 5.8Service too l R G.42 1- Remove and refitRemoving1. Drive the vehicle on to a ramp.2. Remove the ex haus t ,silencer and tail pipes and

intermediate pipes 30.10.1 1 and 12.14.24-25.3 . Remove the propeller shaft 47.1 5.01.4 . Using tool No. RG.42 1 to retain th e flange, unscrew

and remove the nut.5 . Remove the drive flange.6. Prise out the seal.

Refitting7. Fi t a new seal into the rear extension.8. Refit the flange.9. Using tool NQ. RG.421 to retain the flange, fit and

tighten the nut to a torque load of 90 to 110 lbf ft(12.4 to 15.2 kgf m).

10 . Refit th e propeller shaft 47.1 5.011 1. Refit the exhaust intermediate pipes, silencer and tailpipes 30.10.11 and 12.14.24-2 5.

FRONT OIL SEAL- Remove and refit 37.23.06Removing1. Remove the gearbox 37.20.01.2. Remove the clutch release mechanism 33.25 .12.3 . Suitably mask the constant pinion shaft splines.4 . Remove the front bearing plate - our setscrews.5 . Prise out the oil seal.

Refitting6. Press a new oil seal into the bearing plate .7. Apply grease to the cover abutment face and fit thegasket.8. With the constant pinion shaft splines covered (see 3),fit the front end cover - four setscrews and plain

washers.9 . Remove the cover from constant pinion shaft splines.

10. Refit the clutch release mechanism 33.25.12.1 1. Refit the gearbox 37.20.01.