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Руководство по эксплуатации Страница: 110

BMW K75 [110/236] Chapter 3 gearbox

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110 Chapter 3 Gearbox 8 Gearbox reassembly 1 All components should be completely clean and renewed or repaired as necessary All bearings or bearing inner races should be installed correctly on their respective shafts and all oil seals oil guides and taper roller bearing outer races should be installed in the housing or front cover as appropriate 2 Refit the detent roller arm and secure it with its circlip ensuring that its spring is fitted as shown in the accompanying photograph 3 Refit the gearchange pedal to the shaft using the mark made on removal to ensure that the pedal is correctly positioned Tighten the pinch bolt securely 4 Fit the return spring and the locating plate to the selector lever as shown in the accompanying photograph and fit the assembly to the housing do not forget the shim between the spring and the housing wall Refit the two retaining circlips Grease the gearchange pedal shaft and refit it taking care not to damage the lips of the shaft oil seal The shaft will fit only one way if the tapered grub screw Is to lock it correctly to the selector lever ensure that the two are correctly aligned apply a few drops of Loctite 242 or similar thread locking compound to the screw threads and refit it tightening it securely Use the torque wrench setting where specified 5 Fit the spacer and claw arm spring to the claw arm ensuring that the spacer fits inside the spring loop Fit the assembly to the claw arm mounting and secure it by refitting the pivot retaining circlip Position the claw arm mounting and refit the guide rod and its circlip to retain it Tap the gearbox breather sleeve into its orifice but be careful not to drive it so far in that the black cap rests on the gearbox housing Refit the black plastic cap to the breather sleeve 6 Install the input shaft in its rear bearing lubricate both bearings with the specified oil 7 Lubricate their bearings bearing surfaces and all other points of contact then mesh together the gear pinions of the layshaft and output shaft assemblies and insert the two as a single unit Rock the input shaft away from the layshaft until its bearing is clear of the layshaft gear pinion teeth Press the layshaft and output shaft into position and straighten the input shaft 8 Note that if the shaft bearings will not fit easily into the housing locations the housing must be heated evenly in an oven or similar to approximately 100 C 212 F to permit this If this is found to be necessary first remove all components which might be damaged by the heat and take great care to prevent any risk of personal injury when heating components or when handling heated components 9 Check that all three shafts are free to rotate then install the selector forks using the marks or notes made on dismantling to identify each fork and which way it is fitted If no marks were made proceed as follows 10 The first fork to be refitted is to the output shaft 3rd gear pinion groove this actually selects 5th gear and is the widest across the claw ends of the three forks It is fitted with its guide pin towards the front of the gearbox housing this will engage the selector drum rear groove 11 The next fork selects 3rd and 4th gears and is fitted to the layshaft sliding gear pinion groove its guide pin will engage the selector drum centre track It is the narrowest across the claw ends and can be identified by its long neck It is refitted with its guide pin towards the rear of the gearbox housing 12 The last fork selects 1st and 2nd gears and is refitted with its guide pin towards the rear of the gearbox housing to engage the selector drum front groove Of medium width across the claw ends it is fitted to the output shaft 4th gear pinion groove 13 Swing all three forks as far as possible away from the selector drum and refit the separate roller to each fork s guide pin retain the roller with a dab of grease 14 Fit the five selector pins and the small locating pin to the selector drum front end refit the selector cam aligning its keyway with the locating pin and insert the drum assembly pressing back the claw arm to permit this 15 Rotate the drum until the cam neutral detent recess is approxi mately in the 12 o clock position from the drum centre ie in the neutral position Swing the forks back into contact with the drum engaging each fork s guide pin roller in its respective drum groove Lubricate and refit the selector fork shafts ensuring that each is pressed fully home in its original location 16 Ensuring that the correct number and thickness of shims are used refit the output shaft and layshaft shims to their respective bearing Fig 3 3 Selector drum and forks 7 Selector drum 2 OH seal 3 Locating pin 4 Selector pin 5 off 5 Selector cam 6 Ball 7 Spring 8 Neutral detent plug 9 3rd 4th gear selector fork 10 Selector fork shaft 11 5th gear selector fork 12 Roller 3 off 13 1st 2nd gear selector fork 14 Selector fork shaft housings in the front cover Press the shims fully into place and use grease to retain them 17 Referring to the accompanying photograph make up a stop from a suitably sized rod a convenient bolt was used for the photograph with a flat ground on one side to ensure that it would not slip or similar to hold the detent roller arm clear of the selector drum cam while the front cover is refitted Apply a thin smear of Loctite 573 or similar jointing compound to the degreased mating surfaces Make a final check that all components have been refitted and that all shafts are free to rotate 18 BMW recommend that the front cover is heated evenly in an oven or similar to approximately 100 C 212 F to permit refitting This was found not to be necessary since the cover could be removed and refitted quite easily by hand If it is necessary to heat the cover take great care to avoid the risk of personal injury when heating components or when handling components that have been heated Remember also to remove first components such as oil seals which will be damaged by the heat and to place the shims on the bearings not in the front cover bores 19 Press the cover into place then refit and tighten to the specified torque setting the cover retaining screws Pull out the roller arm stop a distinct click should be heard as the arm contacts the cam 20 Rotating the input shaft and if necessary the output shaft check that the shafts rotate smoothly and that all gears can be selected with reasonable ease If all is well drift the locking plug into the small orifice drilled next to the detent roller arm pivot 21 Refit the ball and spring of the neutral detent assembly apply a few drops of Loctite 242 or a similar thread locking compound to its threads and refit the neutral detent plug tightening it to the specified torque wrench setting 22 Refit any oil seals which have not yet been installed and install the gear position indicator switch on the gearbox housing rear face do not overtighten its retaining screws or the switch may crack Position the switch carefully so that the cutaway section of the selector drum shaft aligns with that of the switch rotor

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