DISMANTLING STUDY AND ASSEMBLY OF

CONSTANT MESH GEARBOX

A REPORT
DISMANTLING STUDY AND ASSEMBLY OF CONSTANT MESH GEAR BOX
AIM:
To dismantle the given constant mesh gearbox to find the gear ratios and also to
assemble it back to the casing.
APPARATUS REQUIRED:
Constant mesh gearbox, wrench, fork rod pin punch, bearing puller, mainshaft
bearing drift, setting plate adapter, gear puller, bearing drift and counter bearing drift.
DESCRIPTION:
The gearbox has four forward speeds and one reverse. Top gear is obtained by direct
drive, third second and first by gears in constant mesh. In this gear box, all gears on the
main transmission shaft are constantly connected to corresponding gears on countershaft
or lay shaft. In addition, two dog clutches are provided on the main shaft. One dog clutch is
between the second gear and cutch gear and another is between the first gear and reverse
gear. Splines are out on main shaft so that all the gears are feed on it. Dog clutches can also
slide on main shaft and rotate with it. However, all the gears on countershaft are giddily
fixed to it. Different gear ratios (speed ratios) are obtained as follows :
Top or 3rd speed gar is obtained when the left dog clutch is slided to left to mesh
with clutch gear by using the gear shift lever. In this case, main shaft rotates at the same
speed as that of clutch gear or engine crankshaft speed which is the maximum speed. Speed
ratio obtained is 1 : 1.
Second gear is obtained when dog cutch (left side) meshes with second gear. In this
condition clutch gear rotates the drive gear on countershaft and countershaft drives the
second gear on the main shaft. All other gears on main shaft are free, so they do not move.
In the same manner, first gear is obtained when right hand side dog clutch meshes with first
gear. Reverse gear is obtained when right side dog clutch meshes with reverse gear on main
shaft.







INSPECTION:
Test the given constant mesh gear box for any damaged parts and repair the gearbox if it is
found damaged. The following are some of the tests for inspection:
OIL LEAK TEST:
Gearbox is filled with proper lubricating oil and closed with a filler plug. If oil leaks means
the gearbox is cracked or damaged.
GEAR TEETH CHECK TEST:
Gear teeth are checked thoroughly by eye judgement for spotting any damage on their
surface if present.







SERVICING OF THE GEARBOX:
After dismantling the gearbox using the appropriate toolbox, clean the gearbox using a
cloth. Brush or scrap all the dirt from the gearbox with compressed air. To clean a switch or
sensor, use a clean towel.

DISMANTLING THE CONSTANT MESH GEARBOX:
1. Remove the rear power unit mounting.
2. Unscrew the speedometer drive, but do not withdraw the pinion from the bush
unless absolutely necessary, or damage to the oil seal may result on displacement.
3. Unscrew the set screws and remove the gear lever tower and joint washer.
4. Unscrew and remove the six bolts and the rear extension cover and joint washer.
Remove the interlock arm and bracket from the aperture in the rear extension.
5. Unscrew the three countersunk screws and the seven hexagon-headed set screws
holding the gear box cover; remove the cover.
6. Remove the two nuts and six set screws securing the gearbox extension to the
gearbox, at the same time manoeuvring the remote control shaft selector level down
and out from the selectors.
7. Cut the locking wire and unscrew the three change speed fork set screws. Release
the three locknuts and slacken the fork locating screws.
8. Unscrew the two set screws and remove the shifter shaft locating block with shifter
shafts from the gearbox; note the two dowels in the block. If the rods are withdrawn
from the locating block take care to catch the three selector balls and springs.

9. Withdraw the forks from the box in the following order: reverse, top and third, and
first and second.
10. Unscrew the clutch lever pivot nut; extract the pivot bolt and remove the lever with
the thrust bearing.
11. Unscrew the nuts and remove the gearbox front cover complete with the oil seal;
note the bearing shims between the cover and the front bearing. Tap out the
layshaft, allowing the gear unit to rest in the bottom of the box.
12. Unscrew the retaining set screw and remove the reverse shaft and gear.
13. Withdraw the main shaft assembly to the rear and withdraw the first motion shaft
and rear.



DISMANTLING MAINSHAFT GEAR:
1. Remove reverse idler gear together with the shaft
2. Remove the snap ring from the mainshaft end bearing
3. With first and second gears doubly engaged, release caulking on mainshaft nut and
loosen it
4. Remove the following parts from mainshaft in rear extension side:
Main shaft nut
Speedometer drive gear and steel ball
First gear together with needle bearing and bushing
Thrust washer and steel ball
5. Remove snap ring and thrust washer from the counter gear end
6. Drive out mainshaft using mainshaft puller
7. Remove main drive gear and counter gear after driving out mainshaft

EXPLODED VIEW OF MAIN DRIVE GEAR ASSEMBLY


ASSEMBLY OF GEARBOX:
Place the layshaft gear in the gearbox complete the end thrust washer but do not fit
the layshaft; use dummy layshaft to retain the thrust washers in position.
Replace the first motion shaft and insert the needle roller bearings
Insert the third motion shaft assembly from the rear of the gearbox; enter the spigot
in the needle rollers of the first motion shaft.
Use the gasket fitted between the gearbox and the rear extension tom position the
dowel and bearing housing.
Push the shaft right home
Fit the layshaft, lining up the cut-away portion of the front end with the locating
groove in the front cover.

EXPLODED VIEW OF COUNTER GEAR DRIVE ASSEMBLY






Fit the reverse gear and shaft; tighten the set screw and secure with the locking
washer
Refit the front end cover, replacing the bearing shims that was removed on
dismantling
Refit the clutch and lever fork
Position the gear change forks in the gearbox in the following order: first and
second, third and top, reverse.
Bolt the shifter shaft locating block to the rear face of the gearbox; replace the balls
and springs and push change speed forks. Insert, tighten amd lock the three locating
screws
Position the selectors on the rear end of the shifter shafts; insert, tighten and wire
up the set screws.



EXPLODED VIEW OF REVERSE IDLER GEAR ASSEMBLY





MAINSHAFT GEAR TEETH:

GEAR

MAIN
GEAR


1
ST

T3

2
ND

T5


3
RD

T7

4
TH

T9

REVERSE
T11
NO OF
TEETH




LAYSHAFT GEAR TEETH:

GEAR


MAIN
GEAR


1
ST

T4

2
ND

T6

3
RD

T8

4
TH

T10

REVERSE
T12
NO OF
TEETH



RUN OUT VALUES:
RUN OUT IN LAYSHAFT MAIN MAINGEAR =
RUN OUT IN LAYSHAFT BEARING=
RUN OUT IN LAYSHAFT=
RUN OUT IN MAINSHAFT=
THE ALLOWANCE RUN OUT FOR LAYSHAFT=

GEAR RATIO:

GEAR


1
ST


2
ND


3
RD


4
TH


REVERSE

RATIO




















RESULT:
Thus constant mesh gearbox was dismantled, the gear ratios, run out values was
calculated and assembled back to the casing.