NGT 520 - Transmission PDF

Repair
Repair Manual
Manual MAN-00103
BOLERO MAXI TRUCK CNG – BSIV NOV 2010/Rev 1
TRANSMISSION
CLUTCH
NGT 520 - TRANSMISSION
The repair
The repair methodsmethods
givengiven
by thebymanufacturer
the manufacturer
in thisin document
this document are based
are based on theontechnical
the technical specifications,
specifications, current
current at theattime
the time of release.
of release. The methods
The methods may may be modified
be modified as a as a result
result of changes
of changes introduced
introduced by the
by the
manufacturer
manufacturer in theinproduction
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are manufactured. The rThe r eproduction,
eproduction, translation,
translation, transmission,
transmission, in of
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whole of theofpresent
the present document,
document, 133
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are prohibited without the prior written consent of Mahindra & Mahindra Ltd. Ltd. The of
The use use ofdocument
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personnel, at theatAuthorized
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Service CentreCentre of Mahindra
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Ltd., Ltd., will amount
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use and and shall be liable
be liable for penalty/prosecution©
for penalty/prosecution© 20102011 Mahindra
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Repair
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Contents…
� Description…………………………………………………………………. 184
� Trouble Shooting………………………………………………………….. 186
� Care of the Transmission………………………………………………… 188
� In Car Repairs……………………………………………………………… 189
� Transmission Dismantling………………………………………………….. 199
� Transmission Component Inspection……………………………………. 210
� Sub-assemblies………………………………………………………………. 212
� Assembly Inspection………………………………………………….. 231
� Specification……………………………………………………………….. 233
� Tightening Torques……………………………………………………….. 234
� Sealant Recommendation……………………………………………….. 234
� Special Tools……………………..………………………………………… 235
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� Description –
It is a 5-speed gearbox. All the forward speed is synchromesh type. The reverse gear is having sliding
mesh type.
The gear selection is by a direct shift lever tongue operating in between shift rail gate. The accidental
operation of two gears is avoided by an interlocking mechanism. To avoid vibrations passing on to the
shift lever, the shift lever is a two-piece with rubber isolation provided on to the top half.
The gearbox housing is tunnel type Cast iron with an intermediate plate. The Gearbox is mounted
directly on the engine through the integral clutch housing and supported at bottom below the rear
housing. The output shaft is fitted with companion flange which is bolted to propeller shaft in case of 2
wheel drive. If vehicle is equipped with 4 wheels drive the output shaft is splined and is mated to the
transfer case.
Refer illustrations of –
1. NGT520 transmission cross sectional view of 2WD.

2. NGT520 transmission cross sectional view 4WD.
3. Synchroniser pack assembly cross section view used in NGT 520 Transmission.
CLUTCH HOUSING INTERMEDIATE

PLATE SHIFT LEVER
MAIN DRIVE SHAFT SYNCHRO PACK 3 & RD
RELEASE BEARING 4TH

SYNCHRO PACK 3RD &
SLEEVE
4TH
BREATHER SYNCHRO REAR HSG. ASSY.
FRONT
PACK 1ST & 2ND
HOUSING COMPANION
FLANGE
5TH REVERSE
COUNTER SHAFT
SYNCHRO SUB-SHAFT
PACK 1ST &
NGT 520 TM (2WD) Cross-sectional View
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CLUTCH CLUTCH HOUSING
MAIN DRIVE SHAFT

SHIFT LEVER
SYNCHRO
RELEASE
REAR HSG.
PACK 1ST &
BEARING
ASSY
BREATHER INTERMEDIATE SPLINED
FRONT HSG. PLATE OUTPUT
ASSY SHAFT
SYNCHRO PACK 3RD

COUNTER SHAFT 5TH REVERSE
& 4TH
SUB-SHAFT
NGT 520 TM (4WD) Cross-sectional View
Synchronizer Pack Assembly Cross Section View
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� Service Diagnosis / Trouble Shooting –
A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an
incorrect lubricant level check.
Leaks can occur at the mating surface of the gear case, intermediate plate and adapter or extension
housing or from the front/rear seals. A suspected leak could also be result of an overfill condition.
Leaks at the rear of the extension or adapter housing will be from the housing oil seal. Leaks at
component mating surface will probably be the result of inadequate sealer, gaps in sealer, incorrect bolt
tightening, or the use of a non-recommended sealer.
A leak at the front of the transmission will be from either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is severe, it
may also contaminate the clutch disc causing slip, grab and chatter.
A correct lubricant level check can be made only when the vehicle is level, use a two post or a four post
hoist to ensure this. Also allow the lubricant to settle for a minute or so before checking. These
recommendations will ensure that an accurate check and avoid an under fill or overfill conditions.
Hard Shifting
Hard shifting is usually caused by low lubricant level, improper or contaminated lubricants, component
damage, and incorrect clutch adjustment or by a damaged clutch pressure plate or disc; or worn out
brass synchro ring.
Substantial lubricant leak can result in gear, shift rail, synchro and bearing damage. If a leak goes
undetected for an extended period the first indications of a problem are usually hard shifting and noise.
Incorrect or contaminated lubricants can also contribute to hard shifting. The consequence of using non-
recommended lubricants is noise, excessive wear, internal bind and hard shifting.
Improper clutch release is one of the most frequent causes of hard shifting. Incorrect adjustment of a
worn damaged pressure plate or disc can cause incorrect release. If the clutch problem is advanced then
gear clash during shifts can be resulted. Incomplete travel of the clutch pedal due to restrictions at the
end of stroke (upturned carpet, extra carpet or cover or bend clutch linkage can also cause improper
clutch release and hard shift.)
Worn or damaged synchro rings can cause gear clash when shifting any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most
conditions this will decline as the rings wear in.
Transmission noise
Most manual transmissions make some noise during normal operation. Rotating gears can generate
slight whine that may only be audible at extreme speeds.
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Severe obviously audible transmission noise is generally the result of a lubricant problem. Insufficient,
improper or contaminated lubricant can promote rapid wear of gears, synchros, shift rail, forks and
bearing’s. The overheating caused by a lubricant problem can also lead to gear breakage.
Summarizing the common faults and their cause:
PROBLEM POSSIBLE CAUSES CORRECTION

Gear Whine � Low oil level � Top up oil.
� Worn teeth gears � Replace gears
� Worn bearings � Replace bearings.
Knocking or ticking � Chipped gear teeth � Replace gears.

� Foreign matter inside � Remove the foreign matter and
transmission. locate how the foreign matter
came inside e.g. missing
breather and rectify that also to
avoid recurrence.
� Replace the bearings.
� Defective bearings.
Jumping out of gear � Defective detent springs. � Replace the detent springs.
� Worn out grooves in shift rail. � Replace the shift rails.
� Shaft misalignment. � Check & Correct it.
� Worn dog teeth in gear � Replace the gears
� Worn out fork/ fork pads � Replace the fork/ pads
� Worn out synchronizer body. � Replace the body
� Gear lever fouling. � Check & correct.
� Bottom lever slot worn out. � Replace bottom lever.
Unable to select gear � Clutch defective � Rectify the clutch/ clutch

withdrawal mechanism
� Worn out selector mechanism. � Rectify the gear selector
mechanism.
� Worn out brass synchro ring. � Replace synchro ring.
� Gear clutch teeth damaged. � Replace gear.
Hard gear shifting � Clutch defective � Rectify the clutch/ clutch

withdrawal mechanism
� Improper or contaminated � Replace the lubricant with the
lubricants specified lubricant.
� Worn out brass synchro ring. � Replace synchro ring.
� Gear clutch teeth damaged. � Replace gear.
NOTE:
� Transmission assembly steps given below consist of Problems, Causes and Precautions while
assembling of sub components and main assembly.
� For more details on various problems and probable causes refer the assembly procedure section
prescribed in this manual.
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� Care of the Transmission –
Use lubricant meeting oils specification of API GL4 and viscosity 80W90 Synchro.Recommended brand
name is MAXIMILE GO 80W90 Synchro. Recommended fluid replacement interval first is 10000 kms,
then 50000 kms and then after every 40000 kms. The fluid capacity/ quantity in NGT520 Transmission
are 2 Liters.
TRANSMISSION OIL – REPLACEMENT PROCEDURE
NGT 520 - Transmission
Transmission Oil – Replace (Refer above illustration)

1. Remove the Filler plug.
2. Put the oil collection tray under transmission, Remove the drain plug. Allow the oil to
drain out completely.
3. Clean the metal particles if any deposited on the drain plug. Assemble & torque tight the
drain plug with new washer – 27.5±2.5 Nm.
4. Fill fresh transmission oil as per specified capacity & assemble the filler plug with new
washer and torque to 27.5±2.5 Nm.
5. Check Oil leakage / seepage at –
• Transmission Housing Joints.
• Transmission Oil drain plug.
CAUTION: While replacing the transmission fluid ensure that –
� Vehicle is parked on level ground/ 2 post/ 4 post lift.

� If the activity is done on a 2 post lift and vehicle is fitted with LSPV, ensure that
the LSPV spring is disconnected before lifting the vehicle & re-connect the LSPV
spring & ensure that the setting height is correct after job completion.
� The lubricant level should be at the lower edge of the filler plug.
� The filler plug and drain plug on NGT 520 TM to be tightened to 27.5 + 2.5 Nm.
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� In Car Repairs –
Rear Oil Seal Replacement –
� Remove the Rear propeller shaft from

companion flange*
( Only rear propeller shaft in case of 2 wheel drive

vehicle)
� Refer section ‘ removal and installation of

propeller shaft’
� Remove the Speed sensor* from Transmission assembly (*optional)

� Remove the Locking nut from companion flange assembly. Use MST to hold the
companion flange while removing nut.
� Remove washer form companion flange.
� Remove the companion flange from

Transmission assembly.
� Use flange puller in case it found jam.
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� Remove dust cover.
� Remove rear oil seal using tool.
� Always replace with a new seal once it has been removed.
Installation –
� Before installation apply multi-purpose grease to lip of oil seal.

� Install new seal, press until it stops.
� Refit propeller shaft assembly.
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� Gear Position/ Gear Neutral Switch Check -
Micro hybrid vehicles are equipped with ‘STOP START’ system. The Gear neutral Switch is located on the
Adaptor Pivot Plate. Refer illustration below.
� Check continuity, refer below chart.
Switch Gear Position Continuity

Reverse Yes
Reverse lamp switch
Except Reverse No
Neutral Yes
Neutral Position Switch
Except Neutral No
NOTE:
Neutral switch should be fitted with 6 mm gap with sensor; Sensor is fitted on bottom gear
lever.
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� Transmission Rear Insulator Removal –
NGT 520 Transmission

(2WD)
Rear Insulator
Cross Member below

transmission
CAUTION:
� Before separating the transmission from the engine, remove the crankshaft position sensor (OBD)
from the clutch housing.
� Support transmission while removing it from vehicle.
� Remove battery –ve terminal.
NOTE:
� To prevent oil spills, drain transmission oil before removing transmission.
� Ensure and take care of rear oil seal while removing propeller shaft.
� Lift vehicle on four post.
� Remove battery terminal.
� Remove Clutch Slave Cylinder from clutch

housing.
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� Remove Gear Neutral switch connector* from
transmission.
� Remove reverse light switch connector on TM

assembly.
Refer illustration for locations of Reverse light

switch on NGT 520 Transmission.
� Disconnect and remove speedo cable from

speedo sleeve fitted on Transmission.
� Remove starter motor from transmission.
� Remove Rear propeller shaft.
� Remove gear knob and shift lever- upper part.

� Remove insulator below TM and the Cross member below the TM assembly.
CAUTION:
� Support to the TM assembly bottom side for safety purpose and to avoid TM damage.
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� Support engine by placing a jack under oil pan; before removing Bell housing mounting bolts.
� Do not place jack under oil pan drain plug.
� Remove bell housing mounting bolts and separate transmission from engine.
� If vehicle is equipped with 4 wheel drive, ensure to –
� Disconnect and remove four wheel drive Shift

link.
� Put tray below the transfer case, remove drain

plug to drain the Transfer Case oil.
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� Disconnect and remove the speedometer
cable connector on Transfer case.
� Disconnect and remove the front propeller

shaft.
� Remove the transfer case insulator by

removing its mounting bolt.
Put spanner through cross member hole to access

the mounting bolt of insulator.
CAUTION:
Support to the TM assembly bottom side for safety

purpose and to avoid TM damage.
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� Transmission Case Components –
� Transmission Gear Components –

� Main Drive Gear –
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� Main Shaft Drive Gear & Synchronizer–
� Counter Lay Shaft Gear & Synchronizer –
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� Shift Control Components -
PLUNGER
POPPET PLUG
� Selection Biasing and Shift Lever Components –
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� Transmission Components Disassembly –
NGT 520 2WD Assembly NGT 520 4WD Assembly
SCHEMATIC OF NGT 520 TM DISASSEMBLY
� Remove Clutch release bearing and fork.
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� Remove clutch housing from transmission
assembly.
NOTE:
� Use mallet for slight tapping on bell housing
while removing from transmission.
� Remove the bellow and bottom lever

mounting bolts.
� Lever and locating pin removal.
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� Use a lengthy screw driver and put gear in
neutral position for ease of removal of gear
components.
� Remove the Speedo gear along with adaptor.
� Remove Companion flange lock nut and

washer.
� Remove the companion flange from

Transmission end.
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Rear housing Removal -
CAUTION:
� Rear housing should be in straight position
while removing.
� To avoid oil spillage, check and drain
remaining oil residuals from housing.
� Be careful not to damage of rear oil seal.
Front housing removal -
CAUTION:
� Remove the counter shaft front bearing
spacer.
Remove Circlip, Bellevelle washer, Snap ring
and Adjuster shim from end of MD Gear
assembly.
� Remove front release brg. Sleeve.
� Use brass hammer while removing the front
housing from intermediate plate.
� Remove 5th drive gear bearing using puller. Remove Shim and Spacer.
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� Remove 5th gear driving gear by removing roller bearing, using Special tool.
CAUTION:
� Move sub shaft in forward direction.

� Reverse gear fork to be taken forward and
remove Circlip and bearing using puller.
� Remove 5th driven gear with bearing.
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Remove 5th and Reverse hub assembly -
CAUTION:
� Be careful not to lose pin, shifting inserts.
Remove poppet plug fitted on intermediate plate and shaft rail assembly of 5th and reverse.
CAUTION:
� Be careful not to lose ball & spring while removing shaft and rail assembly.
NOTE:
� It is differ as in 2WD and 4WD.
� Output shaft in 4WD provided with lock nut where as in 2WD it is plane OD.
� Output shaft in 4WD is having splines throughout the shaft where as in 2WD it is fitted with
companion flange.
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CLUTCH
Removal of Shift Rail and Fork assembly -
CAUTION:
� Remove insert pin using dolly.
� Remove fork shaft by hand.
� Remove insert pin on 1st/2nd shift rail.
� Remove fork shaft by hand, use mallet if required.
� Remove fork on 3rd/4th and 1st/2nd
NOTE:
� 4WD output shaft having splines throughout the shaft end, whereas 2WD output shaft is having
Companion flange and nut fitment arrangement at the shaft end.
� Remove lock nut on output shaft* in case 4WD transmission.
NOTE:
� Use special tool, lock the free movement of assembly and remove nut.
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CLUTCH
� Take out reverse gear from output shaft
� Sub-Plate and Drive Shaft Removal –

� Remove sub plate fitted on intermediate plate assembly.
(It is located on output shaft side).
� Remove circlip on output shaft main bearing.
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CLUTCH
� Separate drive shaft from intermediate plate -
NOTE:
� Use mallet to remove the main drive shaft
from intermediate plate.
� Remove main drive gear assembly.
� Remove counter shaft bearing and cone from

intermediate plate. Use puller, refer
illustration.
� Remove main shaft main bearing using puller.

MD Gear dismantling –
� Remove synchro ring.
� Remove circlip and bearing using tool.
� Remove roller bearing by hand.
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CLUTCH
� Main Shaft Drive Gear & Synchronizer dismantling –
� Separate Counter shaft from Intermediate

plate.
� Counter shaft front bearing can be removed by

using bearing puller.
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CLUTCH
� Counter shaft rear bearing can be removed by
using bearing puller.
� Remove the circlip.
� Remove the Hub assembly.
CAUTION:
� Be careful not to lose synchro key.
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CLUTCH
� Transmission Components Inspection –
1. Shift Control Rod and Fork Inspection:

� Check contact and sliding surfaces of Shift Rod and Fork for wear, scratches and damage if any.
2. Gear Components Inspection:
� Check gear shafts for cracks, wear and bend

if any.
� Check gears for excessive wear, cracks,

tooth breakage and chips if any.
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Manual MAN-00103
CLUTCH
3. Synchronizers:
� Check splines portion of coupling sleeves,

synchronizer hubs, and gears for wear,
chips, and cracks.
� Check shifting synchro key for wear and
deformation.
� Check synchro key C-spring for deformation.
4. Bearings:
� Ensure that all bearings are roll freely. They

are free from noise, cracks, wear and
pitting.
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CLUTCH
� Transmission Components Assembly/ Sub Assembly –
� Assembly of the Transmission is the reverse of its disassembly. While assembling following care
should be taken.
CAUTION:
� Ensure that front housing, intermediate plate and all components are free from dirt, dust before
assembling.
� Transmission bearings life will reduce in case use of unclean gear components used.
� Assembling Synchronizers (Strut type) -
� Ensure fitment of both sides.

� Check all three key for proper fitment.
� Ensure free movement of hub & sleeve.
� Ensure proper C-spring fitment.
� MD Gear Sub assembly -
� Ensure circlip groove on the bearing to be on

the top side. Refer illustration.
� Circlip to be assembled after bearing fitment.
NOTE:
� In case circlip is missing/ not fitted properly;
excessive play in MD gear will be observed
which can lead to gear slippage.
� Counter Shaft Sub assembly -
� Ensure direction of inner race as shown in

illustration.
� Press bearing as shown in illustration.
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CLUTCH
CAUTION:
� Press bearing to the full depth.
� Maintain run out of counter & sub-shaft within 0.05 mm. (extended countershaft with subshaft)
� Mark counter & sub-shaft with marker on spline end for matching at which the run out is within
specification.
NOTE:
� If run out in counter sub-shaft pairing is not maintained then 5th gear slippage can take place.
� Intermediate Plate assembly -
Bearing installation in intermediate plate-

� Main shaft ball bearing installation in intermediate plate.
CAUTION:
� Ensure counter shaft bearing is pressed such that bearing should be flushing with the rear face of
the plate.
� Ensure torque on M10 bolts for idler shaft. Torque value 43 � 7 Nm.
NOTE:
� In case Idler shaft is not fitted properly or not torque as per recommended value, the 5 th gear
failure issue may come, or 1st gear teeth will foul with idler shaft.
� Insufficient bearing pressing can restrict lever to and fro movement/ gear slippage may occur.
� Over torque or under torque to the idler shaft bolt may lead to reverse gear failure due to
support loosening.
� Front housing sub assembly -
� Ensure that rail end caps are fitted.

� Ensure that dowel slot is inside while entering into front housing.
� Ensure that dowel is pressed fully.
� Place the filler plug.
� Ensure that rail and cap flushed with housing cap.
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CLUTCH
NOTE:
� If end cap not fully pressed then dust can go inside the tm before clutch housing fitment.
� Bearing Retainer/ Clutch Release Bearing Sleeve Sub Assembly -
� Ensure that oil seal direction is correct before

assembly.
� Ensure proper pressing and fitment of oil seal.
NOTE:
� In case oil seal not fitted properly or gets
damage while fitting, the oil leak complaint
may come.
� Apply oil on seal lip for initial lubrication
purpose.
5th Reverse Hub Sub assembly (Double DOP) –

Do entire assembly of 5th/Rev hub on press fitted hub along with sub shaft or do separate sub
assembly of 5th/Rev hub & then press it on sub shaft.
CAUTION:
In case assembly is not proper, hard shifting or reverse gear failure may occurs.
� Match the sleeve in hub with respective

direction. (Plain side of sleeve & grooved side
of hub on upper side.
� Insert three struts. Small length on rev side &

big length on 5th side.
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CLUTCH
� Insert the C-SPRING covering all three struts.
� Place the BELLE VELLE WASHER in hub with

tapper angle down side.
� Place the PROTECTOR & fix the circlip by

hammering using dolly.
� Rotate entire assembly on opposite side i.e.

5th side & fix the C-SPRING.
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CLUTCH
� Check the entire assembly for the fitment.
� Use Double DOP hub having groove on OD.
NOTE:
� In case synchro key is missing or fitted in wrong direction, no shifting will takes place or synchro
will damage in running.
� If sleeve is fitted in opposite direction, no shifting will takes place.
� In case C-spring missing or if it is not covering one key, crash shifting occurs.
� If belle velle washer is missing gear box noise may come.
� Gear box will jammed in case of circlip is missing.
� Speedo Sleeve Sub Assembly –
CAUTION:
� Ensure proper direction of oil seal during assembly.
� Ensure proper pressing of oil seal.
NOTE:
� In case oil seal is not pressed properly or damages while assembling, oil leak issue may occur.
The repair
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CLUTCH
� Rear Housing Sub Assembly –
� Tighten the drain plug with nut runner & torque with wrench - (27.5 � 2.5 Nm)
� Use freudenkeg seal (brown colour) for sub assembly & locate it on floating dolly for pressing.
� Check and ensure circlip for proper fitment.
CAUTION:
� Ensure proper direction of oil seal.
� Ensure bearing for fully pressed.
� Ensure oil deflector below the outer race of
cylindrical roller bearing.
� Ensure dowel for pivot fitment.
NOTE:
� Oil leakage takes place in case oil seal is missing or seal lip is damaged or cut.
� Over torque to the drain plug lead to crack on rear housing drain plug side and oil leak start.
� Under torque to the drain plug lead to drain plug falling off and oil leaks.
� If circlip is missing or not fitted properly, 5th driven gear & outer race will come out and get
damage.
� Gear box noise may come in case bearing outer race is missing.
� Output Shaft Sub assembly -
� Put output shaft spline side into fixture.

� Fit the needle cage, put the oil drops and fit
the 3rd gear. Fit the brass ring over it.
� Fit the hub into the spline. Ensure the
direction of hub, refer illustration.
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CLUTCH
� Put the BELLE VELLE washer and fix the circlip
on it.
� Use oil on cone of brass ring.
� Check snap ring for its proper sealing using
the gauge provided. Paint mark on the shaft
after checking.
NOTE:
� If 3rd gear circlip is not fitted properly, circlip
will come out resulting in lever too & fro
movement and 3rd gear slippage.
NOTE:
� In case of 4 WD, the output shaft will have internal threading.
� Ensure end play of 0.175 - 0.375 mm in 1st, 2nd and 3rd gear; in case wrong shims put or shims
missing, 1st/2nd or 3rd/4th gear slippage may occur.
� Ensure brass ring placement on each 1st, 2nd and 3rd gear.
� Ensure proper direction of bearing. (Snap ring groove should be above, away from 1 st gear)
� MAIN ASSEMBLY -
� Power Train Assembly -

� Put MD Gear into fixture.
� Place the pilot bearing in MD Gear / Input
Gear.
� Apply grease to the pilot bearing.
� Insert 4th gear brass ring on MD Gear.
� Ensure that MD Gear and output shaft are

free.
� Put counter gear sub assembly on fixture.
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CLUTCH
� Adaptor Plate/ Intermediate Plate and Bearing Retainer Plate Fitment -
CAUTION:
� Ensure that the pilot bearing is fitted.
� Put locator on counter gear and then fit the
intermediate plate by tapping on plate.
� Ensure that the bearing is flushes with the
rear face of the adaptor plate.
� Ensure that the snap ring fitment before
placing the bearing retainer plate.
CAUTION:
� Apply ANABOND 111 sealant on M8 bolts.
� Torque value for retainer plate bolt is 31 � 4
Nm.
NOTE:
� Ensure fitment & torque tighten of 4WD lock nut over reverse driven gear @ 60 � 10 Nm. (Ensure
spacer sleeve fitment in 2wd models)
� Ensure circlip fitment under 5th driven gear in 4wd models
� Ensure crimping of nut with hammer & dolly.
� If snap ring is not fitted or bolts are not torque properly, crash shifting may occurs.
� SRSF Fitment -
CAUTION:
� Ensure that Reverse driven gear is placed

before 1st/2nd rail is inserted.
� Put the grease before 3rd/4th interlock plunger
is placed.
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CLUTCH
� Fix the fork and insert 1st /2nd rail.
� Fix the ball and insert 3rd/4th rail.
� Press the 1st/2nd split pin. Ensure that 1st/2nd
split pin is not fouling with 3rd/4th rail.
� Ensure that 1st & 2nd split pin flushes with fork
boss.
� Ensure that both pins are pressed.
� Insert the plunger.
� Insert 5th & Reverse fork along with 5th &
Reverse synchro assembly and Reverse sliding
gear.
� Ensure ball and spring insert after 5th/Reverse
rail assembly.
CAUTION:
� Tighten the vibra-seal 516 pre coated puppet plugs & torque (25 � 5 Nm) with use of angle nut
runner.
� In case of 4WD Transmission, put nut above reverse driven gear and torque tighten it.
� In case of 4WD Transmission, put snap ring above 5th gear and circlip below 5th driven gear.
NOTE:
� Shifting will not happen in case split pin not pressed.
� Crash shifting will occur if split pin is fouling.
� In case of ball & spring missing the shifting will be effortless and gear slippage issue may occur.
� In case of brass ring in 5th/reveres synchro assembly is missing, 5th crash shifting may occur.
� In case of no torque/ less torque to puppet plugs may lead to gear slippage; and high torque may
lead to thread slippage and then gear slippage.
� Puppet plug sealant application missing will lead to fluid leakage through poppet plug.
� In case 1st/2nd pin fouling with 3rd/4th hard shifting may occur.
� In case pin is partial pressed or missed out or pin direction is wrong, gear slippage will occur and/
or gear will not shift or double gear engagement will occur.
� If fork is tight in rail, gear shifting will not happen.
� Use mallet to check and ensure that double

shifting is not taking place.
NOTE:
� If there is no gap at the rail end, it may foul
and hard gear shifting may happen.
The repair
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Manual MAN-00103
CLUTCH � Apply sealant LOCTITE – 574 on front

housing face.
� 5th Gear Pair Assembly -
� Put roller bearing on 5th driven gear. Ensure

cone is on bottom side.
� Ensure fitment of brass ring below 5th
driving gear.
� Match the 5th gear couple and press it.
� Ensure output shaft sleeve is not rotating
freely after pressing 5th driven gear.
� Ensure placing of spacer on 5th driving gear
and sub shaft.
NOTE:
� Use 5th driving gear without worm for 4WD Transmission.
� Ensure circlip fitment on gear in case of 4WD Transmission.
� If 4WD circlip is not used then it may lead to gear slippage/ seizure.
� Front Housing Tunnel Insertion -
� Ensure that loctite-574 is applied on front

housing face.
� Ensure ball and spring insertion in the
detent holes.
� Ensure torque tighten both the poppet
plugs.
� Ensure intermediate plate is located in
place.
� Put the assembly in front housing; tap the
intermediate plate if required.
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CLUTCH
NOTE:
� If sealant not applied properly Oil leakage
issue may come.
� Gear shifting problem-Synchro ring
damaged during insertion/improper
insertion.
� Rear Housing Shimming – (In case Housing is being replaced with new)
� Tighten 2 bolts to clamp front housing and

plate.
� Ensure that the front housing bottom face is
resting properly on the locating faces. Use
filler gauge of 0.05 mm to confirm no gap.
Gauge should not pass.
� After shimming put the ball bearing on sub
shaft & press with impactor dolly.
Shim selection procedure:

Dimension B= Intermediate plate face to Sub
shaft collar face.
Dimension A= Rear Housing face to lower face
of bearing bore.
Shim size =A - B -( 0 to 0.120 mm)
NOTE:
� Gear slippage will take place if Shim/spacer or both are missing.
� Gears jam/ not engage /bearing seizure will take place if Shim selection is not proper.
� If rear housing with bracket not used then wire routing on vehicle can't be done.
� Rear Housing Insertion on Main Assembly -
CAUTION:
� Ensure torque on M10 bolts - 8 numbers. - 55 � 5 Nm.
� Ensure one number M10 bolt with hole.
� Use sealant FEVICOL- 171 on external thread of the Speedo sleeve.
� Apply torque on Speedo sleeve - 39 � 4 Nm.
The repair
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CLUTCH
NOTE:
� Apply sealant Loctite-574 on rear housing.
� Ensure that shim is fitted on sub shaft.
� Put dolly on the splines of output shaft for

rear housing insertion & check for 5th
driven circlip fitted.
� Put the rear housing and tighteen the mounting bolts.
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CLUTCH
� Fit the rear housing and 8 nos. mounting
bolts.
� Tighten filler plug and drain plug.
� Assemble Speedo sleeve and Speedo gear.
� Insert ball and spring in detent hole. Ensure
both ball and springs are inserted.
� Tighten the vibra seal 516 pre coated
puppet plug & torque @ (25 � 5 Nm) with
use of Angle Nut Runner.
� Fit the dust shield on the rear housing with
4 bolts.
� Torque the dust shield bolts with angle nut
runner at 25 � 5 Nm .
� Fit companion flange on the output shaft

splines.
NOTE:
� Put the plane washer before fitting
companion flange nut.
� Apply Sealant (Anabond 111) on output
shaft spline/ nut ID.
� Torque the companion flange nut to -
191 � 21 Nm.
� Remove the dolly after fitment of Rear housing assembly.

� Put the washer and Lock nut on output shaft.
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CLUTCH
NOTE:
� Apply Sealant (Anabond 111) on output
shaft thread/ nut ID; before fixing it on
shaft.
� Bearing Retainer / Clutch Release Bearing Sleeve Fitment -
� Ensure shim of MD gear fitment and snap

ring fitment on MD gear bearing.
� Ensure grease application on oil seal in
bearing retainer.
� Place belleville washer on the bearing
retainer before insertion on the MD gear.
� Place the counter shaft spacer before

retainer fitment.
� Use oil seal locator for retainer insertion on
the MD gear spline.
� Torque the m8 bolts to 24 � 4 Nm.
The repair
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in thisin document
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Repair Manual
Manual MAN-00103
CLUTCH
NOTE:
� Apply the Loctite 243 on small side of stud before stud fitment.
� Use new front end Retainer which has groove on OD & suffix ‘O’ ring. Refer sketch.
� If snap ring or spacer is not fitted then gear slippage will take place.
� If M.D gear shim is not fitted then 4th to 2nd crash shifting will take place.
� If torque or tightening of retainer bolts is not done then Oil leakage will take place.
� Adaptor Pivot Assembly / Lever Sub Assembly -
� Adaptor pivot dowel fitment.
NOTE:
� Apply silicon sealant on pivot before inserting dowel. Inadequate sealant application on the
pivot will cause oil leakage.
� In case dowel pin is missing, no proper alignment of lever sub assembly.
The repair
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Manual MAN-00103
CLUTCH � After adaptor dowel fitment, put the

adaptor pivot on fixture/ assembly table.
NOTE:
� If pivot not entering s/a fixture fully then
check whether the pivot pin is inserted fully.
� Torque 3 M8 Bolts. - 24 � 4 Nm.
� Assemble the gear bottom lever into the

Transmission assembly.
NOTE:
� The TM bottom lever assembly differs from
vehicle to vehicle as the NGT 520
Transmission is used for Xylo mDICRDe,
Scorpio M2Di, and in Bolero variants.
� Bottom lever shown in Illustration belongs
to Scorpio M2Di model.
� Assemble the correct gear bottom lever into the adaptor pivot assembly. Refer illustrations -
� Assemble the nylon bush, spring and retension plate. Refer illustartions.
NOTE:
� Ensure bush fittment. In case bush is missing, improper shifting or lever rattling may occur.
The repair
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Manual MAN-00103
CLUTCH
� After placing retension plate, press it and

then install the plunger and spring.
� Plunger and Spring fittmnet.

NOTE:
� In case plunger or spring is missing, biasing will not takes place.
� In case wrong spring used the biasing force will not ok.
� Side cover plate fittment. Ensure proper bolt fittment and torquing.
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Manual MAN-00103
CLUTCH �
NOTE:
In case bolt is missing or not torqued properly, the incorrect biasing may occur.
� Torque the side cover bolts to the torque

value 8 � 2 Nm.
� Lever Fittment -
� Apply inadequate sealant on the adaptor

pivot bottom side mating face.
Refer illustration.
� Put the rubber below over bottom lever and
adaptor pivot.
� After fitment of Bottom lever assembly into the Transmission, torque the adaptor pivot to 24 �
4 Nm torque.
The repair
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in thisin document
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Manual MAN-00103
CLUTCH
� Ensure proper location of pivot assy. with

help of dowel. - Pivot pin facing downwards.
� Fit pivot pin with pivot insertion & pressing
impactor dolly.
� Apply silicon sealant on pivot.
� Fit pivot by tapping it.
� Use new Rubber grommet along with new

metal clip.
� Keep the clips of the metal tie clip towards
5th/rev gear side.
The repair
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Manual MAN-00103
CLUTCH
� Apply sealant (Anabond 413/ Loctite 648)
on breather cap.
� Adapter Pivot & Gear Neutral Switch Fitment -
� Place the sensor on retainer plate.

� Put two lugs of sensor on plate hole and
press it.
� Fit two bolts of M8 40 on sensor lugs and
fit one bolt of M8 20 on plate. Torque them
29 � 2 Nm.
� Put 6 mm gauge between Magnet and

sensor while fitting to ensure gap (6 mm)
between them.
� Fit the Allen screw with help of screw
driver; apply 2.5 � 0.5 Nm torque.
� Fit the grommet on pivot.
� Assembly Inspection -
Make sure that the following check points to be carried out after completion of Transmission
assembly and before fitting it on vehicle –
� Check for presence of railed caps.

� Check for presence of breather.
� Check for static shifting.
� Check for biasing.
� Check for presence of countershaft spacer.
� Check for presence of one number M10 flange bolt with hole.
The repair
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Manual MAN-00103
CLUTCH
� Check for reverse lamp switch lead damage.
� Check for drain plug torque (check if it is loose by hand)
� Check for presence of filler plug.
� Check for free rotation of MD Gear.
Recommendation –
Mahindra & Mahindra recommends that after the fitment of Transmission assembly on vehicle,
check all the parameters ensure all the fitments are completed and do vehicle drives test to check
Transmission behaviour as well as vehicle performance.
NOTE: Vehicle to be run in neutral condition for 5 to 10 min for proper churning or lubrication of
oil.
The repair
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CLUTCH
� Specification –
Figure Description Value
Type Mechanical
Description NGT 520
Gears 5 Forward and one reverse gear
Gear shift Direct shift with rubberized lever
Gears Helical- toothed
1 3 5 Gear Engagement Block synchro ring type synchronizer on

1,2,3,4 & 5th
2 4 R
Gear Ratio
1st 3.778
2nd 2.087
3rd 1.379
4th 0.789
5th 3.524
Reverse
Oil grade/ quantity 80 W90; GL 4
Oil Capacity: 2.0 litres.
Counter shaft bearing One ball bearing/ one Cylindrical roller.

Input Torque capacity 20 Kg-m.
Weight 68 Kg
Kg
Play Limit (mm) Service limit(mm)
1st 0.175 0.375
2nd 0.175 0.375
� 3rd
4th
0.175 0.375
0.175 0.375
5th 0.18 0.3
Fork to groove clearances/ 0.1 to 0.4 mm
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Manual MAN-00103
CLUTCH
� Tightening Torques –
Description Torque in Nm (lbf-ft)

Plug - Shift Rail Poppet Spring 25 � 5 Nm ( 18 � 4 lbf – ft )
Flange Bolt / Nut – Clutch Hsg. To Main Hsg. 43 � 7 Nm ( 32 � 3 lbf – ft )
Flange Bolt – Front Intermediate & Rear Hsg. 55 � 5 Nm ( 40 � 4 lbf – ft )
Drain plug 27.5 � 2.5 Nm ( 20 � 2 lbf-ft)
Filler plug 27.5 � 2.5 Nm ( 20 � 2 lbf-ft)
Reverse light switch 30 � 5 Nm ( 18� 4 lbf – ft )
Bolt – Clutch Release Bearing Support Sleeve 24 � 4 Nm ( 18 � 3 lbf – ft )
Bolt - Idler Shaft 43 � 7 Nm ( 32 � 3 lbf – ft )
Bolt - Bearing Retainer Plate 31 � 4 Nm ( 23 � 3 lbf – ft )
Lever Retention Bolt 24 � 4 Nm ( 18 � 3 lbf – ft )
Companion Flange Nut 191 � 21 Nm ( 140 � 15 lbf – ft )
Speedometer Sleeve 39 � 4 Nm ( 29 � 3 lbf – ft )
Bolt – Gear Box to Transfer case 55 � 5 Nm ( 40 � 4 lbf-ft)
Nut – Reverse Driven Gear 60 � 10 Nm ( 44 � 7 lbf-ft)
*also refer the torque values mentioned during the Transmission assembly and sub-assemblies where
ever applicable.
� Sealant Recommendation –
Sr. No. Location Sealant / Thread Locks Applicability

1 Ft. Hsg. & Intermediate Plate Loctite 574 �
2 Intermediate Plate & Rear Hsg. Loctite 574 �
3 Clutch Hsg. & Front Hsg. Loctite 510 �

Anabond 413
4 Breather �
( Retaining Grade )
RTV Sealant Metlock 920
5 Pivot locking Option 1 – Rhodorseal �
Option 2 – Pidiseal 3P
Between Clutch Hsg. & OD of Ft.
6 Loctite 510 �
Bearing Retainer
Clutch Release Bearing support
7 Loctite 510 �
sleeve
8 Poppet Plug M 12X1.25 Loctite 542 �
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CLUTCH
� Special Tools –
Description/ Part No./ Sketch Usage View
Dolly to press countershaft roller bearing
0703AD0900H002
Dolly to press countershaft roller bearing
0703AD0900H001
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Manual MAN-00103
CLUTCH
Dolly for pressing bearing on output shaft
0703AD0900H011
Intermediate plate bearing pressing dolly.
0703AD0900H005
Dolly for pressing ball bearing in rear

housing.
0703AD0900H015
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CLUTCH
Fixture to press bearing on output shaft.
0703AD0900H007
Assembly fixture.
0703AD0900H004
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Repair

NGT 520 - TRANSMISSION

1. NGT520 transmission cross sectional view of 2WD.

CLUTCH HOUSING INTERMEDIATE

RELEASE BEARING 4TH

CLUTCH CLUTCH HOUSING

MAIN DRIVE SHAFT

SYNCHRO PACK 3RD

NGT 520 TM (4WD) Cross-sectional View

Synchronizer Pack Assembly Cross Section View

PROBLEM POSSIBLE CAUSES CORRECTION

Knocking or ticking � Chipped gear teeth � Replace gears.

Unable to select gear � Clutch defective � Rectify the clutch/ clutch

Hard gear shifting � Clutch defective � Rectify the clutch/ clutch

TRANSMISSION OIL – REPLACEMENT PROCEDURE

NGT 520 - Transmission

Transmission Oil – Replace (Refer above illustration)

CAUTION: While replacing the transmission fluid ensure that –

� Vehicle is parked on level ground/ 2 post/ 4 post lift.

Rear Oil Seal Replacement –

� Remove the Rear propeller shaft from

( Only rear propeller shaft in case of 2 wheel drive

� Refer section ‘ removal and installation of

� Remove the Speed sensor* from Transmission assembly (*optional)

� Remove the companion flange from

� Use flange puller in case it found jam.

� Always replace with a new seal once it has been removed.

� Before installation apply multi-purpose grease to lip of oil seal.

� Refit propeller shaft assembly.

� Check continuity, refer below chart.

Switch Gear Position Continuity

NGT 520 Transmission

Cross Member below

� Remove Clutch Slave Cylinder from clutch

� Remove reverse light switch connector on TM

Refer illustration for locations of Reverse light

� Disconnect and remove speedo cable from

� Remove starter motor from transmission.

� Remove Rear propeller shaft.

� Remove gear knob and shift lever- upper part.

� If vehicle is equipped with 4 wheel drive, ensure to –

� Disconnect and remove four wheel drive Shift

� Put tray below the transfer case, remove drain

� Disconnect and remove the front propeller

� Remove the transfer case insulator by

Put spanner through cross member hole to access

Support to the TM assembly bottom side for safety

� Transmission Gear Components –

� Counter Lay Shaft Gear & Synchronizer –

� Selection Biasing and Shift Lever Components –

NGT 520 2WD Assembly NGT 520 4WD Assembly

SCHEMATIC OF NGT 520 TM DISASSEMBLY

� Remove Clutch release bearing and fork.

� Remove the bellow and bottom lever

� Lever and locating pin removal.

� Remove the Speedo gear along with adaptor.

� Remove Companion flange lock nut and

� Remove the companion flange from

Rear housing Removal -

Front housing removal -

� Move sub shaft in forward direction.

� Be careful not to lose pin, shifting inserts.

� Remove lock nut on output shaft* in case 4WD transmission.