CLARK Manual de Servico Service Manual Biblioteca ee an chads tucenees AM 17 Encl es ”Introdugao Designagées e especificagées...... Lubrificagao .. Operagio... Recomendagées de torque Fluxo de poténcia.... Cuidados na desmontagem e montagem .. Diagnéstico de falhas.. Conjunto da Torre de controle = Remogao e desmontagem .. + Montage... Transmissao = Desmontagem sme = Montagem wrnnnnnnnnnnsnnn Sistema de engate + Desmontagem + Montagem wuss Carretel = Desmontagem + Montagem .. Carcaga da transmisséo + Desmontagem Conjunto do elxo principal - Desmontagem ar + Montagem .. 40 Eixo piloto = Desmontagem 2 42 = Montagem .. 43 Foreword Designations and specifications Lubrication... Operation ... Torque recommendations, Power flow .... Precautions during disassembly and reassembly Trouble shooting .... Shift lever tower assembly = Removal and disassembly + Reassembly_ Transmission + Disassembly .. ~ Reassembly.. Shifting system + Disassembly .. + Reassembly... Countershaft assembly + Disassembly... + Reassembly. Transmission case - Disassembly .... Output shaft assembly + Disassembly . + Reassembly.. Input shaft + Disassembly . + Reassembly semO objetivo deste manual é fornecer informagées detalhadas sobre servigos e reparos na transmissao Clark CL-2205. Ele 6 dividido em duas partes, a saber: 1. Informagées e refer6ncias técnicas; 2. Desmontagem e montagem da transmissao. Como usar o manual Para uma desmontagem e montagem completas, siga o manual em sua seqiéncia natural, Porém, se o problema envolver apenas um componente da transmissao, 0 indice forneceré o némero da pagina referente a ele. Exemplo: Sistema de engate: instrugSes para desmontagem, pagina 31 instrugdes para montagem, pagina 33. Para obter qualquer informacéio mais detalhada sobre melhorias do produto, procedimentos de reparo e outros assuntos relacionados ao servigo, entre em contato com: Equipamentos Clark Ltda. Marketing & Servigos Rua Clark, 2061 - C.P. 304 13270 - Valinhos - So Paulo - Brasil Fones: (0192) 71-9526 e 719527 The objective of this manual is to provide detailed information to service and repair the Clark CL-2205 transmission. This manual is divided into two parts: 1. Technical information and references; 2. Disassembly and reassembly of the transmission. How to use this manual To disassemble and reassemble the transmission, follow the manual in its entirety, However, if the problem involves only one component, refer to the table of contents for the page numbers showing that component. Example: Shifting system: instruction for disassembly, page 31 reassembly instructions, page 33 For more detailed information regarding product improvement, repair procedures or any other matter related to the service, please contact: Equipamentos Clark Lida. Marketing & Service Rua Clark, 2061 - C.P. 304 13270 - Valinhos - So Paulo - Brazil Phone: area code 0192, phone 71-9526 and 71-9527(DESIGNAGOES E ESPECIFICACGES 11157971) 0) DESIGNATIONS ‘AND SPECIFICATIONS Nomenciatura: Nomenclature: CL - 22 05 J Marchas Sincronizadas & frente / Forward Clark — synchronized speeds \______ Nivel do projeto / Design levet x 10: Capacidade Nominal de Torque Para 0 projeto base em Ibpé / x 10: nominal torque capacity for the Basic design in Ibft Importante: Todas as transmissdes Clark sio Important: Every Clark transmission is identified by Identiticadas pelo modelo e némero de série, Estas model and serial number. This information is stamped informagdes esto estampadas na plaqueta do on the transmission identification tag and affixed to identiticagao da transmissao fixada na carcaga da tho case. transmissao. Do not remove or destroy the transmission Nao remova ou destrua a plaqueta de identification tag. identificagdo da transmissao. Torque ~ Relagdes de Redugdo. Volume | Peso |Compri- Modelo tiguldo “ . ‘se mento 1 Sieo (kg) | (mm) wpe | Nm e 2 ot a st | Req) cL2205-A_| 220 | 208 | 3,923 | 2,278 | 1,431 | 1,000 | 239 | 3,556 | 2,2 41 | 509,7 ci2208-8 | 220 | 208 | 3,055 | 1.006 | 1.969 | 1,000 | oeo2 | a411 | 2.2 42 | 708, CL-2205-C 140. 190 9.404 | 2,157 1,378 | 1,000 0,837 | 3.815 22 42 708.0 CL-2205-D 83 126 | 3,746 | 2.157 | 1.978 | 1.000 | oea7 | aes | 22 a CL-2205-E 220 | 208 | 3023 | 2a7e | test | 1,000 | 0759 | 2,566 | 22 41 | 509,7 cuease | so | tos | 4283 | 207 | 47a | 1,000 | 805 | «081 | 22 | a1 | 04,7 Specifications: nous! xv Gear Ratio on | wou |e ode pacity | woignt | Lenght a oO (ka) (mm) wt] Nm 2 e [oe | Rem cu2205a | 220 | 208 | 3.003 | 2278 | 14a1_| 4.000 | 0.099 | asos | 22 | a1 | soar cu2ese | 220 | 200 | 3.055 | 1905 | 1.069 | 1.000 | 0002 | ass | 22 | 42 | 7009 cueees-c | 140 | 190 | 3.aoa | aisy | tora | 1000 | oes | seis | 22 | 42 | roo cuzzos. | so | 126 | vm) aus | sare | 1900 | og [amis | 22 | a1 | sont cies | 220 | 298 | 3.923 | 2a7e | 14a1 | 1.000 | 0760 | as6o | 22 | 41 | soo.7 cuss | eo | 108 | 4283 | 2.007 | 1474 | 1000 | 0095 | 4001 | a2 [a1 | seus Notas: Notes: (1) 0 volume de éieo 6 aproximado, pois depende da (1) The oil capacity is approximate, depending on the Inclinagéo do motor e da transmissao. Encha sempre inclination of engine and transmission. Always rofl a transmissao com 0 éleo especificade até o nivel de the transmission with proper grade and type of abertura do bujao de enchimento (vide lubrificagaio). lubricant to the level of the filler plug opening (see Lubsification). (2) O peso nao inclui a torre de controle. (2) The weight does not include the shift lever tower. (3) © comprimento 6 a medida da face dianteira da carcaga da transmissao até a linha de centro da (3) The length corresponds to the distance cruzeta do garfo-junta universal. between the front face of the case and the center line of the yoke.O procedimento adequado de lubrificagao ¢ a chave para um bom e completo programa de manutengao. Se 0 dleo nao cumpre sua fungao ou se o nivel de dleo & ignorado, todos os procedimentos de manutengao possiveis nao serao suficientes para manter a transmissao funcionando ou para assegurar uma vida longa a ela. As transmissées Clark so projetadas de tal forma que as pegas internas trabalnem circundadas por um banho de dleo, que & circutado pelo movimento das engrenagens eixos. Assim, todas as pegas serao adequadamente lubrificadas se os procedimentos abaixo forem cuidadosamente seguidos: 1. Manter o nivel do éleo, inspecionando-o regularmente; Trocar 0 éleo regularmente; Usar 0 grau e 0 tipo de dleos corretos; 4. Comprar o éleo de um distribuidor de reconhecida confianga. er Lubrificantes recomendados A preferéncia recai sobre o Lubrificante de Extrema Pressao (EP) conforme MIL-L-2105C (ou conforme API GL-5) de viscosidade SAE, como recomenda a figura ao lado. Nao usar outros lubrificantes de EP diferentes do MIL-L-2105 ou APIGL-5. Muitos lubrificantes EP contém compostos quimicos altamente ativos que foram formulados para performance em tipos A especificos de aplicagées. Corrosao severa, depésitos residuais e lubrificagao inadequada podem ser resultado de uma aplicaco T incorreta. BT ! Temperatura Ambiente (A) MIL-L-2105 C Grau 80 W-90 (B) MIL-L-2105 C-75 W Farenheit a gegeage a BBS oa8 ‘The proper lubrification procedure is the key to a good and complete maintenance program. If the oil is not doing its job, or it the oil level is ignored, all the other possible maintenance procedures will not be enough to keep the transmission running or to assure long transmission life. Clark transmissions are designed so that all intemal parts operate in a bath of oil which is circulated by the motion of gears and shafts. Thus, all parts are amply lubricated if these procedures are closely followed: 1. Keep the oil its recommended level by inspecting it regularly; 2. Change oil regularly; 3. Use the correct grade and type of oil; 4, Buy from a reputable dealer. Recommended oils Preference is given to Extreme Pressure (EP) oils as of MIL-L-2105C (or API GL-5) and SAE viscosity as recommended by the figure. Do not use other * oil wich does not comply to MIL-L-2105C or API GL-5, Many EP oils contain highly « active chemical compounds formulated for specific applications. Severe corrosion, » residual deposits, and inadequate lubrication may result from improper application. Prevailing Ambient Temperature 0 (A) MIL-L-2108 © Grau 80 W-90 (orof an API classification GL-5) Celsius (B) MIL-L-2105 C-75 WRUBRIICR ORO ris Stieoits 38 Troca de dleo e Inspegao do nivel A troca periddica de éleo da transmissao elimina possivels falhas de rolamentos, desgaste de anéis e engripamentos, uma vez que produtos normais de desgaste em servigo (mintisculas particulas de metal), que circulam no dleo da transmissao so prejudiciais para estes tipos de pecas. Além disso, 0 dleo se altera quimicamente devido aos repetidos ciclos de aquecimento e resfriamento que ocorrem na transmissAo em servigo. A tabela abaixo mostra os periodos recomendados para inspec&io do nivel e da troca de dleo. Oil change and level Inspection Periodic transmission oil change eliminates possible bearing failures, rings wear and seizures, since the products of normal wear in service (tiny metal particles) wich circulate in the oil are harmful to these parts, On the other hand, the oil changes chemically due to the repeated heating and cooling cycles of a transmission in use. The table below shows the recommended periods for oil level checks and changes. ‘Ap6s 0s primeiros 5.000 km rodados Tocar 0 dleo | After the first 5,000 km of use Change the oil Acada 10,000 km rodados | Vorificar o nivel de dleo Uso em estrada © possiveis vazamentos Highway use| Every 10,000 km of use Check the oil level and possible leaks Acada 40.000 km rodados Trocar o dleo Every 40,000 km of use Change the oil | Apés.0s primeira 5.000 km rodados Trocar 0 dleo Alter the first 5,000 km of use Change the oii Acada 7.500 km rodados Verificar o nivel de dleo Uso fora de estrada e possiveis vazamentos Off-highway use Every 7,500 km of use Check the oil level and | possible leaks A cada 15.000 km rodados Trocar 0 leo Every 15,000 km of use ‘Change the oi! Drenagem do dleo € fundamental drenar a transmissao enquanto 0 éleo estiver quente. Para drenar 0 dleo, remova 0 bujéo magnético-dreno do fundo da carcaga. Em seguida, limpe o bujdo antes de reinstala-lo, Draining Drain the transmission while oil is warm. To drain the oil, remove the drain plug at botton of case. Then, clean the drain plug before re-installing.TERED RNS SUED Lavagem ‘Apos a drenagem 6 recomendavel lavar a transmissao. Para tanto, deve-se recolocar 0 buj&o magnético-dreno e encher a transmiss&o ao nivel correto com um éleo de lavagem fino. Gire a transmissao em neutro por um periodo curto de tempo de maneira que as engrenagens na transmissao girem sem carga. Esta operagao remove o 6leo antigo aderido a carcaga, tampas e varoes. Assegure-se da drenagem do leo de lavagem antes do enchimento com dleo novo. Este procedimento é importante na primeira troca de dleo. Reenchimento Limpe a carcaga ao redor do bujéio de enchimento, remova o bujao e encha a transmissdo até o nivel de abertura de enchimento. A quantidade de dleo necessa- ria para o reenchimento depende da inclinagao da transmisséo. Nao encha a transmisso acima do nivel, pois o dleo sera forgado para fora da carcaga através da tampa retentora do rolamento do exo piloto, tampa de controle, torre de controle, etc. Inspegao Sempre que verificar 0 nivel do éleo, limpe antes ao tedor do bujdio e se necessario adicione dleo suficiente para manter o nivel correto. Nao adicione éleo de diferentes tipos e marcas, pois poderé ocorrer incompatibilidade entre eles. Hicthety poseerachsoteagi [ners ots LUBRICATION: Flushing After draining, flushing is desirable. To do this, replace the drain plug and fill the transmission to the proper level with a light flushing oil. Drive the transmission for a short period at fast idle so that the gears rotate without load. This operation removes the old oil clinging to the case, covers and shift rods. Be sure to drain all the flushing oil before refilling with new oil, this procedure is important in the first oil change. Refilling Clean the case around the filler plug, remove the plug and refill the transmission to the level of the filler opening. The quantify of oil necessary to rofill the transmission depends on its inclination. Do not fil the transmission above the recommended level. This will cause oil to be forced out of the case through the front bearing cover, the control cover, the shift lever tower, etc. Inspection Everytime the oil level is being checked, clean the area around the filler plug and, if necessary, add sufficient oil to maintain the correct level. Do not add oils of different brands and kinds for they might be incompatible.A aplicagao correta de torque ¢ importante The correct torque application is important to para garantir uma vida longa para a assure a long transmission life. Use a torque transmisséo. Usar um torquimetro para obter wrench to obtain the recommended torque. © torque recomendado. CL-2205-B Lect 515 no dameto Sine eave 25.00 Lip 2441 No) ‘only Lcite 515 on Leite 262 na rovea des paaivsos 25.0 Lit (04-41 Hm) torque aan ‘eply Locte 262 on treads Kae Ul pict Lotto 615 na supercede ‘nao da tarpaotntra doe plcto ‘ppl Locte B15 on contact sutace of ‘put chattbewrg cover Aoicar compost de vcnra0 DOW CORNING 70" a do prangamento a varorssio ‘Aplcr compost de vedagdo. Torgue 1020 bps (14.27 Nm) ——_“Hosircaclngcorpound OOW COMMIS 720 on coict DOW CORNING 70 a nga TOSDLUE(I4-27 Hr) torque, ‘EH Sea compound DOW CORN das careages da embecageme tranamissdo Apply seating compound DOW ‘CORNING 780 on contact ‘surface of transmission case “Torque 25:90 Lbpé (94-81 Ne) ‘and clutch caso ‘Loote 262 na rosea dos paralusos 25-30 Lb (94-41 Nm) torque ‘Apply Lozite 262 on threads Torque 11-13 Lbpé (15:19 Nm) Loctto262 na rosca dos paratusos 41-18 Loft (15-19 Nm) torque Apply Loctite 282 on threads Torque 11-13 Lopé (15-19 Nm) Loctte 222 na rosea des paratusos 11-13 kb (15-19) torque Aoply Locte 222 on threadsEsquema de mudangas da alavanca de marchas The shift lever pattern for the speeds is as follows | | NEUTRO. ——— | 2 4 R Informagao geral As transmissdes CL-2205 tém 5 velocidades para frente e uma ré. Para mudar as marchas que vao a frente basta seguir 0 esquema acima. Jé para a marcha a ré, a alavanca deve ser pressionada para baixo, na posigao de neutro, entre a terceira e a quarta, e levada para a posigao indicada no esquoma. Conselhos ao motorista - Sempre use a embreagem para as mudangas de marcha. A incorreta ultilizagao da embreagem pode causar falhas prematuras no conjunto sincronizador; - Selecione sempre uma marcha de saida que fornega reduc (torque) suficiente para as condig6es de carga e utllizago (terreno) do veicuto; + Nunca force a alavanca de mudangas, batendo ou dando solavancos, para completar um engate de marcha; - Nunca ande com a transmissao em ponto neutro numa descida. 1 | 5 NEUTRAL ——— | 2 4 R General information CL-2205 transmissions have 5 forward speeds and one reverse and are shifted following the shift pattern shown above. To engage the reverse speed gear, the shift lever is to be pressed down at the neutral position, between the 3rd and the 4th speed gears, and then taken to the position inai- cated by the pattern. Tips for the driver - Always use the clutch to change the gears. The incorrect use of the clutch may cause premature failures of the synchronizer assembly. - Always select a starting gear that will provide sufficient reduction for the load and terrain, - Never slam or jerk the shift lever to complete gear engagement. Never leave the shift lever in the neutral position while going down hill.CL-2205-A/E “Torque 20-25 Lops (27-34 Nr) Lactte 262 na rosea dos paralusos 25.30 Lat (34-41 Nm) torque Apply Loctite 262 on treads Torque 25.20 Lops (34-41 Nm) Lotte 515 no didmeto do inteceréneia Locite 262 na rosea des paralusos ‘Apply Loctite 515 on interference clemeter 25-30 Loft (34-41 Nm) torque ‘Apply Loctite 262 en treads {Guarnigo na jungBo de torre {de conroe e prclongamenio Gasket on contact surface of 7 hit ever foxer an extension oo __) OC} LI = Loy He ster Leto 55:8 shri conta tanya oa pio. uW || Terque 8090 Lop (108-12 Nn) Sp Locto 160 comact p Teporsaeteosia ries ctimetont celmion toe ee we eng cover Sroubert Aen composi do vosazao Torq 1020.BpE (1427 Nm) Aono do peongamencom a eae ca tarsi DOW CORNING 780 na 10:20 Lb (14.27 Nm) torque ‘Apply sealing compound DOW CORNING 780 on contact unglio da carcaga da ‘surface of extension and transmission ‘de opace doa Apply sealing compound Bbircomtia Toon tora autan tart Sincase antes “Torque 25-00 Lbpé (94-41 Nm} Loctite 262 na rosca dos parafusos (25.30 Lb (34-41 Nm) torque ‘Apply Loctite 262 on treads “Torque 11-18 Lbpé (15-18 1Nm) Lette 262 na rosea dos paralusos 17-13 Lot (15-19 Ni) torque Apply Locito 262 on ttveads Torque 11-13 Lbpé (15-19 Nm) Locte 222 na rosea dos paralusos 11-13 Lot (15-19) orque Apply Loctte 222 on inreads(LEIS TI a TORQUE RECOMMENDATIONS | CL-2205-C Loctite 515 no kdmetro de inteteréncia Apply Loctite 515 on interferance clameter Torque 25-90 Lbpé (94-41 Nn) Loute 262 na rosea dos parafisos 25-90 Loft (94-41 Nm) torque ‘Apply Locite 262 on treads Guamigo 5316506 da tampa by ‘alentora do eixo pilolo Lp 18316526 gasket of input shaft easing cover A ‘Aoliear composto do vedeco DOW CORNING 780 na scones ve Torq 1020161427 moss poergnans nena a este Se car ae eee W Citar lestnsonenstanoe fplocns cuca Secon taste ‘Soyatat coun DOW CORNING 780.00 ‘contact surface of transmis- sion caso and eutch ease Torque 25-30 Lbps (94-41 Nex) Loctto 262 na rosea dos paratusos 25-90 Lb (24-41 Nm) torque Apply Loctite 262 en treads Torque 11-18 Lops (15-18 Nm) Loctite 262 na rosea dos parausos 11-18 Lit (15-19 Nm) torque Apply Loctite 262 on treads 10Guamigdo 3316526 da tampa’ Felentora do oixo ploto {8316526 gaskot of nout shat Daring cover Torque 11-19 Lbpé (15-19 Nim) Loctite 262 na rosea dos parafusos: CL-2205-D/F Loctite 518 no cimet de intartréncia iy Loctto 815 en ntererence damotor Torque 25:20 Laps (4-4 Nm) “ey Lect 262 na rosea dos paralsos 25:20 Lt (4-41 Ni) ore ‘App Locte 262 on threads Apicar composto do vedago DOW CORNING 780 na |uncio do prolongamento com a carcaga da transmiseio Torque 10-20 Lopé (14.27 Nm) MRK ‘DOW CORNING 720 on YOdOLWN(1427 Nr trae Enact ure of entnton and Yanan ‘Aplcar composto de voting DOW CORNING 780 a jung cas carcagas da ‘embreagom e vansmisséo Apply sealing compound DOW CORNING 780 on contact ‘surface of transmission case and clutch case ‘Torque 25-50 Lepé (94-41 Nn) Locte 262 na rosea dos parafucos 25:20 Lot (34-41 Nm) torque ‘Apply Loctite 262 on treads 11-13 Lot (15-19 Nm) torque Apply Locite 262 on threads 1"A transmissao deve transferir com eficiéncia a poténcia do motor para as rodas traseiras do veiculo. € essencial o conhecimento do que acontece na transmiss4o durante a transferéncia de torque para se realizar uma pesquisa de defeitos ou quando ha necessidade de se fazer reparos. 1 = O torque do motor é transferido ao cixo piloto da transmissao. 2- O torque é transferido & engrenagem motriz do carretel. 3+ O torque é transmitido para todas as engrenagens do carretel. 4- O torque é transferido para a engrenagem do eixo principal correspondente a marcha engatada. A seceao transversal abaixo ilustra a posigo da engrenagem de 3* velocidade. 5 - Os dentes de engate da engrenagem do eixo principal engatada transferem 0 torque para o cixo principal através do conjunto sincronizador. 6 - O eixo principal transfere 0 torque diretamente ao eixo cardan através do garfo-junta universal. The transmission must efficiently transfer the engine's power to the vehicles’s rear wheels, It is essential to know what happens in the transmission during torque transfer in order to detect troubles, or else, when repairs become necessary 1. The torque from the engine is transferred to the input shaft. 2. The torque is transferred to the countershaft drive gear. 3. The torque is delivered to all countershaft gears. 4, The torque is transferred to the corresponding engaged output shaft gear. The cross section below shows the 3rd speed gear engaged 5. The internal clutching teeth of engaged output shaft gear transfer torque to output shaft through the synchronizer assembly. 6. The output shatt transfers torque directly to the drive shaft through rear yoke.CUIDADOS NA DESMONTAGEM EMONTAGEM Limpeza e manuseio Para que as pegas fiquem totalmente limpas, mergulhe-as num liquido tipo solvente (querosene, por exemplo), movimentando cada uma lentamente para cima e para baixo, até que todo o lubrificante velho e material estranho estejam dissolvidos. Atengao: Deve-se tomar cuidado para evitar arranhées na pele, riscos de incéndio e inalagao de vapores ao usar liquidos do tipo solvente. Rolamentos nao vedados Mergulhe os rolamentos em um liquido de limpeza novo. Movimente-os lentamente para cima e para baixo a fim de que as particulas aderidas nas partes dos Tolamentos se desprendam. Seque os rolamentos usando ar comprimido sem umidade. Repita a operagao acima até que ‘os rolamentos estejam totalmente limpos. Rolamentos vedados (sealed-clean) Os rolamentos vedados nao devem ser mergulhados em liquido de limpeza e as vedagées laterais ndo podem ser removidas. Este tipo de rolamento por ser auto-lubrificante no necesita de limpeza ou lubrificacdo interna. A remogao do rolamento do seu local de trabalho deve ser cuidadosa e a limpeza felta apenas externamente, com um pano seco @ sem felpas. Conjuntos sincronizadores S40 sensiveis a batidas, especialmente no cubo. Assim, evite o manuseio inadequado, quedas e/ou batidas na desmontagem/montagem, pois poderao causar seu travamento. PRECAUTIONS PRECAUTIONS DURING DISASSEMBLY AND REASSEMBLY Cleaning and handling In order to completely clean the parts, put them into a bath of solvent (kerosene, for instance), moving every part up and down slowly until all the old oil and foreign material have been dissolved. Caution: Care must be taken to avoid skin rasher, fire hazards and vapor inhalation when using solvents. Non sealed bearings Immerse the bearings in clean solvent, Move them up and down slowly in order to loosen the deposits of particles. Dry the bearings by means of moisture free compressed-air. Repeat the operation until the bearings are thoroughly clean. Sealed-clean bearings Sealed bearings must not be washed in a cleaning liquid bath and the side seals must not be removed. This type of bearing, being self-lubricated, does not need cleaning or internal lubrication. The removal of a bearing from its working place has to be very careful and the cleaning can be made only on the outside by means of a dry lint free cloth. Synchronizer assembly The synchronizer is very sensitive to shocks, especially on the hub. Therefore, avoid any inadequate handling, drops and/or bumps during disassembly/reassembly since this, may cause internal locking.eS: Observe para que as marcas existentes, uma na face da capa e outra na face do cubo, sejam coincidentes, porque estas indicam: 1. Que os ajustes transversais e entre dentes foram selecionados dentro do especificado; 2. O trabalho das trés lamelas internas em seus respectivos locais. Carcagas Limpe completamente 0 interior e 0 exterior das carcacas, tampas, etc. As pecas fundidas podem ser limpas em tanques com solug6es quentes alcalinas fracas (recomendamos 0 uso de uma solugao aquosa 7% de éleo soldvel desengraxante a uma temperatura de 60°C), desde que tais pegas nao tenham superficies retificadas ou polidas. As pegas devem permanecer na solugdo 0 tempo suficiente para ficarem completamente limpas e aquecidas. Isso ajudard a evaporagao da solugao de limpeza e da agua de lavagem. As pecas limpas em tanques de solucdo devem ser totalmente lavadas com Agua limpa para remogao de todos os vestigios alcalinos. Atengaio: Deve-se tomar cuidado e evitar inalag&o de vapores e arranhdes na pele ao usar liquidos aloalinos. Todas as pegas lavadas devem ser totalmente secas imediatamente, utilizando-se ar comprimido sem umidade ou panos absorventes macios e sem felpas, livres de material abrasivo como limalhas, 6leo contaminado ou composto de polimento. Inspegao A inspegao cuidadosa e completa de todas as pecas é de importancia fundamental na vida da transmissao. A troca de todas as pecas que apresentam desgaste ou fadiga evitard a ocorréncia futura de falhas dispendiosas e previstas. Make sure that the marks on the cup and on the hub faces are aligned because this, indicates that: 1. The radial play and backlash were selected according to specification. 2. The three internal shifting plates are in their respective positions. Cases/covers Clean interior and exterior of cases, covers, etc, thoroughly. The cast parts may be cleaned in hot weak alkaline solution baths (we recommend a 7% soluble degreasing oil solution at the temperature of 60°C), provided the parts do not have any ground or polished surfaces. The parts are to remain in the bath for the time it takes to become completely clean and warmed up. This will help the evaporation of the cleaning solution and the water rinse. The parts cleaned in alkaline solutions are to be rinsed with clean water to remove any alkaline trace. Caution: Care must be taken to avoid vapor inhalation and skin rashes when using alkaline solutions. Every cleaned part must be totally dried at once by means of moisture free compressed-air, or else, by means of a lint free soft cloth, not containing any abrasive material such as metal filings, contaminated oil or polishing compounds. Inspection A thorough and careful inspection of all the parts is of fundamental importance for the transmission life. The replacement of the parts showing either wear or fatigue will avoid future expensive and foreseen failures.Engrenagens, eixos e sincronizadores: Havendo disponibilidade de magna-flux, esse processo deve ser usado para verificagao das pegas, Examine cuidadosamente os dentes de todas as engrenagens quanto a desgaste, ‘pitting’, lascamento e trincas. Se os dentes da engrenagem apresentarem dreas onde a camada comentada esta bem gasta ou trincada, a engrenagem deve ser substituida por uma nova. Examine os eixos verificando se nao estéio empenados, com desgastes excessivos ou com estrias danificadas. Quanto aos conjuntos sincronizadores, observe para que as marcas de ajuste entre a capa e 0 cubo sempre coincidam, Carcagas, tampas, ete. Examine as carcagas, tampas, etc, verificando se esto completamente limpas eas superficies de contato, furos de rolamentos, estdo livres de rebarbas ou entalhes, Verifique todas as pecas cuidadosamente quanto a sinais de trincas, desgastes excessivos ou outras condigdes gue possam causar vazamento de dleo ou falhas subseqtientes. Rolamentos de agulhas Inspecione cuidadosamente todos os roletes quanto a desgastes, lascamentos ou trincas, determinando se sdo apropriados para continuarem em uso. Apés a inspeco, banhe os rolamentos em dleo e embrulhe-os em um pano limpo e sem felpas ou papel, para protegé-los até o momento da montagem. Rolamentos vedados Devido as vedagGes laterais, este rolamento deve ser inspecionado apenas extemamente, observando-se: ~ Excesso de giro no diametro interno de acoplamento no eixo ou no didmetro externo de acoplamento na carcaga (0 excesso de giro ¢ facilmente notado por fortes riscos de cor azulada), - Se as vedagées laterais esto com batidas, amassamentos ou labios das vedagdes queimados. Gears, shafts and synchronizer assemblies: Whenever magna-flux is available, this process should be used to check the parts. Examine carefully the teeth of all the gears for wear, pitting, chipping and cracks. If the gear teeth show spots where the case hardening is worn through or cracked, the gear has to be replaced by a new one. Inspect the shafts by checking If they are not warped or excessively worn or having damaged splines. As to the synchronizer assemblies, make sure the cup and hub marks are always aligned. Cases, covers, etc. Inspect the cases, covers, etc to see if they are completely clean and if the contact surfaces and bearing bores are free from nicks or burrs. Check carefully all the parts for cracks, excessive wear or for any other condition that may cause oil leak or subsequent failure. Needle roller bearings Inspect carefully every needle roller for wear, pitting or spalled areas determining whether they are suitable for use. After inspection, dip the needle roller bearings in an oil bath and then wrap them in a lint free cloth or paper, so as to protect them until they are used in the reassembly. Sealed clean bearings Due to the side seals, these bearings should be inspected only on the outside as to: - Excess rotation of the inner ring (shaft) or the outer ring (seat), The excess rotation is easily dected by the deep blueish markings. - Beating, bumping or burning of side seals.Vedadores de dleo, anéis retentores Vedadores de éleo, anéis retentores, etc, danificados em retrabalhos devem ser substituidos por pegas novas. A troca de vedadores de dleo ¢ anéis retentores é mais econémica quando a transmissao esta desmontada do que numa reviséio prematura posterior, s6 para trocar esas pegas. O vazamento posterior de dleo por um vedador gasto, pode resultar na falha de outras pegas mais caras do conjunto. Os elementos de vedagao devem ser manuseados cuidadosamente, particularmente durante a montagem. Cortes, arranhées ou enrolamento sob 0 labio do vedador prejudicam seriamente sua eficiéncia, Observagées: © Quando a substituigdio de pogas for necesséria, use somente pegas Clark genuinas para assegu- rar continuidade da performance e vida longa da transmissao, @ Considerando que 0 custo de uma pega nova equivale normaimente a uma pequena fracao do custo total do tempo parado e do servigo, evite reutilzar uma pega questionével que pode levar a reparos @ custos adicionais logo apés a manutengao inicial. © Para ajudar na decisao de reutlizar ou substituir qualquer pega da transmisséo, consideragées devem ser feitas quanto a hist6ria da transmissao, quilometragem do veiculo, aplicagdes, etc. Oil seals and snap rings Any oil seal, snap ring, etc. damaged during maintenance, should be replaced by a new part. The replacement of the oil seals and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time. An oil leakage through a worn seal may result in failures of other more expensive components of the transmission. The sealing elements are to be handied carefully, particularly during reassembly. Cuts, scratches or rolled up seal lips decrease the sealing efficiency. Notes: © When part replacement is deemed necessary, use only genuine Clark replacement parts to assure an extended transmission performance and a long life. © Since the price of a new part usually corresponds to a small fraction of the down time and of the replacement cost, avoid reusing any doubtful part wich may cause repairs and additional costs soon alter an initial maintenance, © To help in the decision as to reusage or replacement of any transmission part, considerations have to be made as to the transmission history, vehicle mileage, application, ete. 16TABELA DE FALHAS E CAUSAS PROVAVEIS FALHAS CAUSAS PROVAVEIS Rluido em ponto neutro Docalirhamento dovido a parausos de mantagem soto; Faka de lbriicante ou nivel bao, Engrenagons com desgasie excessive ou danced: FRolamertos com desgasle excessivo ou daniicados, Impurezas metacas ro hbrieante (cotaminac) Ruido com as marchas engatadas Desatinnamento da tansmissdo x caka de embreagem x motor; Engrenagem com contatoiregulr, olga excessiva ou daniieada; Rolamertos com desgasie excessio ou daniieados; Fala oe luoeicanto ou bai nv, txo principal ou contra-exo empenados: Inpurezas metlcas no lubsicante (contarinad); Lubiicante nadequac. Ruido externo (em = Ventiador desbalanceado; relagdo a transmissdo) | ~ _Amorocedor de vbragdes deletuso (noporants + Volante desbalareeado Embreagem desbalanceada; + Supore do motor (coxin) sles ou inoperantes: = Junta universal (ruzeta) asa, daniicads ou instalad incoretamente (ora de fase =_Cardan desbalanceado ou empenado. Dificuldade no engate = _ Embreagem com mau funelonamanta (no tbera completamente): | das marchas ~ Lubiflanta nde espectcas ou com nivel bax: | = Componentes do conjunta da torre ce controle amperradios ou daniicados; = _-Alusie selotvo da capa e cubo de engate regular (ou) + Gomponentas da tampa de controle (var, salores, gavfoe) gastos ou emperrados; + _Aluste incoroto do curso do pedal da embreagem. Raspa ao engatar Kite incorto do curso do pel da embreagem (nau funlonamento) © Elovada retagéo da marcha lena | - Engrenager eou sneorizaderos com dont de engate danicados; | + Andis sincrerizaores com desgeste na esta ds rosea = aga des andis mela do conjurtasreonizador aia (aca) ‘Ajute incorto do curso do pedal da embroagem (ma funonamenta ‘Aust eleva da capa ecubo de engat regula (x): Exo principal desannado ou empenade: ‘Companertes do corunto da tore de contol empetados ou daneacos " Dificuldade para 0 desengate das marchas Escape de marchas = Desalinhamania da transmiseao x caixa de embroagem x motor (escape da S* marcha); = Denies de engate com desgasie ou danicadoe; = Engato parca \ibraeao excessiva na slavanca de mudanga, provecada polos coxine do mator ou da transmiseBo {inoparantes); Foga axial excessiva das engronagens do exo principal Excentviciade nes dentes de engate (capa e engrenagem); Interoréncia do protoor de po na alavanca forganda 0 desengate Vazamento de éleo = Nivel de too acima co especticad (bujo de enchimanto) Vesedores daniteados au gastos. Carcaga da tansnisso, tapas ou relenores vineads eu com porosidade: Faces de uncéo empanadas; Respir entupido; Paraluso com torque baixo au sem adesvo vedador. Falhas dos | + Fata do tabileegéo ini na montagor rolamentos de agulhas : Impurozas moleas no lubrfeante (conaminado + Falta de lubsiicante, nivel baixo ou lubieante nadequado; = Montagem inadequada (impacto, sm cispostivo) Engate de duas marchas simultaneamente + Fats do pino tava das buchas seletores, 7LIST OF MOST PROBABLE FAILURE CAUSES FAILURES PROBABLE CAUSES Noise arising in neutral Msaigamon! due la lose capsarews; Lack or ow evel of xing of Damaged or excessively wor goa eth; Damaged or excessively worn bearing; Forigh melt paris inte isoatng 08 (contamination) Noise arising in gear ‘Misalignment of ransmssion x cllch housing x engna Gears with ieguiar contact, excossive pay or damages; ‘Damaged or oxcossvely worn bearings! Lack or iow level of usicating of, Warped output shat or courtorhalt; Fereign meialicparlosin the kibricang oi (contamination); Inconoc ubricat. Noise arising outside + Outotbalanc fas {in relation to the : Ferri sbi effective); transmission) uta balance eich assembiys Loose or nt otacve engine mountings; ‘Wen, damaged or ncorecty instal (out of phase} yoke (universal in), ‘Out-oF balance or warped ve shat Difficult shitting Improperly operating cach (oes net release propery [Non spect ow tvel urieatng of Warped or damaged shit lvor tower components; lela selective adjustment ofthe cup ans, \Wiorn on warped componants af the conte cover assembly (shit rods, sectors, forks); Ineomect uth pedal vaveladsiment Clashing on + Incorrect clutch pedal ravel adjustment (maltunctioning); enon: > igh iting ofthe engine: igagement + Geer andor synchronizes with damaged clutch tooth; + Synchronizer tings with wom thread eres, Low tension inthe synchronizer spring ings Incorrect clutch peda! travel adjusiment, i Inregular selective adjustment ofthe eup and hub Misaignad or warpad cutput shaft ‘Sticking of damaged shill bar housing assembly components Sticking in gear fr = _ Misalignment of transmission x cutch housing x engine (sliping outa Sh gear, Slipping out of gear + Wem or damaged gear teeth + Partial engagement: Excessive vibration on the shit ever ce to engine or transmission suapet pads (ot etfectve): Excessive pay ofthe output shaft gears; CCiutch teeth excentity (cup and gear) Dust cover intrtaring withthe shit lever. Oil leak + Oittevetigher spectiod: + Wom or damaged ol seas; + Cracked or porous transmission case, covrs or bearing covers: ‘Warped contact surfaces; + Obstructed breather; + _Gapseraw with fo torque cr without octite apphication. Needle roller bearing = Lack o ital ubvicaton on reassembly in unit overhaul failure + Forcign metalic partes in th ban, + Lack, fo lavel or ineorcet cant Improper reassembly in unit overhaul impact without proper tue). Engagement of two gears | - Missing shit rod locking pin or mesh lock balls. simultaneously 18DESMONTAGEM E MONTAGEM ‘As sequiéncias de desmontagem e montagem desctitas a seguir mostram uma transmissao CL-2208 tipica. As operagdes comuns a todas as transmissdes so ilustradas por figuras que podem nao refletir exatamente, na aparéncia, uma determinada transmissao (tamanho do prolongamento, flanges, etc.); no entanto, nestes casos de procedimentos comuns, a operagdio em questo ¢ exatamente a mesma para qualquer modelo de transmissao. As operagdes de desmontagem e montagem peculiares, as quais ndo sao idénticas para todos 0s modelos de transmissao, sao evidenciadas pela linha de contorno mais grossa do quadro da Tespectiva ilustragdio. Nestes casos a identficagzo dos modelos de transmissao para esta operacao é feita por meio das letras respectivas (sufixo da transmissio), Posicionadas no canto superior esquerdo do quadro da ilustrago. As figuras a seguir ilustram os diversos tipos de transmissao. CL-2205-A CL-2205-E DISASSEMBLY AND ASSEMBLY The disassembly and assembly sequences shown are typical of a CL-2205 transmission. The operations that are the same for all models of transmission, are shown by illustrations that may not reflect exactly a specific transmission in appearance (extension size, yokes, for example); however, in this cases of common. procedures, the service operation is exactly the same for any transmission model. The specific disassembly and assembly operations, that are not the same for all transmission models, are shown by the thicker picture square line of the specific illustration. In this cases, the identification of transmission models are made by their letters (transmission suffix), positioning at the upper left side comer of illustration picture square. The illustrations below show the different models of transmission. CL-2205-B a Ze CL-2205-C CL-2205-D CL-2205-F 19Antes de iniciar a desmontagem da transmis, Before initiate the transmission disassembly, cettiicar-se de que a transmissdo esteja limpa certify that the transmission are clean exter- exteramente e isenta de dleo lubrificante. nally and without lubricant. 1 = Protetor dep / Dust cover. 2 Analtrava/ Snap rng, 43 = Bucha de apoio / Support bushing. 4 + Alavanca infor / Lower shit lever. 5 - Amuoia de assentamenio/ Seating washer, 6 = Parafuse J Capscrew. 7 + Areuoiadontada ! Washer 8 = Mola de apoio / Support spring. 9 - Careaga/ Housing. 10 - Mola 475*/ 4tn/Sih spring 11 = Suporte 495 / 40/51, support, 42 + Suporte 1° o18/ Rew /tst, support 18 + Mola 1 © ré/ Reu/tst. sping. 14 = Pino/ Ph, 15 + Suporte trava da ré/ Rev. lock support. 16 - Parafuse / Capscrew. 17 - Guamiggo / Gasket 18 = Bucha / Bushing. 19 = Ane aval! Snap rng 20 = Bucha/ Bushing 21 = Pina/ Pin, 22 Alavanca superior / Upper shit over 114 Remover 084 paralusos e auolas, 0 conjunto da tore da 12. Prende 2tor de controle a morea, Remover o prottor de controle e a guard, 5, mando euidado para néo rasgé-o; remover os dois anéis 1L4 Turnout the four capscrews and washers, and remove the shift lrava laterais, as duas buchas do nyion © @pino da alavanca, lever tower assembly and tho gasket ‘toned: No inoror da alavanca existe uma bucha de borracha, 41.2. Secure the sit iver lower ina vise. Remove the dust cover ‘manually: remove the two snap rings, the bushings and te pin Attention: Thera isa rubber bushing inside the lover. 20‘18 Puxar a alavanca supetior para cina, para removéla do ‘conjuntoinfevior da alavanca, 1.2. Pull upper shit over upmard, in order to remove it trom the lower assembly. 1 Remover 0 anel vava com um aloale de bk. 44 Remove the snap ring. 115. Punara alavanca infrior para cima (60 necossario, baler Jevornonte com um mario de pléstico na porta estérica da alavanea), para remover toda a part intariorda tore de contol, 15 Pullthe lower shif lover upwards (fnecessary use a rubber ‘mallet at end of fver to jar i), inorder to remove Whole lower part of ‘render a carcaga da ore do auto lado, Ramover 8 dois parafuses inferores a rarer o supore-rava dar 1.6 Socuro the shi over tower housing nother side. Remove the two lower capscrews and then the reverse fock Support. AE 1L7 Remover os dois suportes @ as molas, presslonendo levemenie ‘88 molas com 08 dedos. 1.7 Remove the spring supports and the springs by finger pressing tho springs sight together. “TB Rlengio: A dimensii da face da careaga até o topo do ping ula dove ser do 5,75/5,25 mm (226"/207'). 1.8 Attention: The distance fom the housing face tothe top of the _guco pin must be 6.7515.25 mm (226/207). at2, MONTAGEM / REASSEMBLY (a) 2.1 Moniar em suas posigbes covetas a mola grossa de Trad com © suporte de formato irregular, © a moia mais fra de &® 54 no suporle com formato retanguiar. Ateneo: A mola grossa (1* 0) ‘deve fcarno lado do pina gua, 2.1 Insta ho thick tst/reverse selector spring int megular shape sping support and the thin 4h./Sh, selector spring in the rectangular shape spring suppor, by fingar pressing slighty. 22 Monlar 6 syports-tava da 3, observando o encalve no pino gua [Atongo: Nao sobcopor no suport do forma iregular do 1 8 Monta 0s dos paralusos, aplicando torque de 1520 leps (20-27 Nm) 2 Install the raverse lock support: take care to have the housing {guide pin inserted correcty. Attention: Do not overapit on the Iegular shape support (1s ravers). Insta he two capscrows with ‘argue of 15-20 on (20-27 Nm). ae) [ae J 2.3 Monlara mola de apoio no neror da carcaga, com 9 @amaro maior votado para dentro, Encaixar a saléncla da arruola de assento no metro menor da moa, 23 Insal the support spring inthe housing by inserting tho larger lameter ofthe spring frst. Insert the seating washer ito the smalor siamotor ofthe spring. 2.4 Encaixar a bucha do pale (nylon) na eefora da alavanca, 24 Insert the support bushing (nylon) inthe fulcrum bal RE 25 Monlara alavanca ¢ a bucha (lem 2.4) sobre arvucla a mola (liom 2:3). AteneSio: O rasgo do rosa latral da ponta da lavanea ‘eve fcar do lado do suporte com formato krogula. 225 Poston the shift lever and the bushing (em 2.4) over the seating washer and spring (tem 2.2). Attention: Tho grooved side ofthe shit Ieveris tobe positened othe side ofthe negular shape spring ‘Support 1st /revors}. 28 Encabxar o anol ava no canal inlommo da eareaga, 26 Insert the snap ring into the sic 222.7 Insatr a alavanca superior no conjunto inferior da alavanca, ‘Ateneo: Observar 0 correo ainamonto dos orcs das alavancas Inferior © superior. 27 Insert upper shit lever on lower assomby, Attention: Observe the alignment of holes of upper and lower shit ievers. 2.9 Monta o prototor de po na alavanea, interigando-0 com a ‘arcaga, observando 0 encale perfelto no dismetro malor do canal da carcaga. 129 Positon the cover on the lever by interconnecting it ih the housing. Make sure the lager diameter Is well insevied into the ‘housing stot Instalar 0 pio @ as buchas de nyo: Insalar os andis wave. 28 Install ho pin and the bushings; instal the snap rings. 2359 1 + Vedador de do / Osea 2 - Bucha/ Bushing 3 = Prolongamento Extension. 4 = Retenior/ Cover. 5 + Caleo Shim, 6 ~ Capa rolam. cénico Cup - taper ror, 7 Aneltrava Sap rng. 8. Tampa / plug 9 Carcaga / Case, 10 = Pino tava Flock pin 11 = Defletor de dao fC bata, 12 - Carcaga da embxeagem / Chtch casa ela de pass / Lack washer. 14 - Paraluso / Capscrew. 15 = Tampa / pug, 16 - Vedador do 6100 Ot seat 17 - Capa retamento ebnica ! Cup taper rier 18 - Guamiglo / Gasket 19 - Paratuso Capserow. 20 - Retontor/ Cover. 21 Bujdo expansivo/ Expansion pig. 22 - Placa espacadora / Spacer plata, 23 - Rolamento de aguinas / Neeale bearing. 24 - Paraluso/ Capscrew, 25 - Potea ! Nut 26 - Placa de deniticagSo ! Name pate 27 - Bujio de enchimonto Filer lug. 28 - Bujao magnétca/ Fifer plug 20 - Anal rave! Snap cng 30 = Arruela/ Washer, 31 - Eiko / Shat, 32 ~ Paratuso | Gapseran. 39 = Rolamento de agulhas / Nees rotler bearing. Porea Nut Anel'O"/O"rng = Anol ava! Snap rng. + Ane ‘Aneltrava / Snap ting Estora/ sat + Engrenagem de 5 velae. Sih speed gear, neronizador I Synchro. nh, Lamela/ Shiting pate Cuba Hub Anel mala! Spring ing Capa Hub. Engrenagem da 18 / Reverse gear + Rolamonto ce aguihas/ Necalo bearing. + Engr. moti do volocimetio | Speedemeter drive gear + Arrusla! basher, + Anelrava Snap sing. + Holamento de aguas / Necete bearing. Espagadee/ Spacer ‘Arueia | Washor Gor). sincr S16 / siiview. synchra assy. ‘nel ava! Snap ting, ‘Artuelas bepartiias / Spit washer, olamanls selado / Sealec-elean bearing, Flanges! End yoko, Engr louca da r6/ Rey. idler gear + Artuala | Washer + Arruola J Washer, + Engronagam louca daré/ Rev. flor goa. ‘Anelava ! Snap sng Garretel da 5* velo: / 5th gear countershaf ‘Apel irava / Snap ing, ‘Arrcla | Washer 244, DESMONTAGEM / DISASSEMBLY 111 Secure the transmission in fixing dovico. 112 Coma 3 04 # velocidad ongatada, ramover opine elise 1.2 With the 2nd. or ih, gear engaged, remove the lock pin 11 Remover o ino lateral da bucha selotora das marchas. 1.4 Remove the lock pn of siting sleeve, [ae{U7 Remover 0s 6 paralusos, alas, osolor de ongale e 0 Conjanio o protongamanto. Alengéo: Cuidado com os roletes do rolamento a eepiga de caratol do + velocdade, 1.7 Remove the sk copscrews, washers, the shift lig and the ‘oxtonsion assembly. Attention: Take care with the rollers of Sih. gear ‘countershant {18 Remover os 6 paratisos, arudlas eo corjunto do protongarnen- to, Ateneo; Cuidado com os rletes do rolamento da espiga do caretel de 5 velocidad, 1.8 Remove the six capscrews, washors and te extension assom bly. Attention: Take care With the cols of Sth. gear countershaf. 119 Remover o ane!"Ov 41.9 Pemove the "ring. 110 Remover e anel wave, 1.40 Remove the snap ring. RBCE TT Remover o ramen, 111 Remove te bearing. TAR Romover os andis rave 112 Remove the snap rings. 261119 Remover o anel rave @ e armuole de encanta, 1.13 Remove the snap rng and the washer 1.8 Remover o cartel da 5 wocdace, lean depose, se 118 Romove he Sh cea counsel use dei, trees, 1.14 Remover a corca do velocimetro @ a astara ava. 1.44 Romove the speedometer chive goar an lock bal 1.16 Romovora engranagem de 5 velosidade @ o anol ereronizader. 11.16 Remove the Sth. goar and the synchronize ing. 1318 Fever pn stn 1.18 Remove the lock,1.19 Remover oarame wava 0 paraluso 118 Remove the lock wre and he capserew. 1121 Remover o Conjunto sincronizadr de Sr jntamante com @ gato a aruola 121 Remove the Sth,roverse synchronizer assembly with the fork and washer, 1122 Remover a engrenagom da 6, orolamont de aguihae @ cespagador, 1.22 Remove the reverse gear, the neede bearing and the spacer. 1.23 Remavor o anel wava do Gx seletr. 1.23 Remove the selector shat srap ring. 1.24 Remover o anel vava 1.24 Flomove the snap ring. 28ABE 1125 Remover a engrenagem louca da ea aruela eepagador, 1.25 Remove the reverse idler gear and ihe spacer washer. 1126 Remover a amuela espapadora, a engrenagem louca dare @6 ralamento de aguihas, 1.28 Remove the spacer washer, the raverse idler gear and the ‘noedie bearing. 1.27 Remover 0s 4 parafusos ¢ o conjunto da tampa retontora do rolamanto 9 ea plo. 1127 emove the four eapscrews and the cover assembly of tha input shat beanng, 11.28 Fimover anel ava extomo do rlamento do eh piste 1.28 Remove th outer snap ring of input shat baaring. 129 Remover os 6 paralusos dianieos e as arruolas de pressto, 11.29 Remove the six frat capscrews and the lock washers. 1130 Abiir anel tava e remover a carcaga da ransmissto, ‘Aton: Cuidado com a sequrdaestera e meta ntema do var. 1.30 Open the snap ring and remove the tarsmission case. Altention: Take care wih the second bal and shi rod inner bearing. 20131 Remover simullaneaments os es conjunios. Atonglo: Se necessétio forga para cima o caro, llizando duas alavancas, 1.31 Remove the three assembles skrultancously. Attention: Use two levers fo force up the ceuntershaf, ifnecessary. 139 Remover 0s 2 paralusos @ 0 defietcr da Gea 1.83 Remove the wo capscrows and the of batle, 1132 lemover a porca 60 parafuso do garfo da embreagem. 1.92 Remove the cipscrew and nut ofthe cluch fork 301 ~ Setor de mudanga Shing 2 Bucha/ Sieeve 43 Paratuso / Gapsovew. 4 = Pro eistca / Lock pn 5 + Garlo 112 val. / Ist/2nd ork 6 Bucha selotora intemna ! inside sel sieeve, 7 + Bucha solotora extoma / Outside sa. sloove. 8 = Mola Spring 1, DESMONTAGEM / DISASSEMBLY 11 Alnhar as buchas seleoras eviora e ntema, com a haste do atta da 1424 velocidad, 141 Align the inner and outer selector sleeves lh the 1s./2nd for rod. 9 - Eslera/ Balt 10 = Ei selotor/ Solector shat. 11 = Garlo sy vel / Seat fork 12 - Buchas de nylon/ Nylon pad. 19 - Vaso 896 /Sthtov. shit rod. 14 + Garo 5iK6 / Stor fork. 18 ~ Bucha de nylon / Nylon pad. 16 = Anol ava / Snap rng. 18 Segura’ a bucha seletoraexloma eo garlo de 318 velocidado @ ‘ino eeletor de 5¥ © 1G, ¢ puxar 0 vardo junto com garfo ce 1W2* velocidad, 1L2 Holo the outer selector sleeve, the Sra /Ath, fork and the Sth ‘reverse Shit rod, anc pl outta fod wit) the Ys. fork113 Remover as buchas de nylon dos pans 1.3 Removo the nylon pads of he orks 322, MONTAGEM/ REASSEMBLY ABE | 2:1 Inslalar as buchas de nylon nos palin, 22 Posiconar a bucha seletora externa, o gala OYA" velosidade @ 0 2.4 Insert the nylon pads on forks. ‘xo Seletor do 5° e 6 8 Inlroduzi vardo junto com 0 garo de 1/28 velocdade, Atengzo: Observar a posigéo cota da bucha soletora externa, 22 Posttoning the outer selector sicove, tho 2rd/th fork and tho Stheverse shit rod and insert the rod wit the 1s.2nd, fork, ‘Attention: Verty the comet pasiicning of outer selacior sleeve, 331 = Rolamanta do toias/ Roller bearing 2 + Carelet/ Countershatt 3 = Rolamento de roles Roller bearing 1, DESMONTAGEM / DISASSEMBLY 11 Ramovero rolamento do ros danieio com depostvo, 112 Remover rlamenio de rolos vaseir com dispostv, 11 Remove the front roller bearing using a device, 12 Remove he rear oer bearing using a device, 34CORRE NED re aes 2. MONTAGEM / REASSEMBLY 2.4 Libilicar intalaro rolamento de roles wassiro, 222 Lubricare instalaro olamonio de ros dian. 2:1 Lubricate and install the rear roler beating 222 Lubricate and install he front roller bearing,1 = Retentor/ Cover, 9 - Paraluso/ Capscrew. 2 = Calgo/ Shim. 10 - Bujgo do encrimento/ Filer plug. 3 + Capscrolamentocbrico / Cup-taper ler 11 = Bujdo magnética/ Magnet pug. 4 Ano trava/ Snap ring. 12 = Ani tava Snap ring. 5 - Tampdo/ Plug 13 - Anvela/ Washer. 8 - Caroaga/ Case. 14 - Eixo/ Shaft, 7 = Pino ava Lock pin, 15 + Paraluso / Capscrew. 8 = Placa de identiicagdo / Name plat. DESMONTAGEM / DISASSEMBLY 1 Remover os 4 paralusos Allon, o conjun retonor e os cagos. 1 Remove the four Allen cepscrews, te cover assombly and the shims. 361 = Anal rave / Snap ring. 2 Amusla/ Washer, 3 + Folamonto vodado/ “Sealed clean bearing” 4 Arrusla/ Washer. 5 ~ Rolamento de aguhas / Needle bearing. 6 Espagador/ Spacer. 77 = Anal Sincronizader! Syachr. ring. 8 - Sinct. 12" veloc. con. 1s¥/2nd synchro. assy. 9 Capa/ Cup, 10 = Ane sinct / Synchro. rng. 11. Ehxo principal Output shat, 412 + Anol sinc. Synctro. ing. 453 = Sincr 34" veloc. con./ 34nd synchro. assy. 14 = Anolava/ Snap ring. 18 = Rolamonto cOnico/ Taper roter bearing 16 = Capa/ Cup. 7 = Lamela /Sniting plate 18 = Cubo/ Hub. 19 - Anel mola/ Spring rng. 20 = Engrenagom 3° vale. 3rd speed gear. 21 ~ Engrenagom 2 veloc. 2nd specd gear. 22 - Anol mola Spring ing. 23 - Cubo/ Hub, 24 ~ Lamela/ Shing pate. Anel tava! Snap rng. ngrenagem 1° velot./ fst speed gear. nel rava/ Snap rng. 28 - Cone rolamento cBnico/ Taper roller bearing 37EERRSENT OG BIKE PRINCI DESMONTAGEM / DISASSEMBLY BR SAET ASSEMBLY. | | 1.1 Fixar 0 exo principal para desmontagem, de modo que seus ‘components no sejam daniieacs. 14 Secure the outout shaft for disassembly, in manner thor components won't be damaged, 112 Remover o rolamanto cbnioo com aspostve, 1.2 Romove te taper roller bearing sing a device. 1.3 Flemover o anel tava @ o conjunto sineronizador de 3148 valecace, 1.3 Remove the snap ring andthe Srd.th. synchronizer assembly, 1 Ranoar wa eharizda u orporagon ia Veta 14 Remove the synchronizer ring and the Sd. speod gear. 115 Fivar 0 ixo principal do outro lado para desmeontagam, de modo ‘que sous componenics ndo sejam danincads. 15 Secure the output shaft atthe cther extremity, in manner their components won't be damaged. 38 118 Removoro ancl e a arrucla de encoste do rolamnante sold, 1.6 Ramove the ring, he washer and the “sealed clean” bearing,JUTPUT SHAFT ASSEMBLY ABE “17 Remover anel tava e arusla 66 encosto Go rolamento cbrico, 17 Fomove the snap ring and washer of the taper roter bearing. 118 Remover a engyrenagem de 1 velocidade junlamente com ‘clamonto earruela de encosto, 1.8 Remove the ts. speed gear wih the bearing and washer, 119 Remover o anel vava, orlamento de aguhas © amucla ‘espagadora, 19 Remove the snap tng, the needte bearing and spacer. 111 Remover o anel sincronizador e a engrenagem de 2 velocdade. 1.11 Remove the synchronizer ring and the 2nd. speed goat. 1.40 Remover o anelrava eo conjunto sncronizador de 1/2" velocidade. 4140 Remove the snap ring and tho tst/2nd. eynchronizor assembly.CONJUNTO DO EIXO PRINCIPAL «. ‘ MONTAGEM/ REASSEMBLY OUTPUT SHAFT ASSEMBLY 2.4 Prender 0 eixo peincpal 6m uma mors, com proelores de alumni nos mordentes. 2.1 Secure the output shat ina vse, using aluminium protection on the jaws. 12.2 Lubricaroinsalar a engrenagem de 2° velocidade e o ancl ‘Sineronizador, 122 Lutvicale and instal the 2nd. speed gear and he synchronizor tira 23 Insialare conjuntosineronizador do trava. Atongo: Obsorvar o lado conto sineronizador. 23 Install the tst.2nd. synchronizer assemby and the snap rng. Altontion: Very i synchronizer assembly is coroctly placed. 24 Lubriicare instalar a arrusla espagadora, o rolamonto de aguihas © 0 anal vava. 224 Lubricate and instal the spacer, the needle beating and the snap ing. | Ase | 4A— 25 Lubriicar e instalaro anal sincronizador a engrenagem do 1 Valocdade © 0 anel tava: pronsar 0 olamento cbnico viftzando Spositve, 25 Lubricate and instal the synchronizer ting, the Ist speed geer ‘andthe snap rng: prees the taper role bearing using a device. 26 Insialara arusla de encosto, a engrenagom de 1" veloddade © 0 rolemento de esferas, ullzando dispostivo. Ateneo: Obsarvar © lado conto do rlamnento. 2 install the washer, the tt, spoed gear and the ‘seated clean” Dearing using a device. Attention: Veil Ifthe Bearing is corrocly placed. 40cor | ABE 27 Instalar a arrvela de oncosto 6 0 anel rave do rolomento eelado, £27 Insal the washor and the snap rng ofthe “sesied clean” bearing. 28 Inslalar a arusla do encosto@ o nel tava 6o rolamente cOneD 228 Install the washer and the snap rng ofthe taper roar bearing 2.9 Prendero cio principal do cuto lado, ullzando marsa com prolelores de alsminio nos mordants, 22.9 Secure the output shal tthe thor extremiy na vise, using ‘aluminium protectin on tha jaws 2.10 Lubricareinstalar a engrenagem de 9 voloeidade @ anel ‘Sinoronizador. 2.10 Lubricate and instal the Src. speed goar and the synchronizer ‘ing ABE 2.11 Instalar 0 conjunto sinronizador do 3 © # velocidad e 6 anal tava. Atengiio: Obeervar lado coreto de montagem do ane! sincronizacer 2.41 Install the 34h, synchronizer assembly and te snap ring. ‘Attention: Vent the synctronizor assombly is conecty placed. ‘252 Instalro rolamenta cone, 2.12 Insta the taper rol bearing,OTS EE Baa 88 ASS RR aa Tar oa ITT, (EEE TES TRG Pa eceoetane ED eae 1+ Cone sineronizador/ Synchro. cone 2 + Eko Plelo/ M.D. goar 2 + Rolamento vedado / “Sealed Clean” bearing 4 Anel ava Snap ting 5 + Cone rolamento cénico / Taper oie bearing 6 - Roles / Rover DESMONTAGEM / DISASSEMBLY 114 Remover 0 ane sincrorizadore 0s 18 roles Iniemos, 1.1 Remove the synchronizer rig and the 18 inner rales, [cor ‘13 Remover anel vava, a arta espagadorae o rolamento de ostoras 1.8 Remove the snap sng, the spacer and the “sealed clean” bearing. 112 Remover o rolamonio conico com asposive, 12 Remove te taper roller bearing using a device, 42MONTAGEM / REASSEMBLY COF 2.1 Montar 0 rolamento do estoras, a arucla espagadora eo anal \rava, Ateneo: Obsorvar o lado coteto do folemento 2.1 Install tho “sealed clean” bearing. the spacer and the snap ting. ‘Attention: Vey i the bearing is corrcty placed, Cor 22.3 Mortar os 18 rlees intemas com graxa eo anal snoronizador 23 Assembly the 18 ier roler using grease and install ro ‘synchronizer ing, 43 2.2 Montar 0 rlamento cbnic, 22 Install the taper roiorboaringMONTAGEM / REASSEMBLY 111 Finara careaga de embreagom no dspostvo, 1.1 Secure the clutch case ina proper device. “12 Aplcar cola vedadora (Locte 515) na face do conjunte da tampa retealora do rolamento plot, Far a mesma com 4 paralusos ((oseas recobertas com adesivo Loctite 262), apicando toque oe 11 19 Lops (15-19 Nr, 1.2 Apolysoaiing compound (Lecite 515) on the contact surface of the INPUT shalt bearing cover. Tighten tho cover withthe four ‘capscrews (with the threads coated wih Locite 262), applying 11-19 1 (15-19 Nin torque. Bc NN ‘13 Intl o doer do Seo com 2 paralsos roscoe recobertes cam adesio Loctite 262), epcando torque de 68 Lp (7-11 Nn). 1.3 Insial tho ol bale wth tho two capscrews (with he treads aated wih Lotte 262), applying 6-8 (711 Nn) torque. {14 Tnsllaroparafuso de rogulagom da embreagem, daixando 40 mm da face da carcaga com a face do quacrado éo paraluso. Instatar a contrapore, apicanco torque de 20-30 Lopé (27-41 Nm). 14 Install the clutch fork ajusting screw, leaving a stance of 40 ‘nn trom the case surface to the screw square faco, Intl he counter, applying 20-20 bt (27-41 Nm) torque. 115 Insialar simutaneamenta 0s tes conjutos. 1.5 Insiall the tnoe assembles simuitaneously. “18 Aplcar cola vedadora (DOW CORNING 780) na face de jungao. 1.8 Apply sealing compound (DOW CORNING 780) an the contact curtac.“17 Instlar a moa oa ostora, fxando-as com o daposiive. 117 Install the spring and the bal, holding thom wih a device. 148 Instalar a carcaga da transmisso oobre 0s conjntos, abrir o| ‘ane! ava externa do rolamenia e encalxévla correlamente. 1.8 Postion the transmission case over the assembles; pan the ‘bearing outer snap ring, and force down ihe case uni Mocks. 19 Instalar opin lateral de wave da bucha seleiora das marchas na oso comata 1.9 Insal tho side pin which locks the selector sloove i this posion. ‘110. Fira a careaga com 6 parafusos (as oscas devem estar recobertas com adesho Loctite 262), aplicando toque de 25-30 lbpé (44-43 Ney, 1.10 Tighton the case with six capscrows (nth the threads coated with Loctite 262), applying 25-30 bot (34-41 Nm) torque. [cor | ‘TAT Inalalaro ancl tava eterno do lament do eo plato, 1.41 Install the INPUT shaft bearing outer snap sng. 1:12 Inellar a guamigi 0 a ampa rolontora do rlamento do pilot, fxando com 4 parafusos (as roscas devem estar reccbertas com ‘adesive Locte 262), apicand torque de 11-13 Lops (15-19 Ne. 1142 Install the gasket and the INPUT shaft boating cover, thon it ‘nth four eapserews (withthe treads coated with Loc 262); apoly 11-13 bt (15-19 Nn) torque 45TETTRANSWISSION 1.48 Islalarocorjnto do velonor, para ator una aga ental do 0,0600,200 mm no eno pena, utizando a quad Ge calgos nocessos. Apia lorque da 11-13 ps (15-18 Nm) nos 4 partie 508 oseas cobertas com edesivo Lect 262). 1.19 Insta tho cover assombly, using fo essary amount of shims 1 obtain a clearance of0.0800.200 mm on tbe output shat instal the four capscrews (wit the treads coated wih Lect 262), applying 11-13 bt (15-19 Nn toque. ‘744 inslalar a anuela espapadora ea engrenagem touca dar, ‘Aton: Obsorvar a posigao corela de montagem da engrenagem loves dar, 1.14 Install the spacer and the reverse idler gear. Attention: Very it the rverse idler gears corey placed. PS) 1148 Lubrflcare instalar orolamento de aguas, a engrenagem fovea daré e a eruela expacadora, Ateneo; Observar a posto corre da engrenzagor luca da r. 1.15 Lubricate and instal he noodle bearing, the reverse idler gear and the spacer. Attention: Very ithe reverse idler goariscorecty placed, 1 1.46 Install the snap tng. oor \\ ‘LAT Instalarculdadosamente 0 anel ava do obo eestor. 1147 Install he selector shatt snap rng caretuly. 1.18 Lubiitear instalaro olamento Ge aguitas, a engrenagem da réeaamuela ospagadora, 1L18 Lubricate and instal the noedte bearing the reverse gear and the spacer washer. 46iRiaihicihees Fey dias tea. eae Rigen STE MGs SBaea ea psessuilalinl sonainests peu nono nieces 1.38 Inala conjunto sincronizador de BN, junto com a garfo do ‘mudanga ¢ a auela de encosto das lames. Alongo: Observar o fencaixe coreio nos ts rasgos do cubo. 1119 Instl tho Sth reverse synchronizer assembly withthe shitting {ork and shiting plate washer. Attention: Verity ithe assombly re correctly engaged in the tree sos of the hub, 120 lnstalaro anal vava, 1.20 Instal the snap ring. ABE 1121 Insalar o parafuso opicando torque Ge 6-12 Ubpé (11-16 Nm e amarrar com arame ava, 4.21 Install th capscrow, applying 8-12 bt (19-16 Nm) and lock it withthe wir, 122 salar opino elastic, 1.22 Insal he lock pin, 1.28 Lubicare insalar@ engrenagem do 5 velocdade 0 o anal slnetonizador 1.28 Lubricato and insta the Sth. speed gear and the synctvonizer gear 1124 Instalar 0 earroel da 6 velocKdade, 124 nsiall the Sih. gear countershat.1.26 Instalar a esiora © a coroa do velocimatre, 1.25 Insta the lock bal and the speedometer cive gear, 1125 nslolar a arruela do encosio @ oanel ava, 1.26 Install the washer and the snap ring. ‘BCOF ‘127 Instalaro anol Wava da coroa do velbcimatr, 1.27 Install the snap ring ofthe speedomoter dive gear, “128 instal o anel ava do ol celoter. 1.28 Install he selector shalt snap ring. [sce] f 128 salar orolament, 1.28 instal ho boarng 48 1130 Insta o anal ava, 1.30 Install he snap rng131 Instalar@ anal" 1.31 Install the °O" tng. 1.32 Preparar o prolongamento apkicando cola vedadora (OOW ‘CORNING 789) na faco. Fixar a arruela de encosto do caretl da Velocidade com graxa, coservando a sua posgao correla 1.32 Prepare the extension by applying seating compound (DOW CORNING 780) on the contact eurface. Hold the thurs ofthe Sth. gear counters n place wi grease, observing tis comact placed [ecor) RE 1133 talar prolongamento irando com 6 paralusos (as roscas sdevem esiarrecoberias com adesivo Loctite 262), aplcand torque fo 25.90 Lp (34-41 Nm) 1.38 install and lighten the extension with he sb canscrews (wit the tiveacs coated wih Loctle 262), applying 25-30 bn (34-41 Np torque. ‘134 Instalaro protongamenta junto com 0 setor de engate, Faro prolongamento com 6 paratuscs (as roscas davem estar roccboras ‘com adosivo Lecite 262), aplicando terque de 20:90 Lbpé 7-41 Nn. 1.34 Install the extension withthe Shit lug ard insia the six capscrows {withthe threads costed with Lecte 262), applying 20-30 ett (27-41 Ni) torque. ‘135 Instalar 6 lange. Aplicaradosive Loatie 262 na roaca o salar 18 porea auto trenadora com o torque de 0-90 Lbpé (109-122 Nm). 1.35 instal the yoke, Coat tho thread of nut with Loctite 262 and Insta applying 80-90 tt (109-122 Nm) torque. 49 1136 Inetalara edfera,a mola eo tamoio de relangio com cola Vedado Locte 515 ne sémetro de nterterénca. 1.36 Insalhe ba, tha spring and the plug, applying Lostte 515.0n the interference diameter of he plug.TRANSMISSAO: "2s. TRANSMISSION | Bcor