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MG ZR PG1 Manual Gearbox Overhaul Manual

This manual contains procedures for the overhaul of the gearbox on the bench with the engine removed. Operations also include reference to wear limits, relevant data, torque figures, and useful assembly details. Operations covered in this manual do not include reference to testing the vehicle after repair.

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Aras Serdaroğlu
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2K views43 pages

MG ZR PG1 Manual Gearbox Overhaul Manual

This manual contains procedures for the overhaul of the gearbox on the bench with the engine removed. Operations also include reference to wear limits, relevant data, torque figures, and useful assembly details. Operations covered in this manual do not include reference to testing the vehicle after repair.

Uploaded by

Aras Serdaroğlu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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PG1 MANUAL GEARBOX OVERHAUL MANUAL This gearbox is fitted to the following models:- Rover 218/418 Diesel New Rover 200 Diese! New Rover 218 New Rover 400 Diese! Rover 220 Rover 420 Rover 600 Diesel Rover 600 Ti Rover 820 Rover 800 KV6 MG-F Publication Part No. RCL 0124 ENG (2nd edition) Published by Rover Technical Communication © 1997 ROVER GROUP LIMITED INTRODUCTION INTRODUCTION How to use this manual To assist in the use of this manual the section title is, given at the top and the relevant sub-section is given at the bottom of each page. This manual contains procedures for the overhaul of the gearbox on the bench with the engine removed. For all other information regarding General Information, Adjustments, Removal of oil seals, ‘gearbox unit, consult the Repair Manual for the model concerned. This manual is divided into 3 sections, Description and Operation, Overhaul and Data, Torque & Tools, To assist filing of revised information each sub-section is numbered from page 1 ‘The individual overhaul items are to be followed in the sequence in which they appear. Items numbered in the illustrations are referred to in the text. Overhaul operations include reference to Service Tool numbers and the associated illustration depicts the tool. Where usage is not obvious the tool is shown in use, Operations also include reference to ‘wear limits, relevant data, torque figures, and specialist information and useful assembly details WARNINGS, CAUTIONS and Notes have the following meanings: WARNING: Procedures which must be followed precisely to avoid the possibility of injury. CAUTION: Calls attention to procedures which must be followed to avoid damage to components. NOTE: Gives helpful information. References With the engine and gearbox assembly removed, the crankshaft pulley end of the engine is referred to as the front. Operations covered in this manual do not include reference to testing the vehicle after repair. Itis essential that work is inspected and tested after ‘completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned. Dimensions The dimensions quoted are to design engineering specification with Service limits where applicable. REPAIRS AND REPLACEMENTS When replacement parts are required itis essential that only Rover recommended parts are used. Altention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories, Safely features and corrosion prevention treatments ‘embodied in the car may be impaired if other than Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification Torque wrench setting figures given in this Manual must be used. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. The Terms of the vehicle Warranty may be invalidated by the fitting of other than Rover recommended parts. All Rover recommended parts have the full backing of the vehicle Warranty. Rover Dealers are obliged to supply only Rover recommended parts. INTRODUCTION 1 INTRODUCTION SPECIFICATION Rover are constantly seeking to improve the specification, design and production of their vehicles and alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular ‘component or vehicle. This Manual does not constitute an offer for sale of any particular component or vehicle. Rover Dealers are not agents of Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation, Gearbox identification This overhaul manual is applicable to PG1 gearboxes having the following Serial No. prefixes: caBP R4A0 caBs RADT ceBN S4DTU ceBP S4EM cess SATU S6BSU S6AO CeDTUT S6BN C6DTUTH = S6BNU C6DUTH S6BS CeFTUT S7EMU KaBs vaDT KaBx VeBS K6AO wapT Kean waDTUT KeBs Y4ao K7BSUT K7Bx M5BS 2 INTRODUCTION

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