Gearbox Input Shaft Assembly Type «F»
Press the inner rings of the bearings onto the shafts with a mandrel.
Assembling the output shaft of the gearbox type «F»
Press on the inner ring of the front bearing with a mandrel.
Install the 1st gear gear and the 1st gear synchronizer ring.
Press on the hub assembly with the sliding clutch of the synchronizer of 1st and 2nd gears.
Establish a lock ring of a nave of the synchronizer of I and II transfers and a blocking ring of the synchronizer of the II transfer.
Establish gear wheel of the II transfer and persistent half rings.
Install thrust ring, 3rd gear gear and 3rd gear synchronizer blocking ring.
Press on the hub with the sliding clutch of the synchronizer of III and IV gears.
Fit the 3rd and 4th gear synchronizer hub retaining ring, the synchronizer blocking ring and the 4th gear.
Press on the inner ring of the rear bearing with a mandrel.
Measure the axial clearance of the 1st gear gear with a set of feelers. The values of the axial clearances of the gears are indicated in the subsection «Detailed Specifications».
Use a feeler gauge to measure the axial clearance of the 2nd gear by inserting the feeler gauges between the 2nd gear and the thrust washer.
Use a set of feeler gauges to measure the axial clearance of the 3rd gear gear by inserting the feeler gauges between the 3rd gear gear and the thrust washer.
Measure the axial clearance of the 4th gear by inserting a feeler gauge between the 4th gear and the bearing inner race.
Gearbox Input Shaft Assembly Type «G»
Press the bearing all the way onto the belt next to the 2nd gear gear. Put on the 3rd gear gear and the synchronizer blocking ring.
Press the 3rd and 4th gear synchroniser hub with sliding sleeve, pointing the lubrication grooves on the sleeve towards the 3rd gear gear.
Install the 3rd and 4th gear synchronizer hub retaining ring, the synchronizer blocking ring and the 4th gear.
Press the inner ring of the rear bearing to the stop.
Use a set of feeler gauges to measure the axial clearance of the 4th gear by inserting the feeler gauges between the 4th gear and the inner ring of the bearing.
Use a set of feeler gauges to measure the axial clearance of the 3rd gear by inserting the feeler gauges between the 3rd gear and the 2nd gear. The values of axial clearances of gears are given in subsection «Detailed Specifications».
Assembling the output shaft of the gearbox type «F»
Press the inner ring of the front bearing to the stop.
Put on the 1st gear.
Install the 1st gear synchronizer ring on the 1st and 2nd gear synchronizer hub.
Press on the hub assembly with the sliding clutch of the synchronizer of 1st and 2nd gears.
Install the synchronizer hub snap ring, 2nd gear synchronizer ring and 2nd gear gear.
Press the 3rd gear gear.
Install the 3rd gear retaining ring.
Press on the 4th gear and the rear bearing inner ring until it stops.
Measure the axial clearance of the 2nd gear gear with a set of feeler gauges by inserting the feeler gauges between the gears of the 1st and 2nd gears.
Use a set of feeler gauges to measure the axial clearance of the 1st gear gear by inserting the feeler gauges between the 1st gear gear and the inner race of the bearing.
Assemble the gearbox in the reverse order of disassembly, taking into account the following:
- on gearboxes of the type «F» check the runout of the input and output shafts and the gap between the gearshift forks and synchronizer clutches;
- before joining the clutch housing and gearbox, apply a thin layer of sealing mastic to their mating surfaces.