Disassembly and assembly of gearbox shafts.
1 - secondary shaft,
2 - needle bearing of the driven gear of the second gear,
3 - second gear driven gear,
4 - inner conical synchronizer ring,
5 - double conical synchronizer ring,
6 - synchronizer ring,
7 - the hub of the synchronizer of the first and second gears,
8 - crackers,
9 - crackers spring,
10 - first and second gear synchronizer clutch,
11 - synchronizer ring,
12 - double conical synchronizer ring,
13 - inner conical synchronizer ring,
14 - driven gear of the first gear,
15 - needle bearing of the driven gear of the first gear,
16 - the inner ring of the bearing of the driven gear of the first gear,
17 - output shaft bearing,
18 - needle bearing of the driven gear of the third gear,
19 - driven gear of the third gear,
20 - inner conical synchronizer ring,
21 - double conical synchronizer ring,
22 - synchronizer ring,
23 - the hub of the synchronizer of the third and fourth gears,
24 - crackers,
25 - crackers spring,
26 - third and fourth gear synchronizer clutch,
27 - synchronizer ring,
28 - spacer,
29 - retaining ring,
30 - thrust ring,
31 - input shaft gear,
32 - input shaft bearing,
33 - ring,
34 - needle bearing of the input shaft,
35 - intermediate shaft,
36 - rear intermediate shaft bearing,
37 - front intermediate shaft bearing.
Note: when assembling, it is necessary to select the dimensions of the parts indicated in the assembly drawing by the inscription "Selection".
Withdrawal Notes
1. Synchronizer hub for shifting third and fourth gears.
A) Using two slotted screwdrivers and a hammer, remove the circlip.
Note: Do not reuse the removed circlip.
b) Hold the synchronizer hub with your hand and, striking with a plastic hammer on the secondary shaft, remove the hub.
2. The hub of the synchronizer of the first and second gears.
Using a press, remove the bearing, 1st gear, synchronizer assembly, and 2nd gear from the output shaft.
Attention: during the procedure, hold the output shaft with your hand to prevent it from falling.
3. Input shaft bearing.
Using a press, remove the bearing from the input shaft.
4. The outer ring of the rear bearing of the intermediate shaft.
Using a press, remove the rear bearing outer race from the intermediate shaft.
Attention: during the procedure, hold the intermediate shaft with your hand to prevent it from falling.
5. Using a puller, remove the intermediate shaft front bearing.
Installation Notes
1. The hub of the synchronizer of the first and second gears.
A) To assemble the synchronizer, align the grooves on the synchronizer rings with crackers.
Note: standard sizes of crackers are shown in the figure.
b) Align the tabs on the synchronizer ring with the grooves on the inner cone ring.
V) Align the tabs on the double taper ring with the holes in the gear.
G) Install the 1st and 2nd gear synchronizer hub onto the output shaft.
d) Align the mark on the synchronizer hub with the cracker as shown in the figure.
e) Using a press, install the bearing, 1st gear, synchronizer assembly, and 2nd gear on the output shaft.
Attention: be careful when using the press, do not damage the parts.
2. Synchronizer hub for shifting third and fourth gears.
A) To assemble the synchronizer, align the grooves on the synchronizer rings with crackers.
Note: standard sizes of crackers are shown in the figure.
b) Align the tabs on the synchronizer ring with the grooves on the inner cone ring.
V) Align the tabs on the double taper ring with the holes in the gear.
G) Install the 3rd and 4th gear synchronizer hub onto the output shaft.
d) Align the mark on the synchronizer hub with the cracker as shown in the figure.
e) Install spacer and circlip.
and) Measure the gap between the circlip and spacer.
- Gap - 0 - 0.05 mm
If necessary, select the thickness of the retaining ring to ensure the specified clearance.
Note: Thrust washers are available in thicknesses from 1.0mm to 1.90mm in 0.00mm increments.
3. Input shaft bearing.
Using drifts and a press, install the bearing onto the gearbox input shaft.
4. The outer ring of the rear bearing of the intermediate shaft.
Using drifts and a press, install the rear bearing outer race onto the countershaft.
5. The outer ring of the front bearing of the intermediate shaft.
Using drifts and a press, install the front bearing outer race onto the countershaft.