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ATTENTION! The transmission consists of a large number of details, many of them are similar therefore for simplification of assembly of a detail it is necessary to display on sheets of paper one after another and it is obligatory to sign everyone. |
We merge from the transmission oil (see Check of level and replacement of oil in the transmission).
We remove the transmission (see Replacement of the transmission).
We remove a fork of the drive of switching off of coupling and the bearing of switching off of coupling (see Replacement of a press disk assembled and the coupling switching off bearing).
Carefully we clear of dirt, we wash a transmission case with a brush and hot water with detergent outside and we put it on a workbench a coupling case down.
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We part with two screw-drivers sectors of the expansion plug and... |
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... we remove it and the rubber plug of a damper. |
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Head "on 13" we turn off two nuts of fastening of a support... |
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Head "on 10" we turn off a nut of fastening of the drive of a speedometer... |
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... also we remove the speedometer drive. |
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Key "on 22" we unscrew the backing light switch... |
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Key "on 13" we turn off an emphasis of movement of the lever of gear shifting. |
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Head "on 13" we turn off two nuts of fastening of an arm. |
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We remove an arm and we take out a bolt with a square head. |
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Head "on 13" we turn off other nuts of fastening of a back cover of the transmission. |
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We remove a back cover, having moved the switching lever to the right to exempt it from rods of inclusion of transfers. |
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Carefully, trying not to damage, we remove laying of a back cover. |
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We remove the back bearing. |
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We remove the leading gear wheel of the drive of a speedometer and its clamp – a steel ball. |
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Head "on 10" we turn off a bolt of fastening of a fork of inclusion of transfer of a backing. |
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We remove a fork of inclusion of a backing and an intermediate gear wheel of a backing. |
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We remove the remote plug from a rod of inclusion of a backing. |
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By stripper it is removed a lock ring from an intermediate shaft. |
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We remove the leading gear wheel of a backing and a spring washer. |
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By stripper it is removed a lock ring from a secondary shaft. |
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We remove the conducted gear wheel of a backing and a spring washer. |
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By impact driver it is turned off four screws of fastening of a lock plate of the bearing and an axis of an intermediate gear wheel of a backing. |
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We take out an axis of an intermediate gear wheel of a backing. |
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Head "on 10" we turn off ten nuts of fastening of the lower cover. |
We put the transmission sideways.
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Head "on 13" we turn off one nut... |
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... and a head "on 17" – six nuts of fastening of a case of coupling to the transmission. |
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We separate cases and we remove laying. |
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Head "on 13" we turn off two bolts of fastening of a cover of clamps of rods. |
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We uncover and take three springs and three balls from openings. |
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We take out a rod of a fork of inclusion of a backing. |
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Head "on 10" we turn off the bolt fixing a fork of inclusion of I and II transfers. |
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We take out rods, at the same time deleting blocking crackers. |
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We take out a rod of a fork of inclusion of I and II transfers. |
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Head "on 10" we turn off the bolt fixing an inclusion fork III and IV transfers. |
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We take out an inclusion fork rod III and IV transfers. |
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Having pressed couplings, we include two transfers at once and a key "on 19" we turn off a bolt of fastening of the forward bearing of an intermediate shaft. |
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Having hooked two screw-drivers for a lock ring, we take out the forward bearing of an intermediate shaft. |
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We push out outside the back bearing of an intermediate shaft. |
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Having inclined, we take out an intermediate shaft from a transmission case. |
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We take out two forks of gear shifting. |
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Having hooked the screw-driver, we take out a main shaft assembled with the bearing and a ring of the synchronizer. |
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We remove the needle bearing from a secondary shaft. |
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Having hooked the screw-driver, we take a spline from a back part of a secondary shaft. |
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Having hooked two screw-drivers, we remove the back bearing of a secondary shaft. |
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We take out a secondary shaft from a transmission case. |
Vertically we establish a secondary shaft, having clamped it in a vice through cardboard laying.
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We remove the coupling of the synchronizer III and IV of transfers. |
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By stripper it is removed a lock ring... |
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... also we remove a nave of the synchronizer and a spring washer. |
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Having hooked the screw-driver, we remove a lock ring, and also the blocking ring and a spring of the synchronizer. |
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We remove a gear wheel of the III transfer. |
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Operev a gear wheel of the I transfer on the rigid basis, the hammer through a pro-rate from soft metal we beat out a secondary shaft... |
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... also we remove from it a gear wheel of the II transfer assembled, the coupling of the synchronizer I and II of transfers, a synchronizer nave, a gear wheel of the I transfer assembled and the plug of a gear wheel of the I transfer. |
Elements of synchronizers I, II and IV (on primary to a shaft) transfers understand similar to the transfer synchronizer III.
For removal of the bearing of a main shaft...
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... by a stripper it is unclenched a lock ring... |
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... also we remove it together with a spring washer. |
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Operev the bearing on the rigid basis, the hammer through a drift from soft metal we beat out a main shaft. |
For removal of the lever of gear shifting from a back cover of a case of the transmission...
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... we disconnect a returnable spring from the lever. |
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Key "on 10" we turn off three nuts of fastening of a spherical support of the lever and... |
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... we remove the lever from hairpins. |
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For replacement of a cuff of the leading (primary) shaft we beat out a drift a cuff through an opening in a forward cover of the transmission and... |
Carefully we wash out all details in kerosene or diesel fuel and we examine them. On teeths of gear wheels and couplings there should not be chips, zadir, fatigue vykrashivaniye and noticeable wear. Surfaces of shaft, axes and rods of gear shifting have to be absolutely smooth, without zadir, sinks and strong wear. On a case there should not be cracks and забоин, and in boring under bearings – wear and traces of a provorachivaniye. On vents of shaft corrosion and traces a smyatiya and jammings are inadmissible. Insignificant damages can be eliminated with a small skin with the subsequent polishing, but it is better to replace the damaged details new.
All rolling bearings, both ball, and roller, have to be in a perfect state, their radial side play should not exceed 0,05 mm, on paths and bodies of swing any defects are unacceptable. Separators should not have gaps, contacts of rings and oplavleniye (at plastic). In general, if "run" of a box exceeds 120 thousand km and repair of the unit with dismantling is made, it is better to replace all bearings new irrespective of their state, especially if strong damages of gear wheels and couplings of inclusion of transfers were noticed. We replace cuffs new anyway. At assembly we grease all details of a box, including nests of bearings and bearings with gearbox oil, we cover joints of a case and covers with a thin layer of oilproof sealant, and a switching mechanism detail – SHRUS-4 lubricant.
We assemble the transmission as it should be, the return to dismantling. The spring of a clamp of a rod of a fork of a backing differs from others in rigidity and has a black covering. Before installation we cover a working surface of cuffs with a thin layer of Litol-24 lubricant. We tighten a bolt of a tightening washer of the bearing of an intermediate shaft the moment 8,1–10,0 кгс.м. We tighten a nut of the back end of a secondary shaft the moment 6,8–8,4 кгс.м.
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