4.2.3. Features of repair of the five-speed transmission

Dismantling. Before removing a back cover, install the gear shifting lever in neutral situation, turn off nuts of fastening of the mechanism of the choice of transfers and remove the gear shifting lever assembled with the mechanism. Then disconnect nuts of fastening of a back cover and remove it. One of nuts of fastening of a cover turns away from within a transmission case at the removed lower cover. At removal of a back cover it needs to be given not only back, but also to turn to exclude its zadevaniye for the block of gear wheels of a backing and the fifth transfer.

Fig. 4-31. Back part of the five-speed transmission: 1 — a secondary shaft; 2 — the conducted backing gear wheel; 3 — a transfer synchronizer V coupling nave; 4 — the synchronizer coupling; 5 — a washer; 6 — the gear shifting lever; 7 — the blocking synchronizer ring; 8 — a gear wheel and a gear wreath of the synchronizer V of transfer; 9 — a maslootrazhatelny washer; 10 — the plug of a gear wheel of the V transfer; 11 — the leading gear wheel of the drive of a speedometer; 12 — the back bearing of a secondary shaft; 13 — an epiploon; 14 — a flange of the elastic coupling; 15 — a nut; 16 — a sealant of the aligning ring; 17 — the aligning ring; 18 — a lock ring; 19 — a lock washer; 20 — the conducted speedometer drive gear wheel; 21 — the bearing of the block of gear wheels; 22 — a bolt of fastening of the block of gear wheels; 23 — the block of gear wheels of the V transfer and backing; 24 — a back cover of the transmission; 25 — an intermediate shaft



Fig. 4-32. Otvertyvaniye of bolts of fastening of the block of gear wheels and fork of inclusion of the V transfer and backing: 1 — an intermediate gear wheel of a backing; 2 — a bolt of fastening of the block of gear wheels; 3 — a fork rod; 4 — a bolt of fastening of a fork; 5 — a cover of clamps

Fig. 4-33. Removal of the plug of a gear wheel of the V transfer: 1 — the plug

Fig. 4-34. Removal of a rod of a fork of inclusion of the V transfer and backing and block of gear wheels: 1 — a rod of a fork of inclusion of the V transfer and a backing; 2 — a fork of inclusion of the V transfer and a backing; 3 — the remote plug; 4 — the block of gear wheels

After removal from a secondary shaft of an internal ring of the back bearing 12 (fig. 4-31) and the leading gear wheel of the drive of a speedometer weaken bolts of fastening of a cover of 5 (fig. 4-32) of clamps and turn off bolts 2 and 4 fastenings of the block of gear wheels and a fork of inclusion of the fifth transfer and a backing. Remove a maslootrazhatelny washer 9 (see fig. 4-31), and then the plug 1 (see fig. 4-33) gear wheels of the fifth transfer and take out a rod of 1 (fig. 4-34) from a fork 2. At the same time from a rod the remote plug 3 is removed. Then remove from vents of an intermediate shaft the block of gear wheels 4.

Fig. 4-35. Removal of an intermediate gear wheel of a backing, gear wheel of the V transfer assembled with the synchronizer and a fork: 1 — an intermediate gear wheel of a backing; 2 — the coupling of inclusion of the V transfer; 3 — a gear wheel of the V transfer assembled with the synchronizer; 4 — a fork of inclusion of the V transfer and a backing



Fig. 4-36. Removal of the conducted gear wheel of a backing and a nave of the coupling of the synchronizer V of transfer: 1 — an intermediate shaft; 2 — the conducted backing gear wheel; 3 — an axis of an intermediate gear wheel of a backing; 4 — a transfer synchronizer V coupling nave; 5 — a secondary shaft; 6 — a rod of a fork of inclusion of I and II transfers; 7 — an inclusion fork rod III and IV transfers

Remove at the same time intermediate gear wheel of 1 (fig. 4-35) of a backing about axes, a gear wheel 3 assembled with the coupling 2 and a fork 4 from a secondary shaft.
Remove from a secondary shaft a washer 5 (see fig. 4-31), and then by means of figured mandrels like screw-drivers remove from a spline a nave of 4 (fig. 4-36) of the synchronizer of the fifth transfer and the conducted gear wheel 2 backings.

Fig. 3-31. Installation of a piston finger on the A.60325 device for its press fitting in the piston and a head of a rod: 1 — adaptation roller; 2 — a piston finger; 3 — a guide; 4 — the persistent screw

       NOTE
Since 1992 the washer 5 (see fig. 3-31) on secondary to a shaft is cancelled and the configuration of a secondary shaft 1 and naves 3 couplings of the synchronizer V of transfer is changed (on secondary to a shaft diameter under a nave was 28 mm, there were 25 mm; width of a landing part of a nave became thickness washers more and landing diameter is reduced from 28 mm to 25 mm). The specified details are not interchanged with earlier released therefore at repair of the transmission of an "old" design follow the following rules:
— if the washer 5 changes, then the secondary shaft and a nave are put an "old" design;
— if instead of a secondary shaft or a nave the details of the same name of Novaya Gazeta of a design are established, then they should be changed completely, that is when replacing a nave also the secondary shaft and vice versa changes. In this case the washer is not established.

You carry out further dismantling of the transmission in the order described for the four-speed transmission.
If necessary disassemble the lever and the mechanism of the choice of transfers for what:

Fig. 4-37. Mechanism of the choice of transfers: 1 — a washer of the directing plate; 2 — the directing plate; 3 — the gear shifting lever case; 4 — a spherical support; 5 — a spherical washer; 6 — a spring; 7 — a persistent ring; 8 — a stopornry ring; 9 — the gear shifting lever; 10 — a protective cover; 11 — a flange; 12 — a blocking plate of a backing; 13 — a spring; 14 — the directing level; 15 — a sealing ring; And — risk

— remove a protective cover of 10 (fig. 4-37), lock and persistent rings 8 and 7, a spring and a spherical washer 5 from the gear shifting lever;
— note visually an arrangement of details relatively risks And, the directing plate put on that at assembly to connect details in the same situation;
— having turned off nuts from fastening bolts, separate details of the mechanism of the choice of transfers and remove the lever 9, its spherical support 4 and rubber sealing rings 15.
Assembly of the fifth step, the reverse gear and mechanism of the choice of transfers is made in the sequence, the return dismantling, taking into account the following:
— an axis of an intermediate gear wheel of a backing you fix before installation of shaft in a transmission case the moment of 78 N · m (8 kgfs · l);
— before installation of a rod of a fork of inclusion of the fifth transfer and backing to a case, install on it the remote plug;
— an internal ring of the bearing to a napressovyvayta on the block of gear wheels of the fifth transfer and backing, and external — in a nest of a back cover;
— the back bearing of a secondary shaft to a napressovyvayta on a shaft for simplification of installation of a back cover;
— 3 and a fork 4 establish an intermediate gear wheel of 1 (fig. 4-35) of a backing, a gear wheel at the same time;
— 4 (see fig. 4-32) establish a bolt on a germetizator of threaded connections of TB-1324;
— at assembly of the lever of gear shifting cover with LSTs-15 lubricant a spherical head or the sphere of a spherical support;
— a bolt of fastening of the block of gear wheels tighten the moment of 78 N · m (8 kgfs · l);
— before installation of a flange 14 (see fig. 4-31) on a secondary shaft apply UG-9 sealant on vents.