4.2.4. Dismantling and assembly

Dismantling. Wash out the transmission and install it at the stand. Merge oil and remove the lower cover with laying.
Remove a coupling switching off drive fork, and from the directing plug of a forward cover of the transmission — the coupling assembled with the bearing and a connecting spring.

Fig. 4-15. Coupling case interior. Red shooters specified nuts of fastening of a case of coupling to the transmission; the white arrow specified an opening in a forward cover for production of oil from a transmission case that there was no oiling of clutch plates

Remove a case of coupling with laying and a forward cover of the transmission (together with an epiploon and a spring washer) (fig. 4-15).
Remove the speedometer drive with laying and the backing lamp switch, being careful not to deform its case.
Turn out a bolt of fastening of a fork of switching III and IV transfers. Establish on a main shaft a clamp 41.7816.4068 or at the same time include two transfers. It will prevent a provorachivaniye of primary, secondary and intermediate shaft and will allow to execute the subsequent operations on dismantling.

Fig. 4-16. Removal of a lock ring

Remove a lock ring from the end of a secondary shaft of the transmission (fig. 4-16).

Fig. 4-17. Removal of the aligning ring of the elastic coupling of the driveshaft a pusher of A.40006/1 and a stripper of A.40005/4

Having unbent a lock washer, turn off a nut on several turns to shift the aligning ring of the elastic coupling, and again wrap a nut. A pusher of A.40006/1 with a stripper of A.40005/4 remove the aligning ring of the elastic coupling of the driveshaft (fig. 4-17) from the end of a secondary shaft.

Fig. 4-18. Removal of a flange of the elastic coupling stripper of A.40005/3/9B/9C: 1 — a flange of the elastic coupling; 2 — bolts of fastening of adaptation to a flange; 3 — a level 9C of a stripper of A.40005/3; 4 — a stripper of A.40005/3

Remove a sealant of the aligning ring of the elastic coupling from the end of a secondary shaft, turn off a nut and a stripper of A.40005/3/9B/9C remove a flange of the elastic coupling (fig. 4-18).

Fig. 4-19. Interior of a back cover of the transmission: 1 — the screw with an ear of fastening of an ottyazhny spring of the lever of gear shifting;
2 — an ottyazhny spring of the lever; 3 — the gear shifting lever; 4 — the screw of restriction of the cross course of the lever. The arrow specified the direction in which it is necessary to move the lever to bring him out of gearing with heads of rods of gear shifting and to remove a back cover of the transmission

Remove a back cover of the transmission, having turned off nuts of its fastening and the screw 4 (fig. 4-19) of restriction of the cross course of the lever and having moved the gear shifting lever to the left to exempt it from rods of inclusion of transfers.
Remove the back bearing from a secondary shaft. Remove the leading gear wheel of the drive of a speedometer.
Remove from a rod of inclusion of a backing a fork with the remote plug. Remove an intermediate gear wheel of a backing from an axis.

Fig. 4-20. Removal of a lock spring ring of a gear wheel of a backing from an intermediate shaft

Remove a lock ring of the leading gear wheel of a backing from an intermediate shaft (fig. 4-20); remove a gear wheel and a spring washer.
Remove a lock ring of the conducted backing gear wheel from a secondary shaft, pressing a mandrel 41.7816.4069 spring washer to unload a lock ring. Remove the conducted gear wheel of a backing and a spring washer.
By means of figured mandrels (like screw-drivers) and rod drifts take out forward and back bearings of an intermediate shaft from a transmission case. On internal rings of the two-row forward bearing put tags on which establish these rings on former places in an external ring of the bearing.

Fig. 4-21. Extraction of an intermediate shaft from a transmission case

Take out an intermediate shaft from a transmission case, having inclined it, as shown in fig. 4-21.

Fig. 4-22. Gear shifting drive: 1 — a fork of inclusion of a backing; 2 — an ottyazhny spring of the lever of gear shifting; 3 — the directing lever cup; 4 — a spherical support of the lever; 5 — the gear shifting lever; 6 — a spherical washer; 7 — a lever spring; 8 — a lock ring; 9 — the locking plug of a damper; 10 — elastic plugs of a damper; 11 — the remote plug of a damper; 12 — a persistent pillow of a damper; 13 — a gear shifting lever core; 14 — a switching off fork III and IV transfers; 15 — a fork of inclusion of I and II transfers; 16 — a rod of a fork of inclusion of I and II transfers; 17 — an inclusion fork rod III and IV transfers; 18 — a rod of a fork of inclusion of a backing; 19 — blocking crackers; 20 — a cover of clamps; 21 — the plug; 22 — a clamp spring; 23 — a clamp ball; 24 — a back cover of the transmission; 25 – backing lamp switch; 26 – remote plug of a rod of a fork of a backing

Uncover 20 (fig. 4-22) of clamps of rods together with laying, take out springs and balls of clamps. Take out from a transmission case a rod of the 18th backing, a rod of the 17th fork of switching III and IV transfers. Turn off a bolt of fastening of a fork of I and II transfers, take out a rod and forks. Taking out rods, at the same time remove three blocking crackers 19.

Fig. 4-23. Otvertyvaniye of screws of fastening of a lock plate of the intermediate bearing of a secondary shaft drill screw-driver. The arrow showed the direction of the shock course of a holder of the screw-driver; to use the hammer

Remove a lock plate (fig. 4-23) of the intermediate bearing of a secondary shaft and an axis of an intermediate gear wheel of a backing.

Fig. 4-24. Extraction of a main shaft from a transmission case

By means of mandrels (like screw-drivers) take out a main shaft together with the bearing and a ring of the synchronizer (fig. 4-24) and remove the needle bearing from the forward end of a secondary shaft.

Fig. 4-25. Extraction of a secondary shaft from a transmission case

Beat out a secondary shaft from the intermediate bearing, take out the intermediate bearing and, having inclined, as shown in fig. 4-25, take from a case a secondary shaft assembled with gear wheels, couplings and rings of the synchronizer. Remove the coupling of the synchronizer III and IV of transfers from a shaft.

Fig. 4-26. Details of a main shaft: 1 — a lock ring; 2 — a spring washer; 3 — the bearing;
4 — a main shaft; 5 — a synchronizer spring; 6 — the blocking synchronizer ring; 7 — a lock ring; 8 — the bearing

Sort a main shaft (fig. 4-26):
— remove the lock ring 7 blocking a ring 6 and a spring of the 5th synchronizer;
— establish a shaft on a press and, having squeezed a mandrel 41.7816.4069 spring washer 2, remove a lock ring 1, then a spring washer and the bearing 3.

Fig. 4-27. Details of a secondary shaft: 1 — a lock ring; 2 — a spring washer; 3 — a synchronizer nave; 4 — the synchronizer coupling; 5 — a lock ring; 6 — the blocking synchronizer ring; 7 — a synchronizer spring; 8 — a washer; 9 — a gear wheel of the III transfer; 10 — a secondary shaft; 11 — a gear wheel of the II transfer; 12 — a washer; 13 — a synchronizer spring; 14 — the blocking ring; 15 — a lock ring; 16 — a synchronizer nave; 17 — the synchronizer coupling; 18 — a lock ring; 19 — the blocking synchronizer ring; 20 — a synchronizer spring; 21 — a washer; 22 — a gear wheel of the I transfer; 23 — the plug of a gear wheel of the I transfer; 24 — the bearing; 25 — a backing gear wheel; 26 — a spring washer; 27 — a lock ring; 28 — a speedometer drive gear wheel; 29 — the back bearing; 30 — an epiploon; 31 — a flange of the elastic coupling; 32 — a nut; 33 – sealant; 34 — the aligning ring; 35 — a lock ring

Sort a secondary shaft (fig. 4-27):
— remove from the back party of a shaft a gear wheel 22 1st transfers with the plug 23, a nave 16 with the sliding coupling of switching of I and II transfers, a gear wheel 11 II transfers together with the blocking ring of the 14th synchronizer;

Fig. 4-28. Installation on secondary to a shaft of a lock ring: 1 — a mandrel 41.7816.4069;
2 — a lock ring; 3 — a basic half ring;
4 — a spring washer; 5 — a press rod

— establish a secondary shaft with a mandrel 41.7816.4069 on a press (see fig. 4-28), enclose basic half rings 3 under a gear wheel of the III transfer, and, pressing a mandrel a spring washer, remove a lock ring 2, then a spring washer 4, a nave of the sliding switching coupling III and IV transfers and a gear wheel of the III transfer.
Disassemble the lever of gear shifting and a back cover:

Fig. 4-29. Gear shifting lever details: 1 — a bolt of an ottyazhny spring; 2 — a washer; 3 — an ottyazhny spring; 4 — laying; 5 — the directing cup; 6 — laying; 7 — a washer; 8 — a restrictive bolt; 9 — the gear shifting lever; 10 — a spherical support; 11 — a spherical washer; 12 — a spring; 13 — a basic washer; 14 — a lock ring; 15 — laying; 16 — a flange; 17 — a spring washer; 18 — a nut; 19 — a cuff; 20 — an internal cover; 21 — a lever core; 22 — the handle; 23 — a persistent pillow; 24 — the elastic plug; 25 — the remote plug; 26 — the elastic plug; 27 — the locking plug

— remove a cover of 20 (fig. 4-29) of the lever, then a lock ring 14, a washer 13, a spring 12 and a spherical washer 11;
— disconnect an ottyazhny spring 3 levers from an ear of a bolt 1;
— remove a cuff 19, turn off nuts of fastening of a flange 16 and remove the lever together with a flange, a support 10 and a cup 5.
Assembly of the transmission is carried out to the sequences, the return dismantling. At the same time consider that:
— the spring 22 (see fig. 4-22) a ball of a clamp of a rod of a fork of a backing differs from others in elasticity, it is painted in green color or has a cadmic covering;
— at installation of a case of coupling with a forward cover of the transmission, the opening in a forward cover has to be located as it is shown in fig. 4-15;
— before installation cover a working surface of epiploons with LITOL-24 lubricant;
— at assembly of secondary and intermediate shaft use mandrels 41.7853.4028, 41.7853.4032, 41.7853.4039;

Fig. 4-30. Installation on secondary to a shaft of a lock ring of a gear wheel of a backing:
1 — a spring washer; 2 — a mandrel 41.7816.4069; 3 — a locking ring; 4 — a gear wheel of a backing of a secondary shaft

— at installation of a lock ring of a gear wheel of a backing use a mandrel 41.7816.4069, as shown in fig. 4-30.