11.6. Dismantling and assembly of the transmission

 PERFORMANCE ORDER

We merge oil from the transmission, we remove a fork and the bearing of switching off of coupling (see appropriate sections).

We dismantle a flange of the elastic coupling from a sock of a secondary shaft (see Replacement of an epiploon of a secondary shaft) …

… and the switch of lamps of a backing (see Replacement of the switch of lamps of a backing).

The mechanism of the choice of transfers can be dismantled on the car, without removing the transmission. For descriptive reasons we carry out these operations on the removed transmission.

We remove a cuff of the mechanism of the choice of transfers.

We install the gear shifting lever in neutral situation.

Head "on 10" we turn off three nuts of fastening of the case of the lever of gear shifting …

… also we take out the mechanism of the choice of transfers.

Connection is condensed with laying.

With marker it is marked a relative positioning of washers and the directing mechanism plate.

Head "on 10" we turn off two nuts of fastening of a blocking plate of a backing, holding bolts a key of the same dimension, …

… also we remove a blocking plate.

Having turned off one more nut...

… we remove the lower washer of the directing plate.

Having taken out one directing level with two springs, …

… we remove the directing plate from the lower end of the lever.

We remove the top washer of the directing plate.

We remove the gear shifting lever case.

We take out rubber sealing rings of bolts from the protocheck of the case.

We remove the lower laying of the case of a spherical support.

We remove a flange with a protective cover …

… and top laying of the case.

By nippers it is removed a lock ring.

We remove a washer and a spring.

We remove a spherical washer …

… also we separate the lever and the case of a spherical support.

We install the transmission by a coupling case on a workbench.

Head "on 10" we turn off ten nuts of fastening of the lower cover of the transmission.

We uncover …

… and sealing laying.

The screw-driver through an opening of the mechanism of the choice of transfers we shift a rod of a fork of inclusion of the I-II transfers down (at the same time the II transfer joins).

Key "on 13" we turn off the nut of fastening of a back cover located in the box case.

Key "on 13" we turn off five nuts of fastening of a back cover located outside of the case.

We tap with the hammer on inflows of a cover, at the same time the screw-driver (or a suitable piece of a pipe at the removed epiploon of a secondary shaft) we hold the back bearing on secondary to a shaft.

We shift a cover from hairpins and we remove, turning it clockwise (looking from a shaft of a secondary shaft) to exclude zadevany covers for rods and the block of gear wheels of the V transfer and backing.

We remove laying of a cover.

For replacement of the bearing of the block of gear wheels of the V transfer and a backing …

… we hook bearing rollers the screw-driver...

... also we take out rollers from a separator.

We take a separator.

Having hooked a hook an external ring of the bearing, …

… we take out it from a nest of a back cover.

We remove a persistent ring of the back bearing of a secondary shaft.

We remove an external ring of the bearing with a separator and rollers.

We remove an internal ring of the bearing.

We remove the expansion plug …

… and maslootrazhatelny washer.

For latching of shaft from a provorachivaniye it is necessary to include two transfers. The II transfer was included at removal of a back cover. Before including back or the V transfers, we release a fork of inclusion of these transfers. For this purpose …

… a key "on 10" we turn off a bolt of fastening of a fork to a rod.

Having pressed the screw-driver a fork down, we turn on the reverse gear.

Cap key (head) "on 17" we turn off a bolt of fastening of the block of gear wheels of the V transfer and a backing.

We take out a bolt …

… also we remove the block of gear wheels from shliyets of an intermediate shaft.

We clamp the block of gear wheels of the V transfer and backing to a vice with overlays of sponges from soft metal.

By two screw-drivers it is pressed an internal ring of the bearing of the block of gear wheels …

… also we remove an internal ring.

We remove the plug of a gear wheel of the V transfer, …

… a gear wheel with the blocking synchronizer ring...

… nave …

… and synchronizer coupling.

Having turned a fork of inclusion of the V transfer and a backing on a rod to a secondary shaft, …

… we remove an intermediate gear wheel of the reverse gear.

Cap key "on 13" we turn off two bolts of fastening of a cover of clamps.

We uncover also laying.

We take out springs of clamps (the spring of a rod of the V transfer and a backing is longer than two others and has dark color of a covering).

By the magnetized screw-driver it is taken out all three clamps.

We take out a rod of inclusion of the V transfer and a backing with a fork.

We remove a fork from a rod.

The magnetized screw-driver took out a blocking cracker from a transmission case opening which is located between case nests under rods of the V transfer and a backing and the III-IV transfers.

We remove the conducted gear wheel of the reverse gear from a secondary shaft.

From a groove of a shaft we take out a spline.

Head "on 10" we turn off a fastening bolt to a rod of a fork of inclusion of the III-IV transfers.

We take out a rod.

The blocking cracker is inserted into an opening of a rod, …

… we take out it.

The magnetized screw-driver took out a blocking cracker from a transmission case opening which is located between case nests under rods I–II and III and IV transfers (this cracker is much longer than the cracker located between a rod of inclusion of the V transfer — a backing and a rod of inclusion of the III-IV transfers).

Head "on 10" we turn off a fastening bolt to a rod of a fork of inclusion of the I-II transfers.

We take out a rod.

By impact driver with a crosswise tip it is turned off three screws of fastening of a lock plate of the intermediate bearing of a secondary shaft.

Screws are stopped by special washers.

We remove a lock plate.

Cap key "on 19" we turn off a nut of fastening of an axis of an intermediate gear wheel of a backing, holding an axis from a provorachivaniye a key "on 24".

We take out an axis of an intermediate gear wheel of a backing.

Having turned off nuts of fastening of a case of coupling (see Replacement of an epiploon of a main shaft)...

… we divide cases of coupling and the transmission.

We remove laying.

We remove from a main shaft a spring washer with a conic surface (it is turned by smaller diameter to the bearing).

We clamp in a vice with overlays of sponges from soft metal a shlitsevy part of a main shaft.

Cap key "on 19" we turn off a bolt of a tightening washer of the forward bearing of an intermediate shaft.

We remove a tightening washer of the bearing.

Two screw-drivers hooked for an adjusting ring the forward two-row bearing of an intermediate shaft …

… also we remove the bearing.

At removal of the bearing its back internal ring can remain on a shaft.

By two screw-drivers it is pressed a back internal ring of the bearing …

… also we remove it.

We take out a persistent ring of the back bearing of an intermediate shaft.

Having inserted the screw-driver between end faces of the bearing and a gear wheel of the I transfer of an intermediate shaft, we shift the back bearing.

We take out an external ring of the bearing with a separator and rollers.

We remove an internal ring of the bearing from a shaft sock.

Having shifted an intermediate shaft back, …

… we take out it from a transmission case.

Having hooked two screw-drivers for an adjusting ring the back bearing of a main shaft, …

… we take out a main shaft assembled with the bearing and the blocking synchronizer ring.

By nippers it is unclenched a lock ring …

… also we remove it.

We remove a spring washer.

Opirayem an end face of an external ring of the bearing on sponges of a vice.

With plastic brisk we strike with the hammer blows in an end face of a main shaft …

… also we press the bearing.

By nippers it is unclenched an adjusting ring …

… also we remove it.

Having shifted the blocking synchronizer ring, by nippers it is unclenched a lock ring …

… also we remove it.

We remove the blocking ring …

… and synchronizer spring.

The blocking rings of synchronizers of other transfers are removed similarly.

We remove the needle bearing from a forward sock of a secondary shaft.

We remove inclusion forks I and II, III and IV transfers.

Two screw-drivers hooked for an adjusting ring the intermediate bearing of a secondary shaft …

… also we remove it.

Having inclined, we take from a transmission case a secondary shaft assembled with gear wheels, couplings, naves and the blocking rings of synchronizers.

We remove from the back party of a shaft the plug and a gear wheel of the I transfer assembled with the blocking ring.

We take out the plug from a gear wheel.

We remove the coupling of the synchronizer of inclusion of I and II transfers.

We remove a synchronizer nave.

We remove a gear wheel of the II transfer assembled with the blocking ring.

We remove the coupling of the synchronizer III and IV of transfers from the forward end of a secondary shaft.

Having clamped a secondary shaft in a vice with overlays of sponges from soft metal, …

… by nippers it is removed a lock ring.

We remove a spring washer (it is established by the convex party by the forward end of a shaft).

We remove a nave of the synchronizer III and IV of transfers...

… and a gear wheel of the III transfer assembled with the blocking synchronizer ring.

Assembly of the transmission is carried out in the return sequence.
If at removal of the forward two-row bearing of an intermediate shaft its back internal ring remained on a shaft, then before installation the bearing needs to be assembled. For this purpose from an external ring of the bearing …

… the screw-driver accurately we take out a separator with balls …

… also we put on it the internal ring (removed from a shaft).

The separator with balls and an internal ring is inserted into an external ring of the bearing.

At assembly of a main shaft …

… a suitable piece of a pipe napressovyvay the bearing on a shaft, leaning on its internal ring.

After installation in a case of the transmission of secondary and intermediate shaft we press forward and back bearings of an intermediate shaft, the intermediate bearing of a secondary shaft and an internal ring of the bearing of the block of gear wheels.
External ring of the bearing of the block of gear wheels of the V transfer and backing …

… we press a tool head of the suitable size (a pipe piece) in a nest of a back cover.

We insert a separator and rollers into an external ring of the bearing.
For prevention of an otvorachivaniye of a bolt of fastening of the block of gear wheels of the V transfer and a backing we apply carving sealant on a bolt carving.
For convenience of installation of a back cover we install on a secondary shaft the back bearing assembled.
It is desirable to grease all sealing laying with a thin layer of silicone sealant.
At assembly of the mechanism of the choice of transfers we apply Litol-24 lubricant on a spherical support.