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A secondary shaft of transmission TE DOHC
A secondary shaft of transmission TE DOHC 1 - the bearing;
2 - a conducted gear wheel of 4th transfer;
3 - spacer;
4 - a gear wheel of 3 transfers;
5 - a gear wheel 2nd transfers;
6 - a synchronizer ring 2nd transfers;
7 - a lock ring;
8 - the synchronizer of 1st / 2nd transfers;
| 9 - a ring of the synchronizer of 1st transfer;
10 - a gear wheel of 1st transfer;
11 - the bearing;
12 - a secondary shaft;
13 - biscuit spring retainer;
14 - sliding sleeve of the synchronizer of 1st / 2nd transfers;
15 - lock cracker;
16 - a nave of the synchronizer clutch 1st / 2nd gear |
Preliminary checks
GEAR CLEARANCE OF 1 TH TRANSFER | PERFORMANCE ORDER | | 1. Measure the clearance between the first gear transmission and differential gear. Nominal backlash: 0,05-0,28 mm
Maximum permissible backlash: 0,33 mm |  | 2. If the clearance exceeds the limit, check the contact surface of the first gear transmission, differential gear and synchronizer clutch 1st / 2nd gear. Replace worn or damaged parts. |
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CLEARANCE GEAR 2nd gear | PERFORMANCE ORDER | | 1. Measure the clearance between the gear 2nd gear and third gear transmission. Nominal backlash: 0,18-0,46 mm
Maximum permissible backlash: 0,51 mm |  | 2. If the clearance exceeds the limit, check the contact surface of the gear 2nd gear, 3rd gear transmission and clutch synchronizer of 1st / 2nd gear. Replace worn or damaged parts. |
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Dismantling
Bearings and gears 4th transfer | PERFORMANCE ORDER |  | Using a press and special adaptation OK201 172 008, remove a gear wheel of 4th transfer. |
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GEAR 2ND AND 3RD GEAR | PERFORMANCE ORDER | | 1. Remove the retaining ring. | | 2. Move the gear to shesterne1 second transmission. |  | 3. Using a press and special adaptation OK201 172 008, remove the gear 2nd gear and 3rd gear. |
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Synchronizer of 1st / 2nd gear, synchronizer ring and the driven gear 1 TH TRANSFER | PERFORMANCE ORDER | | 1. Remove the retaining ring. |  | 2. Using a press, remove the synchronizer of 1st / 2nd gear synchronizer ring and the driven gear 1st gear |
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BEARING | PERFORMANCE ORDER |
| Using a press and special adaptation OK130 171 013, remove the bearing. |
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Check
GEAR | PERFORMANCE ORDER | | 1. Inspect the synchronizer cones for wear. | | 2. Inspect the condition of the surface of the gear teeth for damage, wear and cracks. |  | 3. Visually inspect the condition of the ring of the synchronizer on absence of damages, deterioration and cracks. |
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Synchronizer ring | PERFORMANCE ORDER | 1. Visually check the condition of the synchronizer ring teeth for damage, wear and cracks. |  | 2. Check the condition of the conical surface for damage, wear and cracks. | | 3. Establish a synchronizer ring in a gear wheel. |  | 4. Measure the clearance between the synchronizer ring and the surface of the flange gear. Nominal backlash: 1,5 mm
Minimum clearance: 0.8 mm |
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SYNCHRONIZER | PERFORMANCE ORDER | | 1. Visually check the condition of the synchronizer and its working capacity. | | 2. Visually check the condition of the synchronizer ring teeth for damage, wear and cracks. |  | 3. Check the condition of crackers lock for damage, wear and cracks. |  | 4. Measure the gap between the sliding sleeve and the synchronizer forks.
Clearance mm
Element | Nominal | Limits | 1st / 2nd | 0.1 - 0.45 | 0.95 | 3rd / 4th | 0.10 - 0.40 | 0.90 | 5th / ZH | 0.10 - 0.36 | 0.86 |
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INTERIM reverse gear | PERFORMANCE ORDER | | 1. Visually check the condition of gear teeth for damage, wear and cracks. |  | 2. Measure the clearance between the sleeve of the intermediate reverse gear and the lever. Nominal backlash: 0,01-0,32 mm
Minimum clearance: 0.5 mm |
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BEARING | PERFORMANCE ORDER | 
| Check the bearing on absence of damages and smoothness of rotation. |
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Primary and secondary TREES | PERFORMANCE ORDER | | 1. Check the gear in contact with the surface of the shaft for wear and damage. | | 2. Check the shaft splines for wear and damage. | | 3. Visually inspect the gear teeth for damage, wear and cracks. | | 4. Check the channel for supplying lubricant to clogging. |  | 5. The indicator of hour type measure palpation of primary and secondary shaft. The beating of the input shaft: 0.05 mm
The beating of the secondary shaft: 0,015 mm |
A warning  If replacement of the output shaft, adjust the bearing preload.
|  | | Oil gap, mm
Element | Val (outer diameter) | Gear (inside diameter) | Bush (outer diameter) | | First | 39.445 - 39.470 | 39.500 - 39.525 | 0.03 - 0.08 | | 2nd | 34.945 - 34.970 | 35.000 - 35.025 | | | 3rd | 35.945 - 35.970 | 36.000 - 36.025 | | | 4th | 30.945 - 30.970 | 31.000 - 31.025 | | | 5th | 34.000 - 34.025 | 33.945 - 33.970 | |
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SPEED SENSOR (speedometer driven gear) | PERFORMANCE ORDER | | 1. Visually check the condition of the teeth for damage, wear and cracks. |  | 2. Check the O-ring for damage and wear. |
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Assembly
Coupling hub SYNCHRONIZER | PERFORMANCE ORDER |  |  | Place crackers and spring retainer into the sleeve of the synchronizer hub.
Dimensions biscuit lock mm
Element | 1 | 2 | 3 | | 1st / 2nd | 19.0 | 4.25 | 50 | | 3rd / 4th | 17.0 | 4.25 | 50 | | 4th / ZH | 17.0 | 4.25 | 50 |
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BEARING (DIFFERENTIAL SIDE) | PERFORMANCE ORDER | 
| Using a press and special adaptation OK900 175 AA1, establish a new bearing. |
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Gear wheel of 1st transfer, a ring synchronizer of 1st TRANSFER AND synchronizer of 1st / 2nd gear
A warning On the synchronizer ring 2nd gear teeth are absent in three places along the perimeter, to distinguish it from other synchronizer rings.
| PERFORMANCE ORDER |  | 1. Install the first gear transmission ring of the synchronizer of 1st transfer and the synchronizer of 1st / 2nd gear as shown in the figure. |  | 2. Align the notch ring synchronizer with clamp crackers. |  | 3. Using a press and special adaptation OK900 175 AA1, establish a nave of the synchronizer clutch 1st / 2nd gear. |
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Synchronizer ring 2nd transfers and a gear wheel 2nd and 3 TRANSFERS | PERFORMANCE ORDER | | 1. Establish a synchronizer ring 2nd transfers and a gear wheel 2nd transfers. |  | 2. Using a press and special adaptation OK900 175 AA1, establish a gear wheel of 3 transfers. |
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GEAR 4th transfer and the bearing inner ring | PERFORMANCE ORDER |  | 1. Using a press and special adaptation OK900 175 AA1, establish a gear wheel of 4th transfer and the bearing inner ring. |  | 2. Measure the clearance between the first gear transmission and differential gear drive. Nominal backlash: 0,05-0,28 mm
Maximum permissible backlash: 0,33 mm | 3. Measure the clearance between the second gear and third gear. Nominal backlash: 0,10-0,22 mm
Maximum permissible backlash: 0,27 mm |  | 4. If backlashes do not correspond demanded, disassemble and reassemble the secondary shaft. |
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