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Dismantling, check and assemblage of the fifth / reverse gear and back cover TE DOHC
Fifth / reverse gear and back cover TE DOHC 1 - Back Cover;
2 - lock nut;
3 - Coupling of the synchronizer of a reverse gear;
4 - cone sleeve reverse gear;
5 - synchronizer ring;
6 - spacer;
7 - a plug of 5th / reverse gear;
8 - the synchronizer of 5th / reverse gear;
9 - synchronizer ring of 5th transfer;
10 - a leading gear wheel of 5th transfer;
11 - bush gear wheel of 5th transfer;
12 - a conducted gear wheel of 5th transfer;
13 - a bolt;
14 - a bolt;
15 - tube retainer, the spring and steel ball;
16 - reversing light switch;
17 - the transmission housing;
18 - Magnet;
19 - an intermediate shaft reverse gear;
20 - an intermediate gear for reverse gear;
21 - switching rod 3rd / 4th transfers;
22 - the lever of a rod of switching of 5th / reverse gear;
| 23 - pin;
24 - a shaft of the gear change;
25 - the shift lever assembly;
26 - plug and switching rod;
27 - ball retainer;
28 - a spring;
29 - a primary shaft;
30 - a secondary shaft;
31 - differential;
32 - clutch;
33 - biscuit spring retainer;
34 - sliding sleeve of the synchronizer;
35 - lock cracker;
36 - a nave of the synchronizer clutch;
37 - a plug of switching 3-ej / 4th transfers;
38 - the plug;
39 - a control lever;
40 - a plug of switching of the 1st / 2nd gear;
41 - stock;
42 - the lever rod
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Repairs | PERFORMANCE ORDER | | 1. Dismantling spend in the sequence designated in figures in drawing. | | 2. Check the condition of all details and, if necessary, replace them. | | 3. Reassembly is effected in reverse order of removal. | | 4. Removal and installation of the individual parts and components listed below. |
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Check backlash gear 5th gear
| PERFORMANCE ORDER |  | 1. dial indicator, measure the backlash gear 5th gear. Nominal backlash: 0,10-0,22 mm
Maximum permissible backlash: 0,27 mm | | 2. If the backlash exceeds the limit, check the contact surface of gear 5th gear and tighten the nut. If necessary, replace worn or damaged parts. |
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Unscrewing the locknuts | PERFORMANCE ORDER | | 1. Set the gearbox on the stand OK130 990 007 with adapter OK130175011A. |  | 2. adaptation OK201 323 021 lock the gearbox output shaft. | | 3. Simultaneously turn on the gears of the 1st and 2nd gear, not to crank the gearbox output shaft. | | 4. Bend the lock nut locking plate shoulders. | | 5. Remove the lock nut from the primary and secondary shafts. |
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Removing the forks and shift rod | PERFORMANCE ORDER | | 1. Align the ends of the sleeve with the lever (arrow). Turn the stem anti-clockwise. |  | 2. With one hand, hold the fork 1st / 2nd gear, the second - the fork 3rd / 4th gear and lift them simultaneously moving synchronizers. | | 3. Lift the rod and remove the ball detent at the same time removing the rod from the clutch housing. |  | 4. Separate the plugs and stocks of synchronizers. |
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Installing the primary and secondary shafts | PERFORMANCE ORDER |  | Set the primary and secondary shafts to the clutch as shown in the figure. |
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Installing forks and shift rod
| PERFORMANCE ORDER |  | 1. Install the plug and the rod gear to gear 2nd gear as shown in the figure. | | 2. Install the spring seat and the spring in the reverse lever shaft, and then set the ball retainer and flat washer. |  | 3. Set the end of the lever opposite the rod rings and insert the rod so that the ball went into the lock shaft. It will put in line with the rod and the rod is aligned with the holes clutch. | | 4. Install the synchronizer to the neutral position, and insert the top rod so that the retainer ball went into the middle groove. |  | 5. Press the bulb so that it clearly came to the middle groove. |
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Installation of the lever rod and rod 5th / reverse gear | PERFORMANCE ORDER | | | Set the lever shaft (1) and stem the 5th / reverse gear (2) and secure with bolt. The inhaling moment: 11,8-13,7 N ??? m |
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Installing the intermediate shaft and the reverse gear | PERFORMANCE ORDER | | 1. Install the reverse gear and the intermediate shaft reverse gear. | | 2. Place the magnet on the clutch housing. |  | 3. Align the end of the sleeve with the lock lever and a bolt-hole for the intermediate shaft in the direction shown in the figure. |
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Installation of the gearbox | PERFORMANCE ORDER | Apply a thin coat of sealant to the mating surface of the clutch and the gearbox, set the gearbox housing and tighten bolts. Torque: 38-51 N ??? m |
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Installing crown wheel of 5th transfer | PERFORMANCE ORDER |  | Set driven gear 5th gear as shown. |
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Install the plug and the synchronizer of 5th / reverse gear | PERFORMANCE ORDER |  | Set along a fork and synchronizer of 5th / reverse gear. |
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Tightening of locknuts | PERFORMANCE ORDER | | 1. Simultaneously turn the gears 1st and 2nd gear, not to crank the gearbox output shaft. | | 2. adaptation OK201 323 021 lock the gearbox output shaft. |
A warning  At installation use a new lock nut.
| 3. Tighten the lock nut and lock it by loosening the locking plate bend beads locknut Torque: 128-196 N ??? m | | | 4. The dial indicator, measure the backlash gear 5th gear and reverse taper bushing. Nominal backlash: 0,10-0,22 mm
Maximum permissible backlash: 0,27 mm |
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