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Dismantling and assembling output shaft
Details of the secondary shaft
Dismantling
| - Install the flange of the drive to the rear end of the secondary shaft (temporarily) and secure it in a vise vertically.
- Remove the nut from the front end and remove the synchronizer III and IV programs and the locking ring.
- Remove the thrust washer III transmission gear III transmission and needle bearing.
- Release the shaft from the grip and remove from the rear end of the thrust washer, I gear transmission and rollers of the needle bearing.
- Set the output shaft in a vise so that the cone II of transmission is on the bottom and a hammer with striker soft metal lower it down so that the freed needle bearing inner race I transmission.
- Loosen the output shaft from the grip and remove the inner ring, thrust washer (if available), synchronizer ring I transmission synchronizer I and II gear synchronizer ring II transmission.
- Remove the thrust washer (if available), transmission gear II and the needle bearing.
- Wash all parts in a solvent (kerosene) and perform fault detection. Note the presence of spiral (ring) springs and balls.
- Put each synchronizer ring on its tapered seat in gear and spend the probe measured between the gear teeth is less than 0.5 mm, replace the synchronizer ring.
- Disassemble the synchronizer. When disassembling the synchronizer with coil springs should wrap it in cloth, mark the position of the hub relative to the sleeve and then pull out the clutch hub. Once the hub will occur offset crackers, balls and springs (spring guide provided on the transmission synchronizer V). Replace worn parts and reassemble synchronizer springs and placing the key into the hub. Then, holding the key down, partially enter into the coupling hub. Put beads one by one into the hub and, when all three are set, the entire hub, push in the sleeve. Note that the synchronizing rings I and II transmission have a bevel on one corner. When installing, check that the bevel facing towards the gear transmission II.
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 | Synchronizer with annular springs |
 | Synchronizer V transmission with annular springs |
 | Synchronizer with coil springs |
 | Synchronizer V transmission coil spring |
 | Checking wear synchronizer ring with feeler gauge |
Disassemble the synchronizer
| - To disassemble the synchronizer ring with springs, note the position of the hub relative to the sleeve, then remove the snap ring (only for synchro transmission V), push the hub of the coupling and pull crackers and springs. Replace worn parts with new ones, and reassemble the synchronizer, restoring the position of the hub relative to the sleeve.
- Note that oblique angle ends of the springs must be in the same crackers, and that the springs have to look in the opposite direction.
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Assembly
| - Install the intermediate shaft vertically in a vise with soft (aluminum) jaws so that its rear end looked up. With the installation of parts, lubricate them with clean grease for the gears.
- Install the needle bearing transmission gear II II transmission and thrust washer (if any).
- Install the synchronizing ring II transmission gear and transmission II zapressuyte synchronizer assembly I and II programs in the slots.
- Establish a synchronizer ring I transmission synchronizer, place thrust washer (if any).
- Heat the inner ring of the needle bearing transmission and I quickly press it onto his place on the driven shaft with a mandrel.
- Put the needle rollers bearing, gear transmission, and I thrust washer. Secure on-site transmission gear I and the needle bearing segment of the tube and flange nuts.
- Turn the shaft in a vice (rear end looks down) and secure it. Install the needle bearing III transmission gear and thrust washer (if any).
- Establish a synchronizer ring III transmission gear III transfer and press them synchronizer assembly III and IV programs on slots, facing forward toward the spline coupling.
- Screw the nut on the front end of the driven shaft and tighten it to a torque of 8.0 kgs.m, lock nut into the groove of the shaft.
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