printable version

Dismantling gearbox

When disassembling the gearbox (manual) If you can not allowed to use a wooden (plastic, aluminum) with a hammer, producing a light tapping.

Dismantling of basic units

PERFORMANCE ORDER

Clean the outside of the KP kerosene and dry. Remove the coupling elements (lever, release bearing, clutch cover). Drain the oil through the drain plug hole, and set it back. Remove the reverse gear shift lever and V transmission previously noted its position relative to the shaft. Remove the retaining ring and washer from the shaft. Unscrew and remove the fastening mechanism gear after removing the leash. Remove the bolts of the front cover to the gearbox housing, noting the position of the spacers for adjusting the axial play of the bearing. Block output flange and remove the special Nuts crown key. Using a puller, remove the drive flange. Remove the bolts back cover and remove it. Remove the worm gear drive of a speedometer from the machine shaft.

Removing the primary shaft of the gearbox 1 - input shaft 2 - a nut with a longitudinal slot 3 - the bearing; 4 - slinger

Four manual

PERFORMANCE ORDER

Remove the intermediate shaft reverse gear. Remove the intermediate shaft and remove the reverse idle gear from the fork gear selection. Remove the nut from the rear end of the intermediate shaft and remove the reverse gear. To facilitate disassembly temporarily replace the output flange, install the locking pin and turn the high gear (IV or V). When in the neutral position, remove the shift fork from the sliding clutch synchronizers. Using barbs, remove the cylindrical pin of the latch fork reverse gear, pull the switch axis. Bend the lock washer, unscrew bolts locking plate and unscrew the nut from the front end of the output shaft. Using a puller, remove the mounting plate and remove the bearings of the intermediate shaft bearings. Similarly, remove the front and rear output shaft bearings. Install the metal tube on the rear end of an intermediate shaft for locking the gear I transfer to needle bearing. Lift the rear end of the output shaft and remove the input shaft through the front of the crankcase. Remove the input shaft, a synchronizer ring IV transmission and needle bearing. Slide the sleeve of the synchronizer III and IV programs in position III transmission. Move the intermediate shaft back and pull it out through the side window casing. Slide the secondary shaft back and pull it out through the side window casing.

A five-speed manual

PERFORMANCE ORDER

Remove the shift fork grooves of synchronizers. Remove the nut from the rear end of the driven shaft. To keep the output shaft from the rotation to temporarily move the synchronizer sleeve on the simultaneous operation of two gears. Remove the bolts of the intermediate casing and remove it along with the bearings. In the case of a tight fit can be left on the intermediate shaft bearing. Remove the stripper V gear transmission intermediate shaft. Remove the screws of the intermediate casing to the main and remove the gasket. Knock knockout cylindrical pin of the lock gear, reverse / V gear and move the dog in the forward position. Pull through the side window mandrel stopper reverse / V transmission with a spring and a ball retainer. Disconnect the intermediate shaft with the reverse gear, releasing the last of the fork. Remove the intermediate shaft with the V gear transmission, needle bearing and synchronizer ring. Remove stripper reverse gear synchronizer transmission and V-ring needle bearing transmission gear V. Remove the crankcase fork reverse gear / V gear. Remove the parallel key from the intermediate shaft and remove the gasket and reverse gear with spline. Inspect the gasket mounted between the synchronizer and a reverse gear, for fault detection. Remove both woodruff key secondary shaft. Loosen the nut of the front end of the bearing of a secondary shaft using shaft fixing simultaneous operation of two gears. Remove the cover from the back of the bearing housing and remove the spacers for adjusting the axial displacement. Remove the inner snap ring and the bearing of the drive shaft. Remove the bearing housing and maslorazbryzgivatel. Remove the rear bearing of a secondary shaft. Fix the metal mandrel gear I transfer the displacement of the needle bearing. Remove the ball bearing (if it was) of the crankcase and remove from the front of the output shaft. If the roller bearing, then you need to, using a hammer with soft brisk, to drive back the output shaft with tapered roller bearing and liner (if available). At the same time the assistant lifts the primary and intermediate shafts. Remove the input shaft and the bearing ring of the synchronizer IV transmission and needle bearing. Wherein the intermediate shaft is located at the bottom of the crankcase. Move the clutch synchronizer III and IV programs in position III transmission and shifting the intermediate shaft back and pull it through the side window casing. Slide the secondary shaft back and pull it through the side window casing.