 printable version
Overhaul Manual transmission
Arrangement of internal components Manual transmission
 | 1 - Front bearing primary shaft
2 - Primary shaft
3 - Pinion 3rd gear
4 - Hub sliding sleeve of the synchronizer
5 - Thrust ring
6 - Sliding sleeve
7 - a blocking ring of 4th transfer
8 - Pinion 4th gear
9 - synchronizer ring reverse gear
10 - cone synchronizer of a reverse gear
11 - Hub sliding sleeve of the synchronizer of 5th transfer
12 - Rear bearing primary shaft
13 - the adjusting ring of the back bearing of a primary shaft
14 - Spring Key
15 - Sliding sleeve Synchronizer
16 - a blocking ring of the synchronizer of 5th transfer
17 - Pinion 5th gear
18 - Retaining Ring
19 - Persistent half rings of the primary shaft
20 - Spring Key
21 - a blocking ring of the synchronizer of a reverse gear
22 - a blocking ring of the synchronizer of 1st transfer
23 - synchronizer ring 2nd gear
24 - the adjusting ring of the back bearing of a secondary shaft
25 - Rear bearing of a secondary shaft
26 - Thrust Washer
27 - Thrust ring | 28 - driven gear 5th gear
29 - driven gear 4th gear
30 - driven gear 3rd gear
31 - driven gear 2nd gear
32 - Thrust ring
33 - Spring Key
34 - driven gear back preedachi
35 - Hub synchronizer of 1-2 transfers
36 - driven gear 1st gear
37 - Output shaft
38 - Front bearing output shaft
39 - Differential Bearing
40 - speedometer drive gear
41 - Box Differential
42 - ring gear
43 - an intermediate gear wheel transmission
44 - The axis of the intermediate reverse gear
45 - Adjustment of the bearing rings
46 - Differential Bearing
47 - Pin
48 - Thrust washer axis of satellites
49 - Satellite Differential
50 - Thrust washer differential side gear
51 - differential side gear
52 - The axis of satellites
53 - Bolt (74 ÷ 88 Nm)
54 - Bolt (16 ÷ 21 Nm) |
The components of the mechanism of a choice of transfers
 | 1 - Plug lock selector fork 3rd and 4th gear
2 - Shift Fork 3-4 Transmission
3 - Retaining Ring
4 - fork for 5th gear
5 - Retaining Ring
6 - Retaining Ring
7 - Stem fork 5th gear
8 - locking ball
9 - Return spring
10 - Check the plug 5 and the rear transmission (16 g to 22 Nm)
11 - Locking spring
12 - The bracket 5 and rear gear
13 - Spring-level reverse gear
14 - Seal
15 - Pin
16 - The axis of the lever reverse
17 - Seal
18 - Pin
19 - Selector shaft
20 - Ball
21 - The device is the reverse gear
22 - Plunger deadlock
23 - Ball Interlock
25 - Ball
26 - Return spring
27 - Retaining Ring
28 - 3-4 Gear Shift Transmission
29 - Ball
30 - Plunger deadlock | 31 - Pin
32 - Bracket
33 - Return spring
34 - damper
35 - foot selector
36 - Return bearings
37 - Sleeve
38 - Spring selector
39 - Ball
40 - pin cam
41 - Return spring
42 - Cam
43 - Pin
44 - Pin
45 - selector
46 - lock lever
47 - Locking rod
48 - Pin
49 - Fork Clamp
50 - Pin
51 - Bracket
52 - 1-2 Gear Shift Transmission
53 - Ball
54 - Return spring
55 - Plug blocker 1-2 gear shift fork
56 - 1-2 gear shift fork
57 - Pin
58 - Bolt (16 ÷ 21 Nm)
59 - Bolt (16 ÷ 21 Nm) |
general information
Composers of the present Management do not recommend to owners of cars on their own to undertake the overhaul Manual transmission. In the course of procedures for disassembly and assembly of the gearbox have to shoot, and then set in place a variety of small components. It is necessary to make an accurate measurement of the weight and, by adjusting the shims, rings and spacer sleeves, clearly put a lot of gaps. In view of the foregoing, the overhaul Manual transmission would be wiser to entrust the service specialist. Note that in many cases there is a possibility on the basis of the exchange to buy rebuilt unit that is often less expensive than conducting a complex repair.
That said, the implementation of self-repair mechanic amateur Manual transmission is not absolutely impossible to exercise. The preconditions are only the availability of the necessary special tools and orderly approach to the implementation of all procedures.
The number needed to complete the refurbishment RKPP tools includes pliers for removing internal and external retaining rings, bearing puller, a hammer with sliding brisk set vykolotok and Kerner DTI gauge and possibly a hydraulic press. In addition, of course, will need a strong, vice-equipped, workbench, or special mounting stand.
In the course of procedures for disassembly RKPP try to remember, and it is better to write, how to install each of the parts removed.
Before disassembling the gearbox, it is wise to try to analyze the symptoms of her failure to approximately determine their causes. Many failures are uniquely related to the failure of well-defined components.
The following section is a schematic descriptions of procedures Manual transmission disassembly and maintenance of its internal components. Dismantling, in-service components and their assembly Manual transmission
Removing components | 1. Schematic layout of internal components and Manual transmission gear selection mechanism is shown in the illustrations.  | 2. Remove the gear through the hole 4th gear, then remove the axis of the intermediate gear and reverse gear itself. |
 | 3. Remove the retaining pin from the clutch housing. |
 | 4. Remove the lever return spring and retaining spring rear transmission mechanism of inclusion of a reverse gear. |
 | 5. Remove the foot rear axle gear transmission. |
 | 6. Remove the reverse gear lever assembly. |
 | 7. Remove the plug lock fork 5th and reverse gear, remove the spring and the ball. |
8. Remove the retaining ring and fixing pins with a rod shift forks 5 / 3-4 and the rear gear.  | 9. Remove the stems 5 / 3-4 and the rear gear. |
 | 10. Remove the assembly of the two shafts (primary and secondary) and fork 1-2 Manual transmission gear with his rod. |
 | 11. Remove final drive assembly. |
 | 12. Remove reverse gear assembly. |
13. Using a special punch (KV32101000), remove the locking pin and remove the selector.  | 14. Remove the drain plug, in order to provide access to the pin mounting arm with a rod. |
 | 15. Remove the pin (use knockout KV32101000) and remove the lever to the stem. |
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Dismantling of a primary shaft assembly
STRIPPING | 1. Before starting to dismantle the input shaft, estimate the value of the axial backlash driving gears 3rd, 4th and 5th gear. 2. If the backlash gears beyond the permissible range (see. Specifications), remove the assembly and check the condition of the mating surfaces of the gear shaft and the hub, then evaluate the clearance of the locking ring and persistent half rings of a primary shaft.  | 3. Remove the rear bearing of a primary shaft. |
 | 4. Remove the assembly synchronizers 5th and reverse gear and pinion gear 5th gear. |
 | 5. Remove the axial retainer, two thrust half rings and pinion gear 4th gear. |
 | 6. Remove the snap ring. |
 | 7. Remove the synchronizer 3-4 gears and pinion gear 3rd gear. |
 | 8. Remove the front bearing of a primary shaft. |
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Checking the status of components |  | 1. Check the input shaft assembly for cracks, deformation and signs of excessive wear, evaluate the state of driving gears. |
 | 2. Check the components for cracks synchronizers signs of excessive wear, cracks and other mechanical defects. Assess hubs, sliding sleeves, locking rings, keys and other parts assembly. |
 | 3. Measure the clearance between the synchronizer ring and gear (for the 4th and 5th gear). The nominal value lies within the range 1.0 ÷ 1.35 mm with a tolerance of wear to 0.7 mm. |
 | 4. Estimate degree of deterioration synchronizer ring reverse gear. Place the locking ring on the appropriate device and place it on the cone synchronizer. Make sure that the projection of a cone falls into the recesses in the perimeter of the device. Firmly holding the cone to the locking ring, using a dial gauge plunger type determine the distance A. If the value of A is less than 1.2 mm, replace the synchronizer ring.
1 - Tsiferblatnyj Meter
2 - cone synchronizer
3 - Buckle (device ST30031000)
4 - a blocking ring
5 - cone synchronizer
6 - Buckle (device ST30031000) |
 | 5. Evaluate the freedom of rotation of the bearing. |
6. Check the bearing assembly for cracks, cavities and other mechanical damage. |
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ASSEMBLY | 1. Assemble the synchronizer of 3-4 transfers. Track correctness of introduction of components into engagement.  | 2. Put the assembly input shaft pinion gear 3rd gear synchronizer ring and the corresponding synchronizer. |
 | 3. Press in the assembly coupling hub synchronizer of 3-4 transfers. Ensure the correct orientation of the components. Select and install the appropriate thrust ring, seeking to minimize the gap in the groove (gap size should not go beyond the range of 0 ÷ 0.1 mm). |
4. Put the pinion gear 4th gear.
5. Choose the appropriate thrust washers, minimizes the gap in a groove (0 ÷ 0.06 mm), and set them on the thrust ring.
6. Install the synchronizer 5th and reverse gear. Fill in the spring keys synchronizer ring reverse gear. Enter the assembly in the sliding sleeve of the synchronizer, - track correctness of input keys in the clutch spring.  | 7. Put the locking ring 5th gear in the proper pinion gear. Set the cone synchronizer of a reverse gear in its locking ring. Place the assembled synchronizer back to preedachi pinion 5th gear. Fill the cone projections in response gear slots.
1 - Pinion 5th gear
2 - Build a reverse gear synchronizer |
8. Place the spring retainer ring synchronizer ring on top of a reverse gear pinion 5th gear.  | 9. Fitting the synchronizer assembly 5 and the rear transmission with gear 5th gear on the input shaft assembly. |
10. Put the assembly input shaft front and rear bearings. 11. Evaluate the value of the axial backlash gears. |
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Removing the secondary shaft assembly
STRIPPING |  | 1. Before dismantling components in the assembly, measure the value of the axial backlash driven gears of the 1st and 2nd gears. If the measurements are outside the permissible range (see. Specifications), remove the components and evaluate the state of the mating surfaces of the shaft, gears and wheel hubs (see. Sub assembly). |
 | 2. Extract the back bearing of a secondary shaft. |
 | 3. Remove the thrust washer and the ring. |
 | 4. Extract the driven gears of the 5th and 4th gear. |
 | 5. Extract the driven gears 3rd and 2nd gear. |
 | 6. Remove the thrust ring. |
 | 7. Remove assemblage of the synchronizer of 1-2 transfers and driven gear 1st gear. |
 | 8. Press out the rear bearing |
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Checking the status of components |  | 1. Inspect the shaft for cracks, deformation and excessive wear, evaluate the state of the gears. |
2. Check the components for cracks synchronizers signs of excessive wear, cracks and other mechanical defects. Assess hubs, sliding sleeves, locking rings, keys and other parts assembly.
3. Measure the clearance between the synchronizer ring and gear (for the 4th and 5th gear). The nominal value lies within the range 1.0 ÷ 1.35 mm with a tolerance of wear to 0.7 mm.  | 4. Evaluate the freedom of rotation of the bearing. Check bearing assembly for cracks, cavities and other mechanical damage. |
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ASSEMBLY | 1. Assemble the synchronizer of 1-2 transfers. Track correctness of introduction of components into engagement.
2. Install the counter shaft 1st gear synchronizer ring 1st gear. Press synchronizer hub gears 1-2. Ensure the correct orientation of the components.  | 3. Put the sliding sleeve of the synchronizer of 1-2 transfers and its locking ring. |
4. By selecting the thrust washers nave of the synchronizer of 1-2 transfers Get minimize the gap groove (0 ÷ 0.1 mm).
5. Put the assembly shaft driven gear 2nd gear.  | 6. Put the gear 3rd gear, then the 4th and 5th. |
7. By selecting the thrust ring Achieve minimize the gap in the groove of the driven gear 5th gear (0 ÷ 0.15 mm).  | 8. Press in the thrust washer, and rear bearing of a secondary shaft. |
 | 9. Put the front bearing. |
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Removing the final drive assembly
STRIPPING | 1. Turn out fixing bolts and remove the castellated driven gear.
2. Remove the speedometer drive.  | 3. Extract the differential side bearings, - remember that the right and left bearings are not interchangeable and the installation should be planted strictly on the former places. |
4. Release the locking pin and remove the pinion gear shaft.
5. Remove the box of differential satellites and side gears. |
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Checking the status of components |  | 1. Check the mating surfaces of differential case, side gears and satellites. |
2. Estimate the wear washers.
3. Check up freedom of rotation of the bearing. Make sure there are no signs of mechanical damage and pitting cavities. |
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ASSEMBLY |  | 1. Place the washer on the side of the differential gear. Fill the side gears and satellites to their regular places in the differential box. |
 | 2. Insert the pinion gear shaft. |
 | 3. Use the special tool and dial gauge plunger, measure the amount of movement of planting the side gear in the differential housing. |
 | 4. The measurement result must not exceed the value of 0.1 ÷ 0.2 mm, otherwise achieve a demanded result by selecting new goals. |
5. Install the pin.  | 6. Install the ring gear. |
7. Install the speedometer drive.  | 8. Fit the bearings on the differential side. |
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Checking the components of the mechanism of a choice of transfers |  | Check the sliding surface of the components of the mechanism gear selection for scratches, abrasions and other mechanical damage. |
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