 printable version
5stupenchatye PPC types FS5W71B / C demolition
Attention! The following procedure applies only to the checkpoint until 1993 Repair CPR after 1993 is performed in the service station. |
| 4.8 Restrictive sleeve backing
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| 4.9a Details crankcase 4 and 5 speed gearbox early release 1.Salnik 2. Dust cover 3. Bearing housing 4. Jam filling holes 5.5stupenchataya CAT 6. Switch neutral 7. Stop Collar reversing 8. Rear kry
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| 4.9b Details sump 5-speed gearbox FS5W71B / C 1. Dust cover 2.12. Gland 3.17. Stop Collar reverse 4. The back cover Bearing housing 5. 6. 7. Bearing transition section 8. Tube filling holes 9. Drain plug 10.
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| 4.10 When removing the front cover falls shim
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| 4.15a Details of the mechanism gear Gearbox release until 1993 1. 2. Handle Lever 3. Top cover retaining ring 4. Cover 5. Lower clamp cover 6. 7. 8. Gasket fork for 5th gear and reverse 9,13,29,31,33. The ball retainer 10.
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| 4.15b Details of the mechanism gear Gearbox manufactured after 1993 (for the rear-wheel drive and / m) 1. 2. Handle Lever 3. Top cover retaining ring 4. Cover 5. Lower clamp cover 6. 7. 8. Gasket fork for 5th gear and reverse 9,14,15
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Stage 1 showdown 1. Clean and wash the transaxle case. 2. Remove the cover of the lever with the clutch housing. 3. Remove the release bearing and hub together with the lever (Ch. 8). 4. Remove the transaxle housing all circuit breakers (photo). 5. At the rear-wheel drive and / m Remove the bolt and the speedometer gear unit (see photo). 6. Remove the retaining ring and knock out the pin (see photo). 7. Remove the cap, pull out the spring and plunger (photo). 8. Remove the two screws and remove the restrictive backing sleeve (see photo). 9. Remove the two screws and separate from the transaxle housing rear cover (see photo). 10. Remove the screws and remove the front cover, remove the shim and the bearing retaining ring (see photo). 11. Separate and remove the transaxle case. 12. Clamp the transition section housing in a vise, privernuv bolts supporting plate (make your own). 13. Knock out the pins shift forks (photo). 14. Remove all three plugs locks. 15. Remove the fork rods (photo). 16. As the extraction rods remove the fork springs and balls. Balls are balls of smaller diameter fasteners.
| 4.15v Details of the mechanism gear Gearbox 1S93 after the release of (all-wheel drive for the a / m) 1. Handle 2. Lever 3. Top cover retaining ring 4. Cover 5. Lower the clamp 6. Cover 7. Gasket 8. Fork inclusion 5 First and Reverse 9,13,15,2
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19. If the observed damage and the backlash exceeds norm completely disassemble PPC and replace worn parts 20. Xpress puller front bearing of the intermediate shaft. 21. Remove the retaining ring. 22. Carefully remove the intermediate and primary shafts. 23. Remove the input shaft retaining ring and thrust washer. 24. Remove the synchronizer of 3rd and 4th transfers and a gear wheel of 3rd transfer. 25. Straighten hammer and beard raskernennye sites nuts secondary and intermediate shaft. 26. Remove the reverse gear and thrust washer. 27. Xpress gear 5th gear and bearing 28. Remove the countershaft nut (the nut should be replaced). 29. Remove the retaining ring and remove the intermediate reverse gear. 30. Remove the retaining ring and remove the speedometer gear reducer. * 31. Remove the 2 locking ring and remove the bearing of a secondary shaft. 32. Remove the input shaft nut (the nut must be replaced)
| 4.17a Details PPC FS5W71B / C (up to 1993) 1. Bearing output shaft 2,13,16. Thrust Washer 3. Bearing driven gear 5th gear 4. Pinion gear speedometer 5,12,51,53,56. Retaining ring 6.7. Nut 8. Rear intermediate bearing in
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| 4.176 Details PPC FS5W71B / C (after 1993) 1. Bearing output shaft 2,13,16. Thrust washer 3. 1 st driven gear 4. The transmission sleeve 5,12,32. Needle bearing 6.28. Synchronizer ring 7.30. 8. Internal synchronizer clutch b
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| 4.17v Details 4-speed gearbox F4W71B / C 1. synchronizer hub 1st and 2nd gear driven gear 2. 2nd gear needle bearing 3. 4. reverse driven gear 5. Nut secondary shaft 6,13,27 . 7. Bearing Thrust Washer 8,25,28,32,34. Stop
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| 4.18 Checking the axial clearance of gears Gearbox Gear 1. 2. 3. Allen clearance Secondary shaft or sleeve
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33. Remove the thrust washer, bushing, needle bearing, gear 5th gear reverse driven gear synchronizer and clip. 34. Carefully knock the transition section of the secondary and intermediate shaft. Output shaft 35. Check the condition of the shaft splines and gear teeth, disassemble and replace worn-out gear. 36. Check the condition of the shaft (splines wear, violation of their straightness, development, taper). 37. Believe state synchronizers, especially if the work of the CPT is noisy. 38. Install the locking ring tightly on the gear and check clearance between the ring gear (photo). 39. When the synchronizer assembly, make sure that the end of the retaining rings on both sides of the hub come in different slots. 40. The assembly start with the installation on the output shaft of the needle bearing. Then set the gear 2nd gear, synchronizer ring and the synchronizer of 1st and 2nd transfers, ensuring proper installation. 41. Set the synchronizer ring gear 1st gear, needle bearing, ball (grease prior to assembly), washer, sleeve and 1 st gear transmission.
| 4.56 Removal of the pin stem slide
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| 4.38 Check the gap between the crown and the pinion synchronizer ring 1. Clearance
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Countershaft 42. The front bearing of the intermediate shaft is removed at dismantling the checkpoint. 43. The rear shaft bearing is in the transition section of the housing. 44. Remove the pinion gear and remove the 2 key. 45. Check the condition of the shaft splines and gear teeth. 46. The assembly is performed in reverse order. Primary shaft 47. Remove the snap ring and shim. 48. Xpress bearing (to be replaced). 49. Fit the new bearing of the outer ring. 50. Put the puck. 51. Pick up the puck in thickness so as to compensate for axial play. Seals 52. Extract the rear oil seal and press in a new one. 1 53. Install the O-ring gear reducer speedometer. 54. Replace the front oil seal, is pressed by a new mandrel. The rear section of the housing 55. Loosen the nut of the pin stem the slide, remove the half. 56. Extract the pin holding the nut (photo). 57. Remove the rod from the lever and remove the stem. 58. Check the condition of shaft and lever and replace if necessary. Replace rod seal. 59. Check the sleeve in the rear section detection of cracks or wear, replace the section. 60. Install stem the slide in reverse order. Assembly 61. Remove the bearings of the intermediate and secondary shaft transition section of the crankcase and check their condition. To do this, unscrew the 6 screws on the holder of the transition section.
| 4.84 Tightening the nut output shaft
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62. Press out the bearings, pushing the outer ring. 63. After washing, check freedom of rotation of the bearing. In the case of seizure, increased noise during rotation or in the case of weakening clips replace bearings. 64. Check the press-fit guide pins in the transition section of the housing. 65. Press in the bearings easily hit total in the transition section. 66. Press fit into the transition zone idler roller at 2/3 of its length so as to slot sign on the roller bearing locking plate. 67. Install the retaining plate and tighten the screws with the specified torque. 68. unstake screws to prevent loosening. 69. Carefully press-fit into the transition section of the rear bearing of the intermediate shaft. 70. Press in the transition section in a secondary shaft, abutting the inner race of the bearing. 71. Press in the intermediate shaft. 72. Put on a secondary shaft needle bearing, gear 3rd gear blocking ring and the synchronizer of 3rd and 4th gear. 73. Install the thrust washer and retaining ring, pick it up in thickness, to minimize the axial play (see. Table below). 74. Put on a primary shaft guide the needle bearing. 75. Enter the pinion input shaft in engagement with the pinion 4th gear. Enter the primary shaft with a pinion meshed with the secondary and intermediate shafts. The pinion shaft press in the secondary segment of pipe of suitable diameter. 76. Install snap ring pinion countershaft, choosing its thickness, to minimize the axial clearance (see. Table below). 77. With the mandrel press them on the intermediate shaft bearing. 78. Put on the intermediate shaft washer remote reverse gear. 79. Replace the roller intermediate gear snap ring, thrust washer, needle bearing, intermediate reverse gear, idler gear thrust washer and the rear snap ring. 80. On the rear side of the secondary shaft, set the clip (if provided), synchronizer, reverse driven gear, bushing, needle bearing and synchronizer ring.
| 4.85 Dependence of the actual torque (with extension) of the indications on the dial key 1. Torque wrench 2. readable point 3. The upper limit of 4. The converted time 5. Lower limit
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81. Put on the intermediate shaft pinion gear reverse. 82. Engage the two gear 5th gear and put them on the intermediate and secondary-shafts. 83. Lubricate the bead with grease and install a ball and thrust washer from the rear of the output shaft. 84. Screw the new nut output shaft and tighten with the set moment.
Attention! To tighten the nut OSS with the specified torque in the torque wrench should extender (photo). In this case, the actual torque is determined from the accompanying chart (see photo). |
85. Put the rear bearing of the intermediate shaft (photo). 86. Tighten the intermediate shaft with the specified torque. 87. unstake nut trees so that crowns went nuts in the sample on the shafts. 88. Check the socket gap gears (see. Above).
| 4.106 Checking protrusion And for adjusting the thickness shim Carter 1. 2. 3. Intermediate shaft bearing
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89. Put on a secondary shaft retaining ring and press them back bearing. 90. Pick rear retaining ring thickness (see. Table). 91. Install the retaining ring, lubricate the bead and replace the output shaft ball and drive pinion gear speedometer. Place extreme snap ring. 92. Install the plug in the socket of the synchronizer plug the 1 st and 2 nd gear. The elongated portion of the plug should be facing towards the intermediate shaft. Install the plug in the socket of the synchronizer of 3rd and 4th gear. The extended portion of the plug should be turned in the opposite direction. 93. At the synchronizer sleeve 5 and the rear gear set plug. The upper hole plug stem must be aligned with the fork 3rd and 4th gear. 94. Insert plug stem 1st and 2nd speeds in the hole in the transition section and a fork. Align the holes and press in a new pin. 95. Align the notch in the rod with a hole and insert the ball, spring and screw cap, lightly brushing sealant. 96. Turn the transition section to the shafts and forks so that the assembled lock appeared in the lowest position. Lower the 2 ball in the hole to lock the 3rd and 4th gears and using a thin tool post balls all the way into the fork stem 1 st and 2 nd gear (unless the transition section is installed correctly, the ball should go to the place). Pass the stock 3rd and 4th gear through the upper hole in the fork 5th gear and reverse gear, and a transition section, and insert the plug in the 3rd and 4th gear. The beads should be installed between the stem and the stem plugs 1 st and 2 nd gear. Align the plug and the rod and press in a new pin. Insert the lock into the hole 3rd and 4th gear ball, spring and screw cap, lightly brushing sealant. Before installing the ball retainer, make sure that the slot coincides with the rod hole. 97. In the remainder of hole 2 ball retainer lower. Insert the plunger plug 5th gear and reverse gear into the hole in the fork and in the transition section. Make sure the balls are installed between the stem and the stem fork 3rd and 4th gear. Make sure that the opening coincides with the latch recess on the rod and insert the ball in the hole, a spring and screw the cap on the sealant. Align the holes and installed the plug rod and press in a new pin. 98. Tighten all 3 plugs with the specified torque. 99. Coat the rods and check the smoothness of their movements. 100. Clear demountable plane of the crankcase and the transition section and with sealant. 101. Carefully put housing on the transition section, making sure the bearings to the intermediate and secondary shaft went into the bore casing. Lightly tap the crankcase besiege the place. 102. Establish a lock ring of the bearing of a primary shaft. 103. Clear demountable planes transition and rear sections, with sealant. 104. Move the fork in the neutral position, and set the rear section, slide the lever must engage with the selector shaft. 105. Tighten crankcase sections with the set moment. Check the protrusion 106. A front bearing intermediate shaft relative to the plane of the housing (photo) and pick up the shim thickness (see. Table).
Table Dimension (mm) | The thickness of the plate (mm) | 2.92-3.01 | 0.6 | 3.02-3.11 | 0.5 | 3.12-3.21 | 0.4 | 3.22-3.31 | 0.3 | 3.32-3.41 | 0.2 | 3,42-3.51 | 0.1 |
107. Secure the washer with grease and put the front cover with a new shaft seal with a new seal without damaging the gland. 108. Grease a sealant, and tighten the cover bolts with the set moment. 109. The remaining operations are performed in reverse order.
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