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Output shaft
NOTE Backed by a secondary shaft parts arranged in the sequence corresponding to the order of their installation on the shaft - it will facilitate the assembly process. |
Removing parts from the secondary shaft spend in the following order:
| Fig. 8.21. The secondary shaft and its parts: 1 - a nut; 2 - clutch; 3 - a washer; 4 - a cup of tapered roller bearing; 5 - tapered roller bearing cone (small); 6 - the input shaft; 7 - tapered roller bearing cone (large); 8 - ring; 9 - Ball bearing bracket; 10 - thrust washer; 11 - a gear wheel of 1st transfer; 12 - the needle bearing of a gear wheel of 1st transfer; 13 - ring of the synchronizer of 1st transfer; 14 - a nave of the synchronizer of 1st / 2nd transfers; 15 - a lock ring; 16 - synchronizer ring 2nd transfers; 17 - the outer ring; 18 - an internal ring of the synchronizer; 19 - a gear wheel 2nd transfers; 20 - the needle bearing of a gear wheel of 3rd transfer; 21 - thrust washer; 22 - the needle bearing sleeve; 23 - the needle bearing of a gear wheel of 3rd transfer; 24 - a gear wheel of 3rd transfer; 25 - ring of the synchronizer of 3rd transfer; 26 - a nave of the synchronizer of 3rd / 4th transfers; 27 - the needle bearing sleeve; 28 - the needle bearing of a gear wheel of 4th transfer; 29 - ring of the synchronizer of 4th transfer; 30 - 4th gear transmission; 31 - thrust washer; 32 - the needle bearing; 33 - the transmission housing; 34 - bearing sleeve; 35 - the plug; 36 - gear 5th gear; 37 - the plug; 38 - the screw
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Puller set so that it grips tightly fixed second gear and remove the parts from the shaft (Fig. 8.21); Remove the rotating hub of the needle bearing and thrust washer; remove from the shaft gear 4th gear, needle bearing and sleeve; Remove the synchronizer of 3rd and 4th transfers with rings. Mark the position of the hub - in the future it will help you set it up correctly; Remove gear 3rd gear, needle bearing and sleeve; Remove the thrust washer, gear 2nd gear and the needle bearing; remove the outer and the inner steel synchronizer ring 2nd gear. Mark their location; Remove the retaining ring; Remove the synchronizer hub 1st / 2nd gear from the shaft. When removing the unit, be careful: Do not damage the synchronizer ring; Remove the first gear synchronizer ring, the first gear and the needle bearing; Remove the bearing bracket with the outer ring of the bearing and washer;
| Fig. 8.22. Bearing support zone "a" may have a width of 3.8 mm or a recess, indicated by the arrow
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removal of tapered roller bearings from the secondary shaft special tool is required. If necessary, dismantling seek professional help of specialized service stations. To remove the bearing supports the shaft need to use puller with two jaws, the puller must be installed under the bearing bracket. Install the necessary support redesigned, whose wall thickness is 3 to 8 mm (Fig. 8.22).
A WARNING When replacing tapered roller bearing are subject to obligatory replacement of his cone and cup. |
Check technical condition of parts is performed as follows: Inspect all taken from the secondary shaft parts. If necessary, replace worn or damaged parts; check the condition of the synchronizer hub. In case of their use complete disassembly of the piece of cloth to prevent the loss of small pieces;
| Fig. 8.23. Check internal synchronizer ring 2nd gear
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| Fig. 8.24. Checking of the external synchronizer ring 2nd gear
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Check the wear of synchronizer rings (Fig. 8.23 and 8.24). To do this, placing rings on the hubs, push them to the hub and probe to measure the gap between the inner surface of the ring and adjacent surface of the sleeve. If the clearance exceeds the limit, replace the synchronizer ring. Dismantling and synchronizer assembly sequence is as follows:
| Fig. 8.25. The missing tooth (marked by arrow) on the ring of the synchronizer of 1st transfer
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| Fig. 8.26. Location recesses (indicated by arrows) in the synchronizer ring 2nd gear
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for the dismantling of the synchronizer hub designate position relative to the sleeve, and the location of springs and crackers blocking three marks for correct installation. Note that the first gear synchronizer ring has a characteristic feature - the absence of three gear teeth on the surface (Fig. 8.25). Second gear synchronizer ring has three notches to install internal retaining rings (Fig. 8.26);
| Fig. 8.27. The synchronizer of 1st and 2nd gear: 1 - a spring; 2 - rusk; 3 - a nave of the synchronizer; 4 - sliding sleeve
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| Fig. 8.28. When installing the synchronizer of 1st and 2nd gear wider shoulder should be directed to a gear wheel of 1st transfer
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for assembling the synchronizer (Fig. 8.27) 1st / 2nd gear, check that the guide slots for the biscuits on the sliding sleeve and the hub are located opposite each other. The wider shoulder should be directed to the first gear (Fig. 8.28). Crackers and springs should be arranged at equal intervals (120 ?�); synchronizer assembly for the 3rd / 4th gear Check that when installing the hub to hub grooves biscuit lock hub and hub are aligned. The inner surface of the hub having a recess should be turned to the first gear. Crackers and springs should be arranged at equal intervals (120 ?�). The installation of the secondary shaft parts spend in the following order: Install new O-rings on the rack supporting the bearing bracket and set the bracket on the shaft; set thin washer bearing lug to the bearing; Install the needle bearing and the first gear; Establish a synchronizer ring 1st gear; Install the guide bushing of the 1st / 2nd gear groove to the first gear and Press fit into place a segment of pipe of suitable diameter; pliers, place retaining ring in the groove on the shaft; install the external synchronizer ring, intermediate ring and the inner ring of the synchronizer sleeve in the control of the 1st / 2nd gear; install needle bearing on the shaft; install the pinion shaft 2nd gear and thrust washer; Press in the needle bearing sleeve gear 3rd gear on the shaft using a piece of pipe of suitable diameter; install needle bearing on the shaft; install the shaft gear 3rd gear; Establish a synchronizer ring to gear 3rd gear;
| Fig. 8.29. The groove on the inner surface of the synchronizer hub 3rd / 4th gear should be directed to the gear transmission 4 minutes
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Install the hub 3rd / 4th gear, making sure the orientation (Fig. 8.29); Press in the hub in place a suitable diameter pipe segment, keeping an eye on the fact that its projections coincide with the grooves of the synchronizer; Establish a synchronizer ring 4th gear needle bearing sleeve and gear wheel of 4th transfer; Install the needle bearing and the fourth gear; thrust washer placed opposite the fourth gear, Press fit the bushing.
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