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Final assembly
Assembling the gearbox is carried out in sequence, return dismantling, using Fig. 161. During assembly, proceed as follows:
| Fig. 197. Setting the output shaft and other parts: 1 - a gear wheel of a backing; 2 - a shaft of a backing; 3 - the driven shaft; 4 - plug the inclusion of the first and second gear
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- Set the output shaft 3 (Fig. 197) with a fork 4 first-second transmission. Push the shaft gear 1 reverse and set the shaft; - Lift the crank reverse gear to later install reverse gear shift lever;
| Fig. 198. Installation of the drive shaft to the fork of the first and second gear: 1 - the output shaft; 2 - plug the inclusion; 3 - the input shaft
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- Slightly lift the output shaft 1 (Fig. 198) with a fork 2 first-second transmission output shaft with 3 engages with the fork and then install these items in the crankcase. When setting the primary shaft gear and the third-fourth speed is necessary to enable near the fourth speed gear located on the driven shaft. Fig. 198 shows how to set the items; - Screw the cap screw Torx located in a separate threaded hole to secure the shaft reverse gear; - Set the swivel arm in the reverse fork and collect items. Swivel lever should snap into the annular groove gear reverse gear; - Screw in the threaded hole Torx screw to secure the swing arm. This lower of the two spaced holes on one side. Used for lifting the gear Reverse gear crank arm can now be removed; - To establish the fifth gear fork and secure it;
| Fig. 199. Setting the console inclusion: 1 - fork; 2 - turn on the console; 3 - shaft gear selection mechanism
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- Withdraw all fork 1 (Fig. 199) to the idle position and fix the console incorporating 2 via the sleeve and bolt. Now you need to center console is turned on. For this purpose the gear selection mechanism shaft 3 and tightened bolt indicated by the arrow. After that, the shaft gear selection mechanism is removed again;
| Fig. 200. The assembly thumb shift console inclusion: 1 - finger switch; 2 - turn on the console
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- Set the gearshift finger 1 (Fig. 200) to enable the console 2 as shown in Fig. 200. The plug is installed in the slot shift finger; - Installed between the finger and the shift console enable parallel key and withdraw the plug into engagement with the shift finger and turn on the console; - Muffle hole in the side gearbox sealing plugs; - Set differential. It is assumed that the differential adjustment already carried out as described in Sect. 8.5; - Lubricate the surface of the gearbox housing with sealant and install the clutch housing. Drive to the crankcase mounting sleeve; - Install bolts and tighten them evenly around the circumference of the tightening torque of 25 Nm; - To collect details of the drive shaft as shown in Fig. 161 and tighten the two screws 1 and 17 to 25 Nm;
| Fig. 161. Details of the gearbox and clutch: 1 - a bolt, 25 Nm; 2 - the drive flange, right; 3 - spring; 4 - an adjusting washer; 5 - conical ring; 7 - bolt 25 Nm; 6 - clutch; 8 - a gear wheel drive of a speedometer; 9 - the directing plug; 10 - differential; 11 - Magnet; 12 - the adjusting pin; 13 - conical ring; 14 - an adjusting washer; 15 - a spring; 16 - the drive flange; 17 - bolt 25 Nm; 18 - thrust ring; 19 - a gear, fifth gear; 20 - the transmission housing; 21 - the adjusting pin
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- Drive shaft fifth-gear, bevel setting it in the direction tapered roller bearing, and install the thrust ring; - Install a new bolt fifth gear with spring washer. The convex side of the spring washer must be facing the gear; - Set on another shaft shim to fifth gear. The inner diameter of the groove has a shim. It is directed toward the needle bearing; - Electrical heat plate on the bearing sleeve, designed for the needle bearing fifth gear to 100 ?� C and rapidly Press on its shaft; - Set the spring on the fifth gear synchronizer ring and set ring on the pinion; - Pick up a fifth-gear synchronizer hub and check on which side of the bead wider. This side should be facing toward the side of the gearbox. Push the hub onto the shaft strikes. At the same time make sure that the synchronizer ring is not jam. Crackers should be in the recesses of the synchronizer ring; - Install the thrust washer onto the shaft end by means of special pliers used for repairing water pumps;
| Fig. 201. The assembly of parts of the synchronizer of the fifth transfer
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- Set sliding sleeve fifth gear, using Fig. 201. In the sliding clutch three protruding tooth (arrow A) and in the middle of the hub cavity between the teeth (arrow B). They should match, as shown in the figure. The sliding sleeve is installed temporarily; | Fig. 164. removing fifth gear (block the transmission in accordance with the arrows 1, 2 and 3)
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- Tighten fifth gear. To do this again to include two shows, as shown in Fig. 164; - Again to remove the sliding sleeve, inserted into the groove of fork and install the sliding sleeve with fork;
| Fig. 163. Removing the shift fork: 1 - a nut; 2 - pin plug
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- Unscrew the locknut 1 (see. Fig. 163) until it is below the fork and screw the bolt 2 with Ball Head. This screw thread lubricants protect against loosening D 000 600 (Loctite); - Transfer all the transmission in neutral and adjust the fifth gear; - Set the transmission in normal position; - Loosen the lock nut 1 (see. Fig. 163); - 2 to turn on the bolt head with a ball while sliding sleeve is flush with the hub inclusion; - Fifth gear and enable the bolt to screw the ball head until the plug until the fifth gear would no longer have a clearance in a groove of the sliding sleeve; - Again to turn on the bolt until the very small gap between the wall of the slot and the lever fork (about 1/8 turn); - Secure from turning bolt with a ball head with a lock nut; - Again turn off the fifth gear. The sliding sleeve must be in the "neutral", and a synchronizer ring must move freely; - Set the cover with a new gasket and tighten the cover bolts evenly around the circumference of 8 N ?� m.
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