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 printable version
Primary shaft
Primary shaft
1 - the plug;
2 - the input shaft;
3 - the needle bearing;
4 - a gear wheel of 3rd transfer;
5 - a blocking ring;
6 - the synchronizer;
7 - a lock ring; | 8 - a blocking ring;
9 - the needle bearing;
10 - 4th gear transmission;
11 - washer;
12 - the bearing;
13 - a lock ring;
14 - shim |
Sleeve with a sealing ring of the primary shaft
| 1 - O-ring;
2 - plug;
3 - the input shaft |
Special tool for adjusting the input shaft
| 1 - special bracket;
2 - the threaded rod;
3 - a bolt;
4 - a nut;
5 - plug;
6 - the input shaft;
7 - clutch |
Adjusting the axial clearance of the primary shaft
| 1 - the input shaft;
2 - a gear wheel of 4th transfer;
3 - the transmission housing;
4 - Stand;
5 - indicator;
6 - Leg indicator;
7 - special plug;
8 - a washer;
and - the measured axial clearance |
Dismantling
| PERFORMANCE ORDER | | 1. To press the ball bearing 12 (see. Fig. Primary shaft). | | 2. Remove the gear April 10 th transmission. | | 3. Remove the needle bearing 9. | | 4. Remove the locking ring 8 synchronizer. | | 5. Remove the retaining ring 7. | | 6. Remove the synchronizer 6. | | 7. Remove the locking ring 5 synchronizer. | | 8. Remove the gear 4 3rd transfer. | | 9. Remove the needle bearing 3. | | 10. Check the clearance between the plunger and coupling the sealing ring 1 (see. Fig. Bush with a sealing ring of the primary shaft). If there is a gap, it is necessary to replace the O-ring 1. | | 11. Press out the plug 2 O-ring 1 of the input shaft 3. |
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Assembly
A warning  Before assembly, lubricate all the details.
| PERFORMANCE ORDER | | 1. Drive sleeve 2 and a new sealing ring 1 to the input shaft 3, while the O-ring must be recessed at 0.8-1.3 mm from the end of the primary shaft. | | 2. Install the needle bearing 3 (see. Fig. Primary shaft). | | 3. Check the gap between blocking rings 5 and 8 and their respective gears 4 and 10 (see FIG. Subsection 5.2.2.1). | | 4. Set the gear 4 3rd transfer. | | 5. To establish blocking ring 5. | | 6. Set chamfer on the synchronizer hub towards the gear 3rd gear, watching thus that synchronizer crackers have got to grooves of a blocking ring. | | 7. Install the retaining ring 7. | | 8. Install the locking ring 8, watching thus that synchronizer crackers have got to grooves blocks-ating ring. | | 9. Install the needle bearing 9. | | 10. To establish a gear wheel on April 10 th transmission. |
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Adjusting input shaft
| PERFORMANCE ORDER | | 1. Fit the clutch special device (see. Fig. Special tool for adjusting the input shaft). Bracket 1 3 bolted to the crankcase clutch 7. On the threaded rod 2 is wound nut 4 and wearing a sleeve 5, rests on the input shaft 6. | | 2. Turn the nut 4, move the input shaft so that between the gear 2nd gear and the output shaft 3rd gear input shaft has turned to 1 mm gap (the gap measure probe). | | 3. Lock in this position the nut 4. | | 4. Install a washer 3.5 mm thick, if there was no washer 11 (see. Fig. Primary shaft) in this configuration. Washer must be installed on the shaft with a radial clearance. | | 5. Install the input shaft 1 (see. Fig. Adjustment of the axial clearance of the primary shaft) special bushing 7 (VW549). The sleeve 7 can make your own based on the size of the ball bearing, input shaft and the transmission housing. | | 6. Install the stand 4. | | 7. Set the indicator 5 foot 6. | | 8. Move the sleeve 7 up and down and remove the indicator, thereby determining the axial clearance "a". | | 9. Choose shim thickness of two sizes of 0.3 and 0.6 mm in accordance with the measured value of the axial gap |
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The measured value of the axial clearance, mm | The thickness of the shim, mm | 0 - 0.46 | The puck is not required | 0.47 - 0.75 | 0.3 | 0.76 - 1.04 | 0.6 | 1.05 - 1.45 | 0.6 0.3 |
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