 printable version
Disassembly and assembly of the gearbox and its details Troubleshooting
You will need: the keys "10", "13", "19", "24", a set of Allen keys, flat-blade screwdriver (two), pliers, snap ring pliers, Bearing puller, a hammer, barbs, chisel. | | 2. Remove the spring clip ... | 3. ... and remove the hinge pin drive gear. Disconnect the plug joint. |
| | 4. fold the edge of the chisel lock plate bracket bolts of a back support of the power unit to the gearbox housing. | 5. Remove the three screws ... |
| | 6. Remove the lock plate ... ... | 7. ... and an arm of a back support of the power unit assembly with hinges drive gear. |
| | | 9. Remove the speedometer drive from the vehicle speed sensor. |
| | 10. Remove the bolt and remove the speedometer drive. | 11. Remove reverse gear switch. |
| | 12. Remove the protective cap ... | 13. ... and remove the plug for the oil filling hole. |
| | 14. Remove the four screws on the housing of the gearshift ... | 15. ... and remove the mechanism and installed underneath the pad. |
| | 16. Remove the eleven bolts back cover of the gearbox ... | 17. ... then remove the cover ... |
| | 18. ... and set the lid gasket. | 19. A hole for mounting the gearshift switch II transmission by moving the screwdriver fork I and II programs. |
| | 20. Remove the screws of the intermediate casing ... | 21. ... and remove the housing assembly from the shaft. |
| | 22. Note that in the crankcase mounted Spacer intermediate reverse gear. | 23. Remove the two screws on the bracket fork V transmission ... |
NOTE Before assembling, apply to the bolt retainer anaerobic thread. |
| | 24. ... and remove the bracket assembly with a fork. | 25. Remove the plug crackers. |
NOTE Worn crackers during assembly replaced. |
| | 26. Special stripper remove a lock ring synchronizer V transmission. | 27. Install trehlapy universal puller on clutch transmission synchronizer V ... |
| | 28. ... and Xpress with shaft clutch assembly with the hub. | 29. Remove the synchronizer ring ... |
| | 30. ... driven gear transmission V ... | 31. ... the needle bearing ... |
| | 32. ... and lock ring. | 33. Remove the two thrust half rings. |
| | 34. Remove the retaining ring pinion transmission V ... | 35. ... and two screwdrivers Xpress gear, using wooden blocks as spacers. |
| | 36. Remove the two screws on the bracket pawl ... | 37. ... install rods plugs consistently to position II, V and III programs, and remove the bracket assembly with a dog. |
| | 38. A hammer with a chisel through the blunt tip emboss plug stem retainer gearshift forks. Note that the latch marked by an arrow ... | 39. ... differs from the other two. After pulling out plugs remove the nests of the intermediate casing and spring stem retainer. |
| | 40. Remove the two screws that secure the locking pin ... | 41. ... remove the bracket ... |
| | 42. ... and remove the pin from the bracket. | 43. Remove the lining of the intermediate casing. |
| | 44. The free end of the stem of the opera at the wooden bar, beat out a beard pin fastening fork intermediate reverse gear ... | 45. ... and remove the stem and fork. |
| | 46. Because of the holes of the intermediate casing, remove the lock pin at the same time the inclusion of two transmissions. | 47. Drive out the pin attachment plug III and IV switch gears ... |
48. ... remove the stem and remove the fork.
NOTE Sleeve gear when removing the plug should be in a neutral position. |
| | 49. Remove the lead with a rod that V transmission. | 50. Remove the lead from the stem. |
| | 51. A stripper for internal retaining rings (working on compression), squeeze snap ring secondary shaft and lock in this position. | 52. The second puller for external retaining rings (working for decompression) Release the lock ring of a primary shaft ... |
| | 53. ... and remove the tail of the primary shaft of the intermediate casing. | 54. Remove the intermediate reverse gear. |
| | 55. Remove the stem from the crankcase of the secondary shaft and remove the shaft assembly, as well as rod and the shift fork I and II programs. | 56. A stripper remove the bore of the intermediate housing retaining ring of the bearing of a primary shaft. |
| | 57. Remove the magnet housing and clean it from debris. | 58. Extract the axis of the intermediate reverse gear from the intermediate casing, holding the shaft in a vise with soft metal jaws and sliding housing to the axis of light hammer blows through the wooden prorate crankcase. |
| | 59. Remove the ten bolts securing the bottom cover gearbox ... | 60. ... and remove the cover with the gasket. |
| | 61. Mark a paint position of the adjusting nut bearing of the differential with respect to the transmission housing. | 62. Remove the bolt locking the adjusting nut ... |
| | 63. ... remove the clip ... | 64. ... and counting the number of revolutions, turn the adjusting nut with a screwdriver as shown in the photo. |
65. Remove the nut O-ring.
NOTE Strong compression, hardened or torn, replace the ring. |
| | 66. Press out of the gland nut axis. | 67. If necessary, replace the bearings of differential turn the adjusting nut, place a couple of wooden beams and press out of the nut the outer ring of the bearing of differential. |
| | 68. Remove the distance ring of the adjusting nut. | 69. Remove the five screws securing the right cover of the differential bearing, remove the lid, remove it from the O-ring, then press out of the gland and, if necessary, the outer ring of the bearing as well as their is extruded from the adjusting nut. |
70. Remove from the gearbox differential assembly. 71. Troubleshooting Before inspecting and thoroughly rinse and dry parts gearbox. 72. Inspect the gearbox housing, intermediate housing and the back cover. They should not be chopped off. In the mating surfaces should not be nicks, scratches, dents, etc. Slight damage to remove fine sandpaper. In severe injuries, replace defective parts. 73. Check the bearing position. These surfaces must be free of wear or damage. If there is damage, replace the housing. 74. Check the condition of stocks in gear. If they are bent or they were bullies, burrs or development wells under tabs, replace the rod. 75. Check the condition of shift forks. If the fork legs bent or worn, replace these parts. 76. Upon detection of a leak in the operation of oil through the seals and their working edges worn seals should be replaced. 77. Check the condition of the bearings. If you find shells on treadmills and rolling elements, trace the indentation of the rolling elements on a treadmill or in the case of damage to the bearing cage must be replaced. 78. Replace damaged or heavily compress the gasket. 79. Clean the magnetic particles from the wear and tear. If cracks on the magnet or magnetic properties are weakened, replace the magnet.
Collect the gearbox in sequence, return dismantling taking into account the following. 1. Before assembly, lubricate all liberally rubbing parts with gear oil. | | 2. Collect all the fittings ... | 3. ... and place the seals using anaerobic thread lock. |
4. Before installing output shaft in the intermediate housing squeeze snap ring pliers and fix the wire in a compressed state. Remove the wire after installing the shaft into the housing, making sure that the ring entered the bore casing at an angle. 5. When installing differential, if not changed his bearings, tighten adjusting nut bearing the same number of turns as when unscrewing, to align the labels put at dismantling. 6. If you changed the bearings of the differential, after its installation, adjust the preload on the bearing value of the moment of resistance-rotation bearings, turning the adjusting nut or turning away. For new bearing drag torque should be 2 Nm (0.2 kgf ?� m) while rotating the ring gear at a speed of 1 / s. If the bearings have not changed, the moment of resistance must be 1 Nm (0.1 kgf-m). 7. Before installing the gearbox bottom cover gasket, lubricate it with grease.
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