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The secondary shaft of a transmission
The secondary shaft of a transmission 1 - double cone;
2 - the inner ring of the synchronizer;
3 - bush gear 2nd gear;
4 - the needle bearing;
5 - a gear wheel 2nd transfers;
6 - a gear wheel of 3 transfers;
7 - spacer;
8 - a gear wheel of 4th transfer;
9 - the inner ring of the bearing;
10 - an internal ring of the bearing; | 11 - a secondary shaft;
12 - a gear wheel of 1st transfer;
13 - ring of the synchronizer;
14 - a gear wheel of a backing;
15 - lock cracker;
16 - a nave of the synchronizer clutch;
17 - the spring of the synchronizer;
18 - ring of the synchronizer;
19 - the synchronizer of 1st / 2nd gear |
Preliminary checks GEAR CLEARANCE OF 1 TH TRANSFER
| PERFORMANCE ORDER |  | 1. Measure the clearance between the first gear transmission and differential gear.
Nominal backlash: 0,05-0,28 mm | | 2. If the clearance exceeds the limit, check the contact surface of the first gear transmission, differential gear and synchronizer clutch 1st / 2nd gear. Replace worn or damaged parts. |
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CLEARANCE GEAR 2nd gear
| PERFORMANCE ORDER |  | 1. Measure the clearance between the gear 2nd gear and third gear transmission. Nominal backlash: 0,05-0,17 mm | | 2. If the clearance exceeds the limit, check the contact surface of the gear 2nd gear, 3rd gear transmission and clutch synchronizer of 1st / 2nd gear. Replace worn or damaged parts. |
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Dismantling Bearings and gears 4th transfer
| PERFORMANCE ORDER |  | Using a press and special adaptation OK201 172 008 remove a gear wheel of 4th transfer. |
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GEAR 2ND AND 3RD GEAR
| PERFORMANCE ORDER | | 1. Move the gear to shesterne1 second transmission. |  | 2. Using a press and special adaptation OK201 172 008 remove the gear 2nd gear and 3rd gear. |
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Check GEAR
| PERFORMANCE ORDER | | 1. Inspect the synchronizer cones for wear. | | 2. Inspect the condition of the surface of the gear teeth for damage, wear and cracks. |  | 3. Visually inspect the condition of the ring of the synchronizer on absence of damages, deterioration and cracks. |
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Synchronizer ring
| PERFORMANCE ORDER | | 1. Visually check the condition of the synchronizer ring teeth for damage, wear and cracks. |  | 2. Check the condition of the conical surface for damage, wear and cracks. | | 3. Establish a synchronizer ring in a gear wheel. |  | 4. Measure the clearance between the synchronizer ring and the surface of the flange gear. Nominal backlash: 1,4-1,7 mm
Minimum clearance: 0.8 mm |
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SYNCHRONIZER
| PERFORMANCE ORDER | | 1. Visually check the condition of the synchronizer and its working capacity. | | 2. Visually check the condition of the synchronizer ring teeth for damage, wear and cracks. |  | 3. Check the condition of crackers lock for damage, wear and cracks. |  | 4. Measure the gap between the sliding sleeve and the synchronizer forks. | Clearance mm Element | Nominal | Limits | 1st / 2nd | 0.1-0.35 | 0.75 | 3rd / 4th | 0,27-0,50 | 1.80 |
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INTERIM reverse gear
| PERFORMANCE ORDER | | 1. Visually check the condition of gear teeth for damage, wear and cracks. |  | 2. Measure the clearance between the sleeve of the intermediate reverse gear and the lever. Nominal backlash: 0,095-0,33 mm
The minimum allowable clearance: 0,31 mm |
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BEARING
| PERFORMANCE ORDER |  | Check the bearing on absence of damages and smoothness of rotation. |
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Primary and secondary TREES
| PERFORMANCE ORDER | | 1. Check the gear in contact with the surface of the shaft for wear and damage. | | 2. Check the shaft splines for wear and damage. | | 3. Visually inspect the gear teeth for damage, wear and cracks. | | 4. Check the channel for supplying lubricant to clogging. |  | 5. The indicator of hour type measure palpation of primary and secondary shaft. Heartbeat: 0,015 mm |
A warning  If replacement of the output shaft, adjust the bearing preload.
| Oil gap, mm Element | Val (outer diameter) | Gear (inside diameter) | gap | First | 39,445-39,470 | 39,500-39,525
| 0.03-0.08 | 2nd | 35,145-35,170 | 47,009-47,025 |
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Assembly Coupling hub SYNCHRONIZER | PERFORMANCE ORDER | | Place crackers and spring retainer into the sleeve of the synchronizer hub. | Dimensions biscuit lock mm Element | 1 | 2 | 3 | 1st / 2nd | 18.0 | 4.25 | 50 | 3rd / 4th | 17.0 | 4.25 | 50 | 4th / ZH | 17.0 | 4.25 | 50 |
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BEARING (DIFFERENTIAL SIDE)
| PERFORMANCE ORDER |  | Using a press and special adaptation OK900 175 AA1 establish the new bearing. |
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Gear wheel of 1st transfer, a ring synchronizer of 1st TRANSFER AND synchronizer of 1st / 2nd gear
A warning On the synchronizer ring 2nd gear teeth are absent in three places around the perimeter in order to distinguish it from other synchronizer rings.
| PERFORMANCE ORDER |  | 1. Install the first gear transmission ring of the synchronizer of 1st transfer and the synchronizer of 1st / 2nd gear as shown on the image. | | 2. Align the notch ring synchronizer with clamp crackers. |  | 3. Using a press and special adaptation OK900 175 AA1 establish the coupling hub synchronizer of 1st / 2nd gear. |
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Synchronizer ring 2nd transfers and a gear wheel 2nd and 3 TRANSFERS
| PERFORMANCE ORDER | | 1. Establish a synchronizer ring 2nd transfers and a gear wheel 2nd transfers. |  | 2. Using a press and special adaptation OK900 175 AA1 establish a gear wheel of 3 transfers. |
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GEAR 4th transfer and the bearing inner ring
| PERFORMANCE ORDER |  | 1. Using a press and special adaptation OK900 175 AA1, establish a gear wheel of 4th transfer and the bearing inner ring. |  | 2. Measure the clearance between the first gear transmission and differential gear drive. Nominal backlash: 0,05-0,28 mm |  | 3. Measure the clearance between the second gear and third gear. Nominal backlash: 0,10-0,22 mm | | 4. If backlashes do not correspond demanded, disassemble and reassemble the secondary shaft. |
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