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 printable version
Dismantling
 | During the dismantling, try to remember adjusting position of components filmed. This should simplify the subsequent assembly. |
Carburettor models 4.2 l | - Remove the transmission from the vehicle. Clean the outer surface of the assembly, making sure that the solvent does not hit in the clutch release bearing.
- Give fixing bolts and remove a transmission dome clutch release lever and release bearing assembly.
- Give fixing screws and remove the transmission housing top cover gasket (see. Accompanying illustration).
- Give fixing screws and a hammer with soft brisk remove the transmission housing casing extensions (see. Accompanying illustration). Remove the shell gland, and discard it.
- Remove the retaining ring, the holder and the C-shaped ring with the end of the driven shaft.
- Feeler blade, measure the gap behind the fifth-gear intermediate shaft. If the axial backlash is out of range (see. Table sizes and adjustments in the end of this manual), carefully check the ingredients of the fifth transmission (after the removal of the gearbox) for signs of wear.
The components of the intermediate shaft are shown in the accompanying illustration. - Remove the retaining ring and washer from the countershaft.
- Remove the locking plate of the intermediate shaft reverse gear.
- Turn on two simultaneous transmission to prevent rotation of the intermediate shaft and install dvuhzahvatny puller, head of his feet for the fifth gear. Remove the cone synchronizer, fifth gear, synchronizer assembly, shift fork and stem assembly. Remove the clutch fifth gear roller bearing.
| To avoid damage to the teeth, use fifth gear puller with wide jaws. |
- Give bolts and remove the transmission bearing retainer.
- With the help of a stripper to remove the output shaft rear output shaft bearing, fifth gear and spacer sleeve. If necessary, pull back the output shaft by hand to facilitate the installation of a stripper.
- Install bearing cage behind the clutch roller bearing fifth gear, tighten the bolts. With the help of a stripper remove the bearing sleeve from the intermediate shaft (see. Accompanying illustration) and remove the thrust washer, memorizing the installation position of the latter.
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- Install the locking plate of the intermediate shaft and the reverse gear retaining bolt.
- With the help of a stripper remove the bearing output shaft.
be fixed behind the retaining ring of the bearing outer race. When removing bearings are used as a stop block of wood. - Give fixing screws and remove the transmission front cover gasket. Remove the lid and discard oil seal with the gasket.
- Lightly tap the rear end of the intermediate shaft hammer with soft brisk and rotary-translational movement of the transmission housing, remove the outer race of the front bearing of the intermediate shaft.
- Gently tap the hammer with soft brisk on the front end of the intermediate shaft, remove the outer race of the rear bearing and lower intermediate shaft at the bottom of the transmission housing.
| To remove the outer ring of the rear bearing of the intermediate shaft may need a stripper. |
- Rotate the input shaft so that one of the flats of his gear synchronizer turned to the opening of the top cover Remove the input shaft bearing of the transmission housing.
- Remove the front end of the driven shaft guide bearing and synchronizer ring.
- Remove the assembly output shaft and the intermediate shaft of the transmission housing through the hole of the top cover.
The appearance of the output shaft assembly - Give a fixing bolt and remove the retaining plate countershaft reverse gear. Note the installation direction of the intermediate reverse gear and remove the shaft, gear, thrust washers, and roller bearings of the transmission housing.
- Remove the retaining ring and the spacer ring fixing the bearing on the input shaft (see. Accompanying illustration) with the help of the press, equipped with support plates, remove the bearing.
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- Feeler blade, measure the axial backlash of gears of the first, second and reverse gear on the driven shaft. The results of measurements record.
- To measure the endplay third speed gear clamp thereon the bearing retainer and firmly secure the dial gauge on the separator so that it rests on the plunger shaft end (see. Accompanying illustration). Move the gear back and forth and record the readings. If endplay gear is out of range (see. Table sizes and adjustments in the end of this manual), the driven shaft to disassemble components and carefully check the proper gear and its attendant components Replace defective parts.
- Disassemble the driven shaft to the components (see. Accompanying illustration):
- Remove the retaining ring from the front end of the driven shaft.
- Install bearing cage behind the third speed gear and remove it using the press to the base plate, then remove the shaft assembly 3/4 synchronizer gears and roller bearings. Note the installation direction of the synchronizer hub.
- Install the cage behind the second gear and with the help of a press, remove the shaft gear roller bearing and sleeve bearing.
- Remove the retaining ring on the shaft mounting 1/2 gear synchronizer hub.
- Set the output shaft in the press to the base plate, the last resting first gear and remove the shaft assembly 1/2 synchro transmission, first gear and roller bearing.
- Turn the output shaft, and rely on the support plates reverse gear. Remembering installation position of components, remove the shaft reverse gear, the synchronizer assembly and roller bearings.
 | - Disassemble the components of the assembly to the intermediate shaft (see. Illustration):
- Using a press, remove the bearing plates with an intermediate shaft inside the cage front and rear bearings.
- Remove the front end of the shaft retaining ring holder, the disc spring, the toothed ring and the ball.
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- If necessary, disassemble the components on the top cover (see the. Accompanying illustration):
- Give fixing screws and remove the casing of the gear selector from the top cover. Components of the casing of the selector shown in the accompanying illustration.
- Remove restrictive cap from the top of the selector housing, remove the spring and the ball. Remove the remaining stub and remove the spring and plunger, memorizing installation position of each of the components.
- Using a pin punch, remove the mounting bracket on the selector selector shaft.
- Turn the selector housing, give fixing bolts and remove the guide plate. Note the installation position of bolts.
- Knock out punch pin fastening lever on the selector shaft while removing the casing of a spherical cap. Knock selector shaft from the casing of the selector forward. Pick selector bracket and front cap.
- Remove the cover and remove the top cover fixing spring, and guide the ball.
- Remove the gauge-switch of fires of a backing.
- Using a hammer and a screwdriver, remove and discard the plug selector shaft.
- Remove the locking pins fork reverse gear and reverse gear selector lever. Remove selector shaft reverse gear, then remove the plug and the lever, memorizing their installation position. The top cover is removed from the casing of the selector is shown in the accompanying illustration.
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- Remove the fixing pin lever shock, remove the selector shaft, then memorizing installation position of the components, remove the top cover of the lever stroke, shock and fork lock switch. Internal components of the top cover are shown in the accompanying illustration.
- Remove the locking pin and remove the reverse gear control assembly.
- If necessary, disassemble the cover control lever unit
- Remove the clamps and push up the lever rubber protective cover.
- Remove the large retaining ring and remove it from the housing the gear shift lever and spring.
- Remove the retaining ring, pull the shift lever out of the slot and remove the rubber seat (see. Accompanying illustration).
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Models 4.2 liter EFI Dismantling the gearbox is done in the same manner as in models of 4.2 liters of gasoline based on the following changes. Components of output shaft are shown in the accompanying illustrations - in the insets show the synchronizer ring models of late years of release.
| - In step b) and e) of the driven shaft disassembly procedures should remember adjusting position of blocking rings of the synchronizer assemblies 2/3 transmission.
 | - To check the functioning of assemblies blocking rings of the synchronizer 2nd and 3rd gear, measure the clearance between the outer ring and the cone (see. Accompanying illustration) - its value does not exceed 0.2 mm, and between the inner ring and the cone (see. Accompanying illustration) - height difference should not exceed 0.2 mm.
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- When assembling the components of the driven shaft mount synchronizer ring 2nd and 3rd gear according to the made in the process of dismantling the memo.
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| On models with the release in October 1994 removed the remote plug input shaft front bearing and washer cone synchronizer of the intermediate shaft. |
L models 3.0 | - Remove the transmission assembly from the vehicle and clean it from the outside, making sure that the solvent does not hit the clutch release bearing.
- Pull the lever and clutch release bearing from the crankcase (dome) clutch.
- Remove the cap and remove the spring and ball control of the clutch lock, located on the wall of the dome of the clutch (components of the drive gear shown in the accompanying illustration).
Give a fixing bolt and remove the clutch retainer. Remove the O-ring and discard it.
| If the control spring and the ball is not removed before the removal of the sleeve when they may fall within the transmission. |
- If not removed before the spring and remove the ball from the hole in the interface of the housing with the housing elongation control gear lever.
- With knockout beat out a cylindrical pin bracket selector switch on the rod.
- Give fixing bolts and using a hammer with soft brisk remove the cover and lengthening of the bracket with the selector knob. Remove the casing of lengthening gland, discard it.
- Give fixing bolts and remove the top cover gasket, which thread the hole in the lever arm for the installation of the dome off the clutch. Remove the lid from the oil seal and discard it.
- Remove the retaining ring with the outer ring of the bearing to the input shaft and shift shaft. Remove from the stem washer.
- Propped on the back of the output shaft, the clutch dome separate from the carrier plate using a hammer with soft brisk. Remove the thrust bearing and shim from the front end of the intermediate shaft.
- Clamp carrier plate in a vice with soft sponges and give bolt rod of switching back / fifth gear to reverse gear fork. Remove the plunger from the carrier plate.
- Knockout knock the roll pin securing the shock lever and lock switch on the rod. Remove the switch from the rod carrier plate and remove the stroke lever and latch and shift fork 1/2, 3/4 and rear gear, remembering adjusting position of components.
- With the punch, remove the cylindrical pin attachment plug on the rod of the fifth transfer switch. Remove the stem and remove the fork.
- Feeler blade, measure the axial play of the gears of the first, second, third and rear gear on the driven shaft. Also, measure the axial play fifth gear on the intermediate shaft. If axial play any of the gears out of range (see. Table sizes and adjustments in the end of this manual), carefully check the relevant components for signs of wear, replace the defective parts.
- Remove the coupling hub of reverse gear, remember adjusting the direction of its landing. Remove the end of the output shaft retaining ring, and then use the hammer, remove the C-shaped retaining half rings (see. Illustration).
- Remove the retaining ring and washer from the rear end of the intermediate shaft, then using a stripper remove the bearing and reverse gear.
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- Set in a press intermediate shaft and remove the rear thrust bearing, remember adjusting the direction of its landing. Remove the retaining ring from the front end of the intermediate shaft, and then remove the plug, conical spring, toothed ring and ball.
- Remove the retaining ring and washer from the input shaft. Install the input shaft in the press, resting the bearing support plates and remove the latter.
- Using a suitable mandrel, remove the bearings from the carrier plate, the housing extension and the clutch housing.
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Assemble the gear lever
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