6.2.3. Repair of the transmission

Removal of the transmission
Removal of a box needs to be made in the following order:
- to install the car on a platform, the elevator or a viewing hole to provide convenient access to the transmission from below;
- to disconnect from the transmission the gear shifting lever for what from within a body to lift an external rubber sealant of a floor to the lever handle, to remove a rubber protective sealant from a gear shifting mechanism mouth cap, to turn off a cap and to take out the lever from a mouth up;
- to merge oil from the transmission;
- to disconnect the driveshaft from the transmission (see. "Cardan transfer");
- to disconnect a flexible cable of a wire of the switch of light of a backing and the sensor of speed from the transmission if there is no cable;
- to turn off two bolts of fastening of the working cylinder to a coupling case, to lift up the working cylinder with a pusher, without disconnecting it from the pipeline;
- to remove a coupling switching off fork;
— to turn off fastening bolts to a case of the transmission and pipes of the muffler and to remove a connecting arm of a suspension bracket of the muffler;
- to turn off nuts of fastening of a back support to the transmission;
- to disconnect a cross-piece from arms of longerons;
— to turn off nuts of hairpins of fastening of the transmission to a case of coupling and to remove the transmission together with the coupling switching off bearing.
Dismantling of the transmission
Dismantling of the transmission needs to be made in the following order:
— to remove the coupling with the bearing of switching off of coupling from a forward cover of the transmission;
- to remove porolonovy rings from a forward cover;
- to disconnect and remove a back support of the engine with a cross-piece;
- to turn out the backing light switch with laying;
- to turn out сапун;

Fig. 5.16. Otvorachivaniye of a bolt of fastening of an axis of an intermediate gear wheel of a backing on a forward case




- to turn off a bolt of fastening of the plug of an axis of the intermediate gear wheel of a backing located on the left side of a forward case (fig. 5.16);

Fig. 5.13. Transmission (longitudinal section): And — the two-conical synchronizer; 1 — a main shaft; 2 — a cover of the bearing of a main shaft; 3 — an epiploon; 4 — the ball bearing of a main shaft; 5 — a lock ring; 6 — the roller bearing of a secondary shaft; 7 — сапун; 8 — the blocking ring; 9 — the inclusion coupling; 10 — a synchronizer cracker; 11 — a nave of the coupling of inclusion of the 3rd, 4th transfers; 12 — a gear wheel of the 3rd transfer; 13 — the needle bearing of a gear wheel; 14 — a lock ring of half rings; 15 — a half ring; 16 — a gear wheel of the second transfer; 17 — a lock ring; 18 — a gear wheel of the 1st transfer; 19 — a secondary shaft; 20 — a backing gear wheel; 21 — a fork of inclusion of the 5th transfer and a backing; 22 — a nave of the coupling of inclusion of the 5th transfer and a backing; 23 — a bolt of fastening of a plate of a clamp; 24 — a plate; 25 — a spring of clamps; 26 — a ball of clamps; 27 — a spring of the blocking plug; 28 — the plug blocking; 29 — a head of a rod of inclusion of the 5th transfer and a backing; 30 — the switching lever case; 31 — a gear wheel of the 5th transfer; 32 — a washer persistent; 33 — the plug expansion; 34 — a transmission case back; 35 — an epiploon; 36 — an axis of an intermediate gear wheel of a backing; 37 — the needle bearing of an intermediate gear wheel of a backing; 38 — an intermediate gear wheel of a backing; 39 — a pin; 40 — a bolt of fastening of the plug of an axis of an intermediate gear wheel of a backing; 41 — the plug of an axis of an intermediate gear wheel of a backing; 42 — the ball bearing of a secondary shaft; 43 — a ring lock the bearing of a secondary shaft; 44 — a ring lock; 45 — the bearing; 46 — a stopper masloslivny; 47 — the block of gear wheels; 48 — a stopper oil-filling; 49 — a transmission case forward; 50 — adjusting laying




- to turn off bolts of a cover of the bearing of a main shaft 2 (see fig. 5.13) and to uncover;
- to remove laying between a cover and a case of the transmission;
- to remove a lock ring of the bearing of a main shaft;
- to turn off bolts of fastening of forward and back cases;

Fig. 5.17. Separation of forward and back cases




- to separate forward and back cases of the transmission, holding back and moving a forward case (influencing fastening ears to a coupling case) (fig. 5.17). At separation of cases not to influence at all an end face of a sock of a main shaft as it leads to damage of the synchronizer;
- to remove laying between forward and back cases;
- to take out from a nest in a forward case an external holder of the conic bearing;
- to take out from a nest under the bearing of the block of gear wheels in a forward case adjusting laying;
- to turn out from a forward case oil-filling and masloslivny traffic jams;
- to move a rod of inclusion of the 5th transfer and a backing in the provision of inclusion of a backing;
- to turn out lock bolts of fastening of three forks of gear shifting;
- to turn out bolts of fastening and to remove the gear shifting lever case;
- to remove laying of the case of the lever of gear shifting. Pins in a mouth of the case of the lever of switching and in the left sidewall, and also springs and safety locks without need it is not necessary to take out. If safety locks are jammed and badly come back under the influence of springs, then it is necessary to beat out their caps and to take out springs and safety locks from the case;
- to turn out bolts of fastening and to remove a plate of clamps of rods;
- to remove laying of a plate of clamps;
- to take out three springs and three balls of clamps of rods of gear shifting;
- to take out an opening cap under lock plungers on the left side of a back case of the transmission;
- to take out a rod of inclusion of the 5th transfer and a backing with a head;
- to remove a fork with crackers;
- to take out a lock plunger;
- to turn out a lock bolt and to remove from a rod of inclusion of the 5th transfer and a backing a head, the plug blocking and a spring of the blocking plug;
- to take out a rod of inclusion of the 1st and 2nd transfers with a head;
- to remove a fork with crackers;
- to turn out a lock bolt and to remove a head of switching off of the 1st and 2nd transfers from a rod;
- to take out a rod of inclusion of the 3rd and 4th transfers with a lock finger;
- to remove a fork with crackers;
- to take out a lock finger;
- to take out a lock plunger from a back case;
- to take out gear shifting forks from grooves of couplings;
- to turn off a bolt and to remove a stopper of fastening of the union of the conducted speedometer drive gear wheel;
- to take out the union and the conducted speedometer drive gear wheel from a back case;

Fig. 5.18. Otvorachivaniye of a bolt of fastening of an axis of an intermediate gear wheel of a backing on a back case




- to turn out a bolt of fastening of an axis of an intermediate gear wheel of a backing on the left side of a back case (fig. 5.18);

Fig. 5.19. Dismantle of a set of shaft and gear wheels from a back case




- through an opening under the gear shifting lever case (by means of nippers) to part moustaches of a lock ring of the ball bearing of a secondary shaft (at the same time the ring will be drowned in bore of a back case) and to vypressovat a secondary shaft assembled with the bearing from a nest in a back case, influencing a back end face of a secondary shaft (fig. 5.19). At the same time at the same time from a back crater there will be a vypressovka of the block of gear wheels to ball bearings (or to internal holders of conic bearings) and axes of an intermediate gear wheel of a backing assembled;
- to take out from a back case an external holder from the conic bearing;
- to take out from a set of the block of gear wheels an intermediate gear wheel with an axis assembled, a secondary and main shaft assembled.
Dismantling of a main shaft
Dismantling of a main shaft needs to be made in the following order:
- to mark the blocking synchronizer ring that at assembly to establish it on the former place;
- to take out rollers from a sock of a main shaft;
- to remove lock and spring rings of the ball bearing of a main shaft;
- to remove the ball bearing of a main shaft.
Dismantling of the block of gear wheels
For dismantling of the block of gear wheels it is necessary to press ball bearings or internal holders of conic bearings since the ends of an intermediate shaft of the block of gear wheels.
Dismantling of an axis of an intermediate gear wheel of a backing
It is necessary for dismantling of an axis of an intermediate gear wheel of a backing:
- to vypressovat a spring pin from an axis and the plug of an axis;
- to remove from an axis an intermediate gear wheel with bearing needles.
Dismantling of a secondary shaft
To make dismantling of a secondary shaft in the following order:
- to remove lock and spring rings of a nave of the 3rd and 4th transfers;
- to remove from a secondary shaft a nave and the coupling of inclusion of the 3rd and 4th transfers assembled with crackers and springs of the synchronizer for what, holding a shaft vertically, to strike with a shaft sock end face a wooden lining;
- to check existence of the combined tags on a nave and the coupling of inclusion of the 3rd and 4th transfers and if they are absent, to put tags that at assembly to establish these details in former situation;
- to remove the coupling of inclusion of the 3rd and 4th transfers from a nave;
- to take out synchronizer crackers (3 pieces);
- to take out from a synchronizer spring nave (2 pieces);
- to remove a gear wheel of the 3rd transfer with the blocking ring and the needle bearing;
- to remove the blocking ring from a gear wheel of the 3rd transfer;
- to mark the blocking ring that at assembly to establish it on the former place;
- to take out the needle bearing in a plastic separator;
- to mark it that at assembly to establish on the former place;
- to remove a lock ring of half rings of a secondary shaft;
- to remove two persistent half rings;
- to take out lock штиф;
- to remove a gear wheel of the 2nd transfer with the needle bearing and 3 rings of the synchronizer;
- to take out the needle bearing in a plastic separator and to mark it that at assembly to establish on the former place;
- to remove a lock ring from a secondary shaft;
- to remove from a secondary shaft a nave and the coupling of inclusion of the 1st and 2nd transfers assembled with crackers, springs of the synchronizer and with external, internal and average rings of the synchronizer for what, holding a shaft vertically, to strike it with a sock a wooden lining;
- to check existence of the combined tags on a nave and the coupling of inclusion of the 1st and 2nd transfers and if they are absent, to put tags that at assembly to establish these details in former situation;
— to remove the coupling of inclusion of the 1st and 2nd transfers from a nave;
- to take out synchronizer crackers;
- to take out from a synchronizer spring nave;
- to remove a gear wheel of the 1st transfer with the needle bearing;
- to take out the needle bearing in a plastic separator;
- to mark the bearing that at assembly to install it on the former place;
- to remove lock and spring rings of the leading gear wheel of the drive of a speedometer;
- to remove the leading gear wheel of the drive of a speedometer from a secondary shaft;
- to take out a lock ball of the leading gear wheel of the drive of a speedometer;
- to remove the ball bearing;
- to remove a persistent washer of the ball bearing;
- to remove from a secondary shaft a gear wheel of the 5th transfer with the blocking synchronizer ring, the needle bearing in a plastic separator and the expansion plug;
- to remove the blocking ring from a gear wheel of the 5th transfer; to mark the blocking ring that at assembly to establish it on the former place;
- to take out the needle bearing;
- to remove a lock ring of a nave of the coupling of inclusion of the 5th transfer and a backing;
- to remove from a secondary shaft a nave and the coupling of inclusion of the 5th transfer and backing assembled with crackers and springs of the synchronizer for what, holding a shaft vertically, to strike with an end face of a secondary shaft a wooden lining;
- to check existence of the combined tags on a nave and the coupling of inclusion of the 5th transfer and backing and if they are absent, then to put tags that at assembly to establish these details in former situation;
- to remove the coupling of inclusion of the 5th transfer and backing from a nave;
- to take out synchronizer crackers (3 pieces);
- to take out from a synchronizer spring nave (2 pieces);
- to remove a backing gear wheel with the blocking ring and the needle bearing;
- to remove the blocking ring from a backing gear wheel; to mark the blocking ring that at assembly to establish it on the former place;
- to take out the needle bearing in a plastic separator;
- to mark it that at assembly to establish on the former place.
Dismantling of the lever of switching
To make dismantling of the lever of switching as follows:
- to unscrew the handle and to remove a body floor sealant;
- to pull out a pricker the plastic locking plug and to take out the lower part of the lever of gear shifting from top;
- to remove rubber and plastic details of the anti-vibration device;
- to remove a cap sealant, a cap, a saddle of a spring and a spring.
Survey and control of technical condition of engines
After dismantling of a detail of the transmission it is necessary to wash out carefully then attentively to examine them for definition of lack of ruptures of laying, забоин and рисок on privalochny surfaces, a sminaniye and developments in nests under bearings, curvature of rods, iznos of a spherical head of the lever, cracks on a case and covers, injuries of bodies of swing and separators of bearings, a working edge of epiploons, zadir on the stalebabbitovy bearing of a back case, chips on side surfaces and end faces of teeths of gear wheels and gear wreaths of synchronizers, developments on cones, pitting on rollers, necks of a secondary shaft, zadir on persistent washers and openings in gear wheels, curvature of forks and rods of the mechanism of switching of transfer, considerable iznos on pads of forks of switching, zadir and agnails on rods, a razbaltyvaniye of pins and a sminaniye of an opening under them in a gear shifting mechanism mouth etc.
The damaged details need to be replaced.
Assembly of the transmission
Assembly of the transmission is carried out in the sequence, the return dismantling. At assembly it is necessary to consider the following. Each couple of gear wheels is selected at the noise plant therefore replacement of gear wheels can cause some increase in noise of the transmission.

Fig. 5.20. A set of rings of the synchronizer 1 — the 2nd transfers: 1 — an external ring; 2 — an average ring; 3 — internally a ring




At selection of rings of the synchronizer to cones of gear wheels of the 1st, 2nd, 3rd, 5th transfers, a backing and a main shaft it is necessary to pay attention to that rings densely adjoined to a cone surface. Rings need to be ground in to cones; the surface of contact of a ring with a cone has to be not less than 80%. External, average and internal rings of the two-conical synchronizer 1 — the 2nd transfers get used at the same time and after grinding in form not divided set (also as well as the ground-in gear wheels and rings of one-conical synchronizers of other transfers). In the set of rings of the two-conical synchronizer compressed under loading of 10 kg discrepancy of end faces And yes In (rice. 5.20) an external and internal ring from situation in one plane has to be within 0,1 mm.
The gap between an end face of an external ring and an end face of a pryamozuby wreath on gear wheels of the 3rd, 5th transfers, a backing and on primary to a shaft for new details has to be within 1,1 — 1,5 mm.
If conical gear wreaths of the synchronizer of the 3rd, 4th, 5th transfers and a backing were replaced, then it is necessary grinding assembled with a gear wheel to provide a beating of a cone of rather internal opening of a gear wheel no more than 0,025 mm.
Axial gaps of gear wheels of the 1st, 2nd, 3rd, 5th transfers and backing are in limits of 0,15 — 0,35 mm. They are provided structurally and do not demand adjustment.
The axial gap of the block of gear wheels has to be within 0,03 — 0,11 mm. It is provided with selection and installation of adjusting laying between an end face of an external holder of the bearing of the block and an end face of a nest under the bearing in a forward case.
To napressovat naves of couplings of switching to a secondary shaft assembled with couplings, crackers and springs of synchronizers. At statement of naves on a shaft it is necessary to pick up perhaps more dense nozzle.

Fig. 5.21. Installation of springs of the synchronizer




The switching couplings assembled with naves have to have a side gap in vents of 0,01 — 0,05 mm; this gap needs to be received individual selection at assembly, having provided at the same time easy axial movement of details. The unbent ends of both springs of synchronizers have to be located in one cracker, and rounds of springs have to be sent in different directions (fig. 5.21).
The Raznomernost of diameters of rollers of the bearing of the forward end of a secondary shaft, and also rollers of an intermediate gear wheel of a backing has to be no more than 0,005 mm.
Bearings should be napressovyvat on shaft, putting effort only to an internal ring of the bearing.
All details of the transmission have to be greased with a thin layer of gearbox oil, grooves of heads of switching — colloidal and graphitic medicine or solid oil, for convenience of assembly lubricant of roller bearings of the forward end of a secondary shaft and intermediate gear wheel of a backing, ball bearings, crackers and springs of synchronizers and other details by solid oil or konstaliny is allowed. New bearings should be installed in factory preservation.
Before assembly without fail to grease with solid oil or konstaliny the stalebabbitovy bearing of a back case and an edge of epiploons. At assembly of laying and fixing bolts it is necessary to grease with a thin layer of sealant paste.
The damaged laying needs to be replaced new.
At assembly of the transmission it is necessary to consider the sizes of the interfaced details of the transmission (tab. 5.3).

The sizes of the interfaced details of the transmission, mm

Assembly of the lever of gear shifting
It is necessary for assembly of the lever of gear shifting:
- to establish on the lower part of the lever of gear shifting consistently a spring, a spring saddle, a cap, a protective sealant, details of the anti-vibration device of the top and lower parts of the lever of switching, namely: locking plug, lower rubber pillow, expansion plug, top rubber pillow and persistent cone;
- to insert the subcollected lower part of the lever of switching into top and to fix by the locking plug;
- to put on a floor sealant the lever;
- to screw the handle on the lever.
Assembly of a main shaft
It is necessary for assembly of a main shaft:
- to napressovat the bearing on a neck of a main shaft;
- to establish spring and lock rings;
- to insert rollers into a sock of a main shaft (14 pieces);
- to establish the blocking synchronizer ring which is previously ground in with it on a cone of a main shaft.
Assembly of the block of gear wheels
It is necessary for assembly of the block of gear wheels:
- to napressovat removable wreaths of the block of gear wheels on an intermediate shaft. Before a napressovka of a gear wheel to heat in the furnace to temperature of 150 °C within 30 min., and to cool an intermediate shaft in artificial ice within 30 min.;
- to establish a lock ring;
- to napressovat on necks of an intermediate shaft ball bearings or internal holders with rollers of conic bearings, influencing at the same time an internal holder of the bearing.
Assembly of an axis of an intermediate gear wheel of a backing
It is necessary for assembly of an axis of an intermediate gear wheel of a backing:
- to insert needles into an opening of an intermediate gear wheel of a backing (21 pieces);
- to establish an intermediate gear wheel of a backing with needles on an axis;
- to install the axis plug on an axis;
- to turn the axis plug so that zakhodny openings with a facet under bolts of fastening of an axis in the plug and an axis in a head lay in one plane, and to press an elastic pin.
Assembly of a secondary shaft
It is necessary for assembly of a secondary shaft:
- to collect naves with crackers, springs of synchronizers and couplings of inclusion according to the instructions given above;
- to press a pin of a persistent washer of the ball-bearing of a secondary shaft in a secondary shaft. The region of a pin has to be located below the surface of a neck under a gear wheel of the 5th transfer;
- to establish the blocking synchronizer ring which is previously ground in with it on a backing gear wheel cone;
- to install in a backing gear wheel opening the needle bearing in a separator;
- to establish a backing gear wheel with the needle bearing and the blocking synchronizer ring on a secondary shaft;
- to napressovat on a secondary shaft a subcollected nave with the coupling of inclusion of the 5th transfer and backing; at a napressovka to watch that ledges of blocking synchronizer ring on a gear wheel of a backing entered nave grooves;
- to establish a lock ring of a nave of the 5th transfer and a backing;
- to establish the blocking synchronizer ring which is previously ground in with it on a cone of a gear wheel of the 5th transfer;
- to install in an opening of a gear wheel of the 5th transfer the needle bearing in a separator and the expansion plug;
- to establish a gear wheel of the 5th transfer with the needle bearing and the blocking synchronizer ring on a secondary shaft, at the same time to watch that ledges on the blocking ring entered nave grooves;
- to establish a persistent washer of the ball-bearing of a secondary shaft on a secondary shaft, watching that the pin pressed in a shaft entered grooves of a persistent washer; to napressovat the bearing;
- to insert a lock ball into a secondary shaft, to put on the leading gear wheel of the drive of a speedometer;
- to establish spring and lock rings;
- to install in an opening of a gear wheel of the 1st transfer the needle bearing in a separator;
- to establish a gear wheel of the 1st transfer with the needle bearing on a secondary shaft;
- to establish on a secondary shaft external, internal and average rings of the synchronizer, a subcollected nave with the coupling of inclusion of the 1st and 2nd transfers, crackers and springs. At installation to watch that:

Fig. 5.14. The two-conical synchronizer 1 — the 2nd transfers: 1 — the coupling; 2 — a nave; 3 — a secondary shaft; 4 — a gear wheel; 5 — a synchronizer cracker; 7 — a gear wheel of the 1st transfer; 8 — a ring internal; 9 — a ring average; 10 — a gear wreath; 11 — a ring external




• ledges of an average ring entered openings of a gear wreath (see fig. 5.14) the synchronizer on a gear wheel of the 1st transfer.
• ledges of an external ring of a snnkhronizator entered grooves of a gear wreath of a nave;
• short moustaches of an internal ring of the synchronizer entered flutes at a nave end face;
- to establish a lock ring;
- to insert into an opening of a gear wheel of the 2nd transfer the needle bearing in a separator;
- to establish external, internal and average rings of the synchronizer and the gear wheel of the 2nd transfer subcollected with the needle bearing on a secondary shaft. At installation to watch that:
• short moustaches of an internal ring of the synchronizer entered flutes at a nave end face;
• ledges of an average ring entered also openings of a gear wreath of the synchronizer on a gear wheel of the 1st transfer;
• ledges of an external ring of the synchronizer entered on grooves of a gear wreath of a nave;
- to insert a lock ball into a secondary shaft, to enclose two persistent half rings (slanting cuts of half rings have to be turned to a ball) in a flute and to establish on them a lock ring;
- to establish the blocking synchronizer ring which is previously ground in with it on a cone of a gear wheel of the 3rd transfer;
- to install in an opening of a gear wheel of the 3rd transfer the needle bearing in a separator;
- to put on a gear wheel of the 3rd transfer with the needle bearing and the blocking synchronizer ring a secondary shaft;
- to napressovat on a secondary shaft a subcollected nave with the coupling of inclusion of the 3rd and 4th transfers;
- at a napressovka to watch that ledges of the blocking ring on a gear wheel of the 3rd transfer entered nave grooves;
- to establish spring and lock rings of a nave of the coupling of inclusion of the 3rd and 4th transfers.
Subsequent assembly of the transmission
It is necessary for the subsequent assembly of the transmission:
- to press in a back case epiploons aflush with an end face of a mouth and an external holder of the back conic bearing of the block of gear wheels;
- to establish in a back case of the transmission, in a flute, a lock ring of the ball bearing of a secondary shaft;
- to install on subcollected secondary to a shaft the coupling of inclusion of the 5th transfer and backing to the provision of inclusion of a backing;
- to put on a subcollected main shaft a sock of a subcollected secondary shaft; at the same time it is necessary to watch that ledges of blocking synchronizer ring on primary to a shaft entered grooves of a nave of the coupling of inclusion of the 3rd and 4th transfers;

Fig. 5.22. Shaft and gear wheels of the transmission after their assembly




- to put to wreaths of the gear wheels connected primary and secondary by shaft, subassembled blocks of gear wheels and an axis of an intermediate gear wheel of a backing to a gear wheel, having formed a set for assembly (fig. 5.22). The axis of an intermediate gear wheel has to be turned lysky in a set.

Fig. 5.23. Connection by belts in a set of shaft and gear wheels




For convenience of further installation it is possible to pull together the turned-out set with belts (fig. 5.23);
- to establish in a vice vertically back case of the transmission with the established lock ring of the ball bearing of a secondary shaft;

Fig. 5.24. Installation of shaft of gear wheels in a back case




- to insert a set of shaft into a back case, to part the unbent ends of a lock ring and, holding them in such situation, to press in nests on a back case bearings of a secondary shaft and the block of gear wheels on a half of their length, influencing alternately an end face of a gear wheel of the 1st transfer and a forward end face of an intermediate shaft (fig. 5.24);
- to release the unbent ends of a lock ring and to dopressovat the bearing of a secondary shaft in a nest of a back case until the lock ring settles down at the same time in a flute in a back case and in a bearing flute. At the same time at the same time to dopressovat the bearing of the block of gear wheels against the stop in a wall of a nest of a back case;
- to establish on a bed in a back case an axis of an intermediate gear wheel of a backing assembled and to wrap (but not to the full) a fastening bolt;
- to enclose in grooves of couplings of switching of a fork of the corresponding transfers with crackers;

Fig. 5.25. A mandrel for installation of a lock plunger




- to establish a lock plunger of the mechanism of blocking between openings of a rod of inclusion of the 3rd and 4th transfers and a rod of the 1st and 2nd transfers; for convenience it is expedient to use a mandrel (fig. 5.25), consistently inserting it into openings under a rod of the 5th transfer and a backing and into an opening under a rod of the 3rd and 4th transfers;
- to establish a lock finger in a rod of inclusion of the 3rd and 4th transfers;
- to establish a rod of inclusion of the 3rd and 4th transfers with a blocking mechanism finger to an opening of a case and a head of a fork of inclusion of the 3rd and 4th transfers; to fix a fork on a rod by a lock bolt;
- to establish a head on a rod of inclusion of the 1st and 2nd transfers and to fix by a lock bolt;
- to insert a rod into an opening of a case and into a head of a fork of inclusion of the 1st and 2nd transfers, to fix a fork on a rod by a bolt;

Fig. 5.26. Installation of a lock plunger: 1 — a rod; 2 — a lock finger; 3 — a mandrel; 4 — a back case; 5 — small beards; 6 — a lock plunger




- to establish a lock plunger of 6 (fig. 5.26) of the mechanism of blocking against the stop in a rod of inclusion of the 3rd and 4th transfers; for convenience it is expedient to use a mandrel (see fig. 5.25);
- to establish a spring, the blocking plug, a head on a rod of inclusion of the 5th transfer and a backing and to fix by a lock bolt;
- to insert a rod of inclusion of the 5th transfer with a spring, the blocking plug and a head into an opening of a case and a head of a fork of inclusion of the 5th transfer and a backing, to fix a fork on a rod by a lock bolt; at the same time one unbent end of a spring of the blocking plug has to be inserted into an opening in a wall of a back case of the transmission, and another is brought to dredging of the blocking plug so that the mustache of the blocking plug was pressed to a head of a rod of inclusion of the 5th transfer and a backing;
- to move a rod of inclusion of the 5th transfer and a backing in neutral situation at which grooves in heads of all three rods coincide;
- to establish three balls and three springs of clamps of rods;
- to establish laying and a plate of clamps and to fix by fastening bolts;
- to press a cap in an opening under a plunger of the mechanism of blocking (fig. 5.26);
- to install the union and the conducted speedometer drive gear wheel in a back case;
- to establish a stopper of the union of a speedometer and to fix it by a bolt;
- to screw a magnetic oil-filling stopper in a forward case;
- to define a package of adjusting laying of the block of gear wheels.
Thickness of a package of laying of T has to be such that at assembly the tightness of conic bearings of the block of gear wheels within 0,03 — 0,11 mm was provided:
T = AND + WITH + H-B
(or a gap within 0,0 — 0,2 mm in case of installation of ball bearings: T = A+Z-V+S),
- where And — the actual size from a back privalochny end face of a forward case to a nest end face under the bearing in a forward case, mm; N (Z) — a tightness of conic bearings of the block of gear wheels within 0,03 — 0,11 mm:
T = AND + WITH + H-B
(or a gap within 0,0 — 0,2 mm in case of installation of ball bearings: T = A+Z-V+S); In — the actual size from a privalochny end face of a back case to an end face of an external holder of the forward bearing of the block of gear wheels (after installation of the block of gear wheels in a back case), mm; With — the settlement thickness of the paronitovy laying compressed between end faces of forward and back cases, equal 0,33 mm.
Further it is necessary to continue assembly of the transmission for what:
- to install a package of the picked-up laying in a nest of a forward case;
- to establish an external holder of the forward conic bearing of the block of gear wheels in a nest of a forward case;
- to establish in a vice the back case of the transmission subcollected with shaft in vertical position;
- to establish paronitovy laying on an end face of a forward case;

Fig. 5.27. Installation of a forward case




- holding constantly main shaft in extreme top situation (extending it up), to napressovat a forward case on ball bearings of a main shaft and the block of gear wheels, having combined adjusting plugs probes on a forward case with the corresponding openings in a back case of the transmission (fig. 5.27) (it is expedient to perform this operation together);
- to wrap 10 bolts of fastening of forward and back cases;
- to establish a lock ring in a flute of the ball bearing of a main shaft;
- to press an epiploon in a cover of the bearing of a main shaft against the stop;
- to put on on бурт covers of the ball bearing of a main shaft laying;
- to establish a cover of the ball bearing with laying of a main shaft and to fix by three bolts;
- to screw a bolt of fastening of an axis of an intermediate gear wheel of a backing in a forward case and to tighten a bolt of fastening it on a back case;
- to screw сапун in a forward case;
- to install laying on the backing light switch and to screw it in a forward case;
- to screw an oil-filling stopper;
- to establish laying and the case of the lever of gear shifting and to fix them by bolts.