Primary and secondary shafts — disassembly and assembly

Removing the 5th gear, 5th gear synchronizer ring and needle bearing from the output shaft

Removal from the secondary shaft of the synchronizer 3-4 gears, synchronizer ring 3rd gear, gear 3rd gear and needle bearing

Removing the 2nd gear, needle bearing and 2nd gear synchronizer ring from the secondary shaft

Disassembly

1. Disconnect the input and output shafts.

2. Remove the 4th gear synchronizer ring and bearing.

3. Remove the 5th gear, synchronizer ring and needle bearing from the output shaft (see fig. Removing the 5th gear, 5th gear synchronizer ring and needle bearing from the output shaft).



4. From the other end of the output shaft, remove the 3-4 gear synchronizer set spring ring.

5. Remove assembly: 3rd-4th gear synchronizer, 3rd gear synchronizer ring, 3rd gear and needle bearing (see fig. Removal from the secondary shaft of the synchronizer 3-4 gears, synchronizer ring 3rd gear, gear 3rd gear and needle bearing).

Attention! Synchronizers should not be disassembled to maintain the correct position of all their parts.

6. Heat 3rd gear needle bearing ring to 100°C.




7. Using two screwdrivers, remove the 3rd gear needle bearing race.

8. Remove 2nd gear, needle bearing and 2nd synchronizer ring (see fig. Removing the 2nd gear, needle bearing and 2nd gear synchronizer ring from the secondary shaft).

Attention! Needle bearing rings for 2nd and 3rd gears should not be interchanged.

9. Remove the 1-2 gear synchronizer retaining ring.

10. Remove the 1st-2nd gear synchronizer, 1st gear synchronizer ring and gear, and needle bearing.

Attention! Synchronizers should not be disassembled in order not to change the relative position of their parts.

11. Unscrew the output shaft, remove the 5th and reverse gear synchronizer snap ring, remove the reverse gear and needle bearing.

Examination

1. The teeth of the gears and synchronizers must not be chipped or excessively worn, and the surfaces of the teeth must not show signs of scuffing.

2. It should be checked whether the synchronizer hubs are chipped and whether they move without excessive clearances and jamming.

3. The needle bearing should be replaced if there are obvious scratches on the surface, or if there are excessive clearances or signs of wear.

Assembly

Attention! Synchronizers for 1-2 gears, 5th gear and reverse gear are identical, but they must not be interchanged when assembling the gearbox.

When assembling, lubricate all elements, especially the synchronizer rings and the needle bearing, with the oil used for the gearbox.

1. Install the needle bearing and reverse gear onto the output shaft.

2. Install the synchronizer ring and the 5th and reverse gear synchronizer.

3. Install a new set spring ring.

4. Rotate output shaft and install needle bearing and 1st gear.

5. Install the 1st synchro ring, 1st-2nd synchro, and a new set circlip.

6. Install the 1st synchronizer ring, needle bearing and 2nd gear.

7. Heat 3rd gear needle bearing ring to 100°C.

8. Slide the hot ring onto the output shaft.

Attention! The needle bearing ring must be inserted as far as it will go. A new needle bearing must be used during installation.

9. After the ring has cooled, install the needle bearing and 3rd gear.

10. Insert the 3-4 gear synchronizer assembly (shorter side up) and a new set spring ring.

11. Rotate the shaft and install the 5th synchronizer ring, needle bearing and 5th gear.

12. Install 4th gear synchronizer ring and bearing.

13. Connect the secondary and primary shafts.