Interior view of the clutch housing
The red arrows indicate the nuts securing the clutch housing to the gearbox.
The white arrow indicates the hole in the front cover to drain the oil from the gearbox housing so that the clutch discs do not get oiled.
Interior view of the rear cover of the gearbox
1 - a screw with an eye for fastening the withdrawal spring of the gear lever; 2 - retracting spring of the lever; 3 – the lever of a gear change; 4 - screw limiting the transverse travel of the lever
The arrow indicates the direction in which you need to move the lever to disengage it from the heads of the gear rods and remove the rear cover of the gearbox.
Gearshift drive
1 – a fork of inclusion of a backing; 2 - retracting spring of the gear lever; 3 - guide cup of the lever; 4 - ball bearing of the lever; 5 - gearshift lever; 6 - spherical washer; 7 – lever spring; 8 - retaining ring; 9 - damper locking sleeve; 10 - elastic damper bushings; 11 - damper remote bushing; 12 – a persistent pillow of a damper; 13 – a core of the lever of a gear change; 14 – fork of inclusion of III and IV transfers; 15 – fork of inclusion of I and II transfers; 16 – a rod of a fork of inclusion of I and II transfers; 17 – a rod of a fork of inclusion of III and IV transfers; 18 – a rod of a fork of inclusion of a backing; 19 - block crackers; 20 - cover of clamps; 21 - bushing; 22 - retainer spring; 23 - lock ball; 24 – a back cover of a transmission; 25 - reverse lamp switch; 26 – the remote plug of a rod of a plug of a backing
Input shaft details
1 - retaining ring; 2 - spring washer; 3 - bearing; 4 - primary shaft; 5 - synchronizer spring; 6 – a blocking ring of the synchronizer; 7 - retaining ring; 8 - bearing
Output shaft details
1 - retaining ring; 2 - spring washer; 3 - synchronizer hub; 4 - synchronizer clutch; 5 - retaining ring; 6 – a blocking ring of the synchronizer; 7 - synchronizer spring; 8 - washer; 9 – gear wheel of III transfer; 10 - secondary shaft; 11 – gear wheel of the II transfer; 12 - washer; 13 - synchronizer spring; 14 - blocking ring; 15 - retaining ring; 16 - synchronizer hub; 17 - synchronizer clutch; 18 - retaining ring; 19 – a blocking ring of the synchronizer; 20 - synchronizer spring; 21 - washer; 22 - gear wheel of the 1st gear; 23 - bushing gear 1st gear; 24 - bearing; 25 - reverse gears; 26 - spring washer; 27 - retaining ring; 28 - speedometer drive gear; 29 - rear bearing; 30 - stuffing box; 31 – flexible coupling flange; 32 - nut; 33 - sealant; 34 - centering ring; 35 - retaining ring
Gear Lever Parts
1 – a bolt of a retracting spring; 2 - washer; 3 – withdrawal spring; 4 - gasket; 5 - guide cup; 6 - gasket; 7 - washer; 8 - restrictive bolt; 9 - gear lever; 10 - ball bearing; 11 - spherical washer; 12 - spring; 13 - support washer; 14 - retaining ring; 15 - gasket; 16 - flange; 17 - spring washer; 18 - nut; 19 - cuff; 20 - inner cover; 21 - lever rod; 22 - handle; 23 - thrust pad; 24 - elastic sleeve; 25 - remote bushing; 26 - elastic sleeve; 27 - locking sleeve
Disassembly
1. Rinse the gearbox and install it on the stand. Drain the oil and remove the bottom cover with gasket.
2. Remove the clutch release fork, and from the guide sleeve of the front cover of the gearbox - the clutch assembly with the bearing and the connecting spring.
3. Remove the clutch housing with gasket and transmission front cover (complete with seal and spring washer) (see fig. Interior view of the clutch housing).
4. Remove the speedometer drive with gasket and reverse light switch, being careful not to deform its housing.
5. Turn out a bolt of fastening of a plug of switching of III and IV transfers. Install clamp 41.7816.4068 on the input shaft or simultaneously engage two gears. This will prevent rotation of the input, output and intermediate shafts and allow subsequent disassembly operations.
6. Remove the circlip from the end of the transmission output shaft.
7. After unbending the lock washer, loosen the nut a few turns to move the centering ring of the elastic coupling, and tighten the nut again. Using extractor A.40006/1 with puller A.40005/4, remove the centering ring of the flexible coupling of the cardan shaft from the end of the secondary shaft.
8. Remove the centering ring seal of the flexible coupling from the end of the secondary shaft, unscrew the nut and remove the flange of the flexible coupling 1 with a puller 4 А.40005/3/9B/9 (2 - bolts for fastening the fixture to the flange; 3 - strip 9C of the puller A.40005 / 3).
9. Remove the gearbox rear cover by unscrewing its fastening nuts and screw 4 (see fig. Interior view of the rear cover of the gearbox) limiting the lateral travel of the lever, as well as by moving the shift lever to the left to free it from the shift rods.
10. Remove the rear bearing from the output shaft. Remove the speedometer drive gear.
11. Remove the fork with a spacer sleeve from the reverse gear rod, and the reverse idle gear from the axle.
12. Remove the reverse gear retaining ring from the countershaft; Remove gear and spring washer.
13. Remove the circlip of the reverse driven gear from the secondary shaft, pressing the spring washer with a mandrel 41.7816.4069 to relieve the load from the circlip. Remove the reverse driven gear and spring washer.
14. With the help of curly mandrels (screwdriver type) and rod drifts, remove the front and rear bearings of the intermediate shaft from the gearbox housing. On the inner rings of the double-row front bearing, put marks on which these rings should be installed in their original places in the outer ring of the bearing.
15. Remove the intermediate shaft from the gearbox housing by tilting it as shown in the figure.
16. Remove cover 20 (see fig. Gearshift drive) rod retainers together with the gasket, remove the springs and retainer balls. Remove the reverse rod 18, the rod 17 of the shift fork of III and IV gears from the gearbox housing. Turn away a bolt of fastening of a plug of I and II transfers, take out a rod and plugs. When removing the rods, simultaneously remove the three blocking crackers 19.
17. Loosen the screws securing the intermediate shaft intermediate bearing lock plate with a drill screwdriver and remove the intermediate shaft intermediate bearing lock plate and reverse intermediate gear shaft (the arrow shows the direction of the impact stroke of the screwdriver holder when struck with a hammer).
18. With mandrels (screwdriver type) remove the input shaft along with the bearing and synchronizer ring and remove the needle bearing from the front end of the output shaft.
19. Knock out the secondary shaft from the intermediate bearing, remove the intermediate bearing and, tilting as shown in the figure, remove the secondary shaft assembly from the crankcase with gears, clutches and synchronizer rings. Remove the 3rd and 4th gear synchronizer coupling from the shaft.
Disassembly of the input shaft
20. Remove retaining ring 7 (see fig. Input shaft details), blocking ring 6 and synchronizer spring 5.
21. Install the shaft on the press and, squeezing the spring washer 2 with the mandrel 41.7816.4069, remove the retaining ring 1, then the spring washer and bearing 3.
Dismantling the output shaft
22. Remove gear 22 from the rear side of the shaft (see fig. Output shaft parts) 1st gear with a sleeve 23, a hub 16 with a sliding clutch for switching 1st and 2nd gears, a gear 11 of the 2nd gear together with a blocking ring 14 of the synchronizer.
23. Install the output shaft with mandrel 41.7816.4069 on the press, place support half rings 3 under the gear of the III gear, and, pressing the mandrel on the spring washer, remove the retaining ring 2, then the spring washer 4, the hub of the sliding clutch of the III and IV gears and the gear of the III gear.
Dismantling the gear lever and rear cover
24. Remove cuff 19 (see fig. Gear Lever Parts), lever cover 20, then circlip 14, washer 13, spring 12 and spherical washer 11.
25. Unscrew the flange fastening nuts 16, disconnect the release spring 3 of the lever from the eye of the bolt 1 and remove the lever together with the flange, support 10 and cup 5.
Installation on the secondary shaft of the retaining ring of the reverse gear
1 - spring washer; 2 - mandrel 41.7816.4069; 3 - locking ring; 4 - reverse output shaft
Assembly
The gearbox is assembled in the reverse order of disassembly. In doing so, keep in mind that:
- spring 22 (see fig. Gearshift drive) the ball of the reversing fork rod retainer differs from others in elasticity, it is painted green or has a cadmium coating;
- when installing the clutch housing with the front cover of the gearbox, the hole in the front cover must be located as shown in fig. Internal view of the clutch housing;
- before installation, cover the working surface of the seals with LITOL-24 grease;
- when installing the reverse gear retaining ring, use mandrel 41.7816.4069, and when installing bearings and shaft seals, use mandrels 41.7853.4028, 41.7853.4032, 41.7853.4039.