Contents: Cleaning ↓ Crankcase and covers ↓ Seal ↓ Shafts ↓ Gears ↓ Bearings ↓ Rods and forks ↓ Hubs, clutches and synchronizer…↓
Before inspection, thoroughly clean the gearbox parts. Use a brush or scraper to remove all deposits and clean the holes and splines from possible contamination; then rinse to remove and dissolve all remaining oil.
Blow the parts with a stream of compressed air and wipe them carefully. Blow the bearings especially carefully, directing the stream of compressed air so that the rings do not rotate quickly.
Cleaning
Before inspection, thoroughly clean the gearbox parts. Use a brush or scraper to remove all deposits and clean the holes and splines from possible contamination; then rinse to remove and dissolve all remaining oil.
Blow the parts with a stream of compressed air and wipe them carefully. Blow the bearings especially carefully, directing the stream of compressed air so that the rings do not rotate quickly.
Crankcase and covers
There should be no cracks on the crankcase, and no wear or damage on the surface of the bearing bores.
There should be no damage to the mating surfaces with the clutch housing, rear and lower covers to prevent axle separation and insufficient sealing, causing oil leakage. Smooth out minor damage with a file. If the parts are too damaged or worn, replace them with new ones.
Check the condition of the front cover and make sure that the primary shaft does not touch it when rotating. If misalignment of the shaft and cover is detected, replace the damaged parts. Check whether the oil drain hole in the primary shaft cover is clogged (shown by the arrow in Fig. Internal view of the clutch housing). Clean the drain plug.
Seal
Check the seals and ensure that there is no damage, unacceptable wear or unevenness on the working edges of the seals.
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The wear of the working edges of the seals in width is allowed to be no more than 1 mm. If even a minor defect is detected, replace the seals with new ones.
Shafts
The working surfaces and splines of the secondary shaft must not be damaged or subject to excessive wear; the flange of the flexible coupling must slide freely without jamming on the splines. There must be no roughness or burrs on the rolling surfaces of the needles at the front end of the shaft.
Check the condition of the rolling surfaces of the needles in the bore of the primary shaft.
Check the intermediate shaft for chipping or excessive tooth wear.
The surface of the reverse gear pinion axle must be completely smooth, without any signs of seizure. The mounting clearance between the axle and the intermediate reverse gear bushing is 0.056–0.09 mm, the maximum permissible clearance is 0.15 mm. Check the clearance by measuring the diameters of the axle and the gear bushing. The diameters of new parts are:
- gear axis – 19.9+0,094–0,079 mm;
- inner diameter of pressed bushing – 20+0,07-0,05 mm.
Remove minor irregularities on the surfaces with fine sandpaper; in case of major damage and deformation, replace the shaft with a new one.
Gears
There should be no damage or excessive wear of the teeth on the gears. Pay special attention to the condition of the ends of the teeth on the synchronizer rings.
The contact patch of the gear teeth must be located over the entire working surface, which must be smooth and without signs of wear. Check the engagement gap between the gears, the installation value of which must be 0.10 mm; wear limit – gap 0.20 mm.
The mounting clearance between the sleeve and the 1st gear pinion and between the secondary shaft and the 2nd and 3rd gear pinions should be 0.05–0.10 mm; wear limit – gap 0.15 mm.
If wear exceeds permissible limits, replace the gears with new ones.
Bearings
Ball or roller bearings must be in perfect condition. Their radial clearance must not exceed 0.05 mm.
Pressing the inner ring to the outer ring with your fingers, rotate one of them in both directions, the rolling should be smooth. No damage is allowed on the surface of the balls or rollers and the raceways of the rings. Replace damaged bearings with new ones. When replacing the front bearing of the primary shaft, use the A.40006 pusher (see Fig. subsection 4.3); in this case, the flywheel does not need to be removed.
Rods and forks
Deformation of the gear shift forks is not allowed. The rods must slide freely without significant clearance in the crankcase holes.
Check the condition of the rod locking crackers, springs and locking balls. Replace parts that show signs of seizing or wear with new ones.
Hubs, clutches and synchronizer locking rings
Check for signs of seizing on the hubs of the I–II and III–IV gear engagement clutches, especially on the sliding surfaces of the clutches.
Pay special attention to the condition of the ends of the coupling teeth.
Excessive wear of the surface of the locking rings is not allowed. They must be replaced if their end is resting against the synchronizer clutch. Any possible irregularities that prevent free sliding should be removed with a velvet file. Replace parts that are worn beyond the permissible limits with new ones.