Removing the flexible coupling flange with a puller А.40005/3/9B/9С
1 – flexible coupling flange; 2 - bolts for fastening the fixture to the flange; 3 - bar 9C of the puller A.40005/3; 4 - puller А.40005/3
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.
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 gear; 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 - cap; 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.
2. Drain the oil and remove the bottom cover with gasket.
3. 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.
4. Remove the clutch housing with gasket and gearbox front cover, along with oil seal and spring washer (see fig. Interior view of the clutch housing).
5. Remove the speedometer drive with gasket and reverse light switch, being careful not to deform its housing.
6. Turn out a bolt of fastening of a plug of switching of III and IV transfers.
7. 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.
8. Remove the circlip from the end of the transmission output shaft.
9. 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.
10. 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.
11. 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 with a puller A.4005/3/9B/9C (see fig. Removing the flexible coupling flange with a puller А.40005/3/9B/9С).
12. 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.
13. Remove the rear bearing from the output shaft. Remove the speedometer drive gear.
14. Remove the fork with a spacer sleeve from the reverse gear rod, and the reverse idle gear from the axle.
15. Remove the reverse gear retaining ring from the countershaft; Remove gear and spring washer.
16. 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.
17. Remove the reverse driven gear and spring washer.
18. With the help of curly mandrels (screwdriver type) and rod drifts, remove the front and rear bearings of the intermediate shaft from the crankcase of the transmission box. 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.
19. Remove the intermediate shaft from the gearbox housing by tilting it as shown in the figure.
20. 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.
21. Turn away a bolt of fastening of a plug of I and II transfers, take out a rod and plugs.
22. When removing the rods, simultaneously remove the three blocking crackers 19.
23. Remove the intermediate shaft bearing retainer plate and reverse idle gear shaft. The arrow shows the direction of the impact stroke of the screwdriver holder; use a hammer.
24. 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.
25. 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.
26. Remove the 3rd and 4th gear synchronizer coupling from the shaft.
27. Disassemble the input shaft (see fig. Input shaft details). To do this, remove the retaining ring 7, blocking ring 6 and synchronizer spring 5.
28. 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.
29. Disassemble the output shaft (see fig. Output shaft details). To do this, remove gear 22 with bushing 23, hub 16 with a sliding clutch for switching I and II gears, gear 11 of II gear together with the blocking ring 14 of the synchronizer from the rear side of the shaft.
30. Establish a secondary shaft with a mandrel 41.7816.4069 (1) on the press, place support half rings under the third gear gear (3), and, pressing the mandrel on the spring washer, remove the retaining ring (2), then spring washer (4), 3rd and 4th gear sliding clutch hub and 3rd gear gear (5 - press rod).
31. Disassemble the shift lever and the rear cover, remove the cover 20 (see fig. Gear Lever Parts) lever, then the retaining ring 14, washer 13, spring 12 and spherical washer 11.
32. Disconnect the release spring 3 of the lever from the eye of the bolt 1.
33. Remove the cuff 19, unscrew the flange fastening nuts 16 and remove the lever together with the flange, support 10 and cup 5.
Assembly
1. The gearbox is assembled in the reverse order of disassembly.
2. Please note that the spring 22 (see fig. Gearshift drive) The reversing fork stem detent ball is resilient, green or cadmium coated.
3. When installing the clutch housing with the front cover of the gearbox, the hole in the front cover must be located as shown in the figure Interior view of the clutch housing.
4. Before installation, cover the working surface of the oil seals with LITOL-24 grease.
5. When assembling the secondary and intermediate shafts, use mandrels 41.7853.4028, 41.7853.4032, 41.7853.4039.
6. When installing the reverse gear retaining ring, use drift 41.7816.4069 (2), as it shown on the picture (1 - snap ring, 3 - spring washer, 4 - output shaft reverse gear).