Having unscrewed the bolts securing the forks on the gearshift rods, remove the rods and forks. Remove the axle and remove the intermediate reverse gear. Unscrew the bolts securing the gear selection mechanism (figure 82), they take it off.
The primary and secondary shafts are removed simultaneously (figure 83) from the roller bearings of the clutch housing, and then remove the differential (figure 84). If necessary, press out the outer rings of the shaft and differential bearings from the clutch and gearbox housings using mandrels 67.7853.9529/11 and 67.7853.95952. When pressing out the outer ring of the secondary shaft bearing, the oil collector 6 (see figure 77) is destroyed.
Turn out lever 5 (see figure 78) select gears from rod 6 and remove the rod from the clutch housing (figure 85). Unless necessary, do not remove the lever and joint from the gear selection rod, as they are installed with special TB-1324 glue.
If it is necessary to disassemble the secondary shaft, clamp it in a vice with soft material pads, hammer it out, then unscrew the nut and press the bearing off the shaft with a universal puller. Then remove the driven gears of the IV, III, II and I gears and synchronizer parts from the secondary shaft in the order shown in Figure 86.
Figure 86. Secondary shaft parts: 1 - nut; 2 - ball bearing; 3 - thrust washer; 4 — bearing sleeve; 5 — 4th gear pinion; 6 - synchronizer locking ring; 7— needle bearing; 8 — synchronizer clutch of III and IV gears; 9 — hub of synchronizer clutch of III and IV gears; 10 — third gear pinion; II - thrust ring of gears; 12 — 2nd gear pinion; 13 synchronizer hub for 1st and 2nd gears; 14 — synchronizer clutch of 1st and 2nd gears; 15 — 1st gear pinion; 16 - roller bearing; 17 — retainer spring; 18 - cracker; 19 retainer.
The synchronizer clutch hubs are removed using puller A.40005/1/6.
The differential is disassembled, for which:
- if it is necessary to replace the driven gear, unscrew its mounting bolts and remove gear 2 (figure 87) from the differential box;
- remove the axle gears 4 with washers 5 and satellites 10 from the differential box;
- if necessary, press bearings 9 off the differential case using stop 67.7853.9582 and a universal puller. The differential bearing on the side of the speedometer drive pinion is pressed off after removing pinion 7 using a special device that allows the pinion's locking tabs to be pressed off until they exit the differential case's annular groove.
Figure 87. Differential parts: 1 - differential bearing adjusting ring; 2 — driven gear of the main transmission; 3 — satellite axis, 4 — half-axle gear; 5 support washer; 6 — differential box; 7 — speedometer drive pinion; 8 — oil seal; 9 — differential bearing; 10 - satellite; 11 — retaining ring.
If necessary, disassemble the gear selection mechanism, for which unscrew the axle bolt 1 (figure 88) lever 3 and remove the axle from the housing 7 of the gear selection mechanism. In this case, the upper spring 5 of the lever, the thrust washer 4 and the gear selection lever 3 with the lower spring 2 are removed from the axle. The springs of the gear selection lever have different elasticity and to distinguish them, the lower spring has a coating (galvanizing), and the top one is uncoated.
Figure 88. Gear selection mechanism parts: 1 — gear selector lever axis; 2 - lower spring; 3 — gear selection lever; 4 — spring thrust washer; 5 - upper spring; 6 — reverse gear fork; 7 — gear selection mechanism housing; 8 — gear selection rod lever; 9 — gear selection rod; 10 — oil seal cage; 11 — oil seal.
Remove the retaining ring and take the axle with the reverse fork 6 out of the housing. If necessary, remove the speedometer drive by unscrewing its fastening nut and, holding the driven gear shaft, take out the speedometer drive.
Notes
1. A cylindrical mandrel, the punch of which has two belts with a diameter of 25 and 29 mm.
2. The mandrel has a diameter of 25 mm and a rectangular punch measuring 12 by 55 mm.