- To remove a lining between a cover and картером transmissions;

- To remove a lock ring of the bearing of a primary shaft;

- To turn away bolts of fastening forward and back картеров;

Fig. 5.17. Separation forward and back картеров

- To separate forward and back картеры transmissions, keeping back and moving forward картер (influencing fastening ears to картеру couplings) (fig. 5.17). At separation картеров not to influence at all an end face of a sock of a primary shaft as it leads to synchronizer damage;

- To remove a lining between forward and back картерами;

- To take out from a nest in forward картере an external holder of the conic bearing;

- To take out from a nest under the bearing of the block of gear wheels in forward картере adjusting linings;

- To turn out from forward картера маслоналивную and маслосливные stoppers;

- To move a rod of inclusion of 5th transfer and a backing in position of inclusion of a backing;

- To turn out lock bolts of fastening of three plugs of a gear change;

- To turn out bolts of fastening and to remove the case of the lever of a gear change;

- To remove a lining of the case of the lever of a gear change. In a mouth of the case of the lever of switching and in the left lateral wall, and also springs and safety locks without need it is not necessary to take out pins. If safety locks заедают and badly come back under the influence of springs it is necessary to beat out them заглушки and to take out springs and safety locks from the case;

- To turn out bolts of fastening and to remove a plate of clamps of rods;

- To remove a lining of a plate of clamps;

- To take out three springs and three balls of clamps of rods of a gear change;

- To take out заглушку apertures under lock плунжеры on the left side of back картера transmissions;

- To take out a rod of inclusion of 5th transfer and a backing with a head;

- To remove a plug with crackers;

- To take out lock плунжер;

- To turn out a lock bolt and to remove from a rod of inclusion of 5th transfer and a backing a head, the plug blocking and a spring of the blocking plug;

- To take out a rod of inclusion of 1st and 2nd transfers with a head;

- To remove a plug with crackers;

- To turn out a lock bolt and to remove from a rod a head of deenergizing of 1st and 2nd transfers;

- To take out a rod of inclusion of 3rd and 4th transfers with a lock finger;

- To remove a plug with crackers;

- To take out a lock finger;

- To take out lock плунжер from back картера;

- To take out plugs of a gear change from grooves муфт;

- To turn away a bolt and to remove a stopper of fastening of the union of a conducted gear wheel of a drive of a speedometer;

- To take out from back картера the union and a conducted gear wheel of a drive of a speedometer;

Fig. 5.18. Отворачивание a bolt of fastening of an axis of an intermediate gear wheel of a backing on back картере

- To turn out a bolt of fastening of an axis of an intermediate gear wheel of a backing on the left side of back картера (fig. 5.18);

Fig. 5.19. Dismantle of the complete set of shaft and gear wheels from back картера

- Through an aperture under the case of the lever of a gear change (by means of nippers) to dissolve moustaches of a lock ring of the ball bearing of a secondary shaft (thus the ring will be drowned in bore back картера) and выпрессовать a secondary shaft in gathering with the bearing from a nest in back картере, influencing a back end face of a secondary shaft (fig. 5.19). Thus simultaneously from a back crater will occur выпрессовка the block of gear wheels to ball bearings (or with internal holders of conic bearings) and axes of an intermediate gear wheel of a backing in gathering;

- To take out from back картера an external holder from the conic bearing;

- To take out from the complete set of the block of gear wheels an intermediate gear wheel with an axis in gathering, a secondary and primary shaft in gathering.

Dismantling of a primary shaft

Dismantling of a primary shaft is necessary for making in a following order:

- To mark blocking ring of the synchronizer that at assemblage to establish it on a former place;

- To take out rollers from a sock of a primary shaft;

- To remove lock and spring rings of the ball bearing of a primary shaft;

- To remove the ball bearing of a primary shaft.

Dismantling of the block of gear wheels

For dismantling of the block of gear wheels it is necessary to press ball bearings or internal holders of conic bearings from the ends of an intermediate shaft of the block of gear wheels.

Dismantling of an axis of an intermediate gear wheel of a backing

For dismantling of an axis of an intermediate gear wheel of a backing it is necessary:

- выпрессовать a spring pin from an axis and the axis plug;

- To remove from an axis an intermediate gear wheel with bearing needles.

Dismantling of a secondary shaft

Dismantling of a secondary shaft to make in a following order:

- To remove lock and spring rings of a nave of 3rd and 4th transfers;

- To remove from a secondary shaft a nave and муфту inclusions of 3rd and 4th transfers in gathering with crackers and synchronizer springs for what, keeping a shaft vertically, to strike an end face of a sock of a shaft on a wooden lining;

- To check up presence of the combined labels on a nave and муфте inclusions of 3rd and 4th transfers and if they are not present, to put labels that at assemblage to establish these details in former position;

- To remove from a nave муфту inclusions of 3rd and 4th transfers;

- To take out synchronizer crackers (3 pieces);

- To take out from a nave of a spring of the synchronizer (2 pieces);

- To remove a gear wheel of 3rd transfer with a blocking ring and the needle bearing;

- To remove blocking ring from a gear wheel of 3rd transfer;

- To mark blocking ring that at assemblage to establish it on a former place;

- To take out the needle bearing in a plastic separator;

- To mark it that at assemblage to establish on a former place;

- To remove a lock ring of half rings of a secondary shaft;

- To remove two persistent half rings;

- To take out lock штиф;

- To remove a gear wheel of 2nd transfer with the needle bearing and 3 rings of the synchronizer;

- To take out the needle bearing in a plastic separator and to mark it that at assemblage to establish on a former place;

- To remove from a secondary shaft a lock ring;

- To remove from a secondary shaft a nave and муфту inclusions of 1st and 2nd transfers in gathering with crackers, springs of the synchronizer and with external, internal and average rings of the synchronizer for what, keeping a shaft vertically, to strike its sock on a wooden lining;

- To check up presence of the combined labels on a nave and муфте inclusions of 1st and 2nd transfers and if they are not present, to put labels that at assemblage to establish these details in former position;

— To remove from a nave муфту inclusions of 1st and 2nd transfers;

- To take out synchronizer crackers;

- To take out from a nave of a spring of the synchronizer;

- To remove a gear wheel of 1st transfer with the needle bearing;

- To take out the needle bearing in a plastic separator;

- To mark the bearing that at assemblage to establish it on a former place;

- To remove lock and spring rings of a leading gear wheel of a drive of a speedometer;

- To remove from a secondary shaft a leading gear wheel of a drive of a speedometer;

- To take out a lock ball of a leading gear wheel of a drive of a speedometer;

- To remove the ball bearing;

- To remove a persistent washer of the ball bearing;

- To remove from a secondary shaft a gear wheel of 5th transfer with a blocking ring of the synchronizer, the needle bearing in a plastic separator and распорной the plug;

- To remove blocking ring from a gear wheel of 5th transfer; to mark blocking ring that at assemblage to establish it on a former place;

- To take out the needle bearing;

- To remove a lock ring of a nave муфты inclusions of 5th transfer and a backing;

- To remove from a secondary shaft a nave and муфту inclusions of 5th transfer and a backing in gathering with crackers and synchronizer springs for what, keeping a shaft vertically, to strike an end face of a secondary shaft on a wooden lining;

- To check up presence of the combined labels on a nave and муфте inclusions of 5th transfer and a backing, and if they are not present to put labels that at assemblage to establish these details in former position;

- To remove from a nave муфту inclusions of 5th transfer and a backing;

- To take out synchronizer crackers (3 pieces);

- To take out from a nave of a spring of the synchronizer (2 pieces);

- To remove a gear wheel of a backing with a blocking ring and the needle bearing;

- To remove blocking ring from a backing gear wheel; to mark blocking ring that at assemblage to establish it on a former place;

- To take out the needle bearing in a plastic separator;

- To mark it that at assemblage to establish on a former place.

Dismantling of the lever of switching

Dismantling of the lever of switching to make as follows:

- To turn away the handle and to remove a body floor sealant;

- To pull out шилом plastic запорную the plug and to take out the bottom part of the lever of a gear change from the top;

- To remove rubber and plastic details of the antivibrating device;

- To remove a cap sealant, a cap, a saddle of a spring and a spring.

Survey and the control of a technical condition of engines

After dismantling of a detail of a transmission it is necessary to wash out carefully then attentively to examine them for definition of absence of ruptures of linings, забоин and рисок on привалочных surfaces, сминания and developments in nests under bearings, curvature of rods, износов a spherical head of the lever, cracks on картере and covers, damages of bodies качения and separators of bearings, a working edge of epiploons, задиров on сталебаббитовом the bearing back картера, having chopped off on lateral surfaces and end faces of teeths of gear wheels and gear wreaths of synchronizers, developments on cones, питтинга on rollers, necks of a secondary shaft, задиров on persistent washers and apertures in gear wheels, curvature of plugs and rods of the mechanism of switching of transfer, considerable износов on pads of plugs of switching, задиров and agnails on rods, разбалтывания pins and сминания apertures under them in a mouth of the mechanism of a gear change etc.

It is necessary to replace the damaged details.

Transmission assemblage

Transmission assemblage is carried out in sequence, return dismantling. At assemblage it is necessary to consider the following. Each pair of gear wheels steals up at factory on noise, therefore replacement of gear wheels can cause some increase in noise of a transmission.

Fig. 5.20. The complete set of rings of the synchronizer of 1st — 2nd transfers: 1 — an external ring; 2 — an average ring; 3 — internally a ring

At selection of rings of the synchronizer to cones of gear wheels of 1st, 2nd, 3rd, 5th transfers, a backing and a primary shaft it is necessary to pay attention to that rings densely adjoined to a cone surface. Rings are necessary for grinding in to cones; the surface of contact of a ring with a cone should be not less than 80 %. External, average and internal rings двухконусного the synchronizer of 1-1-2nd transfers get used simultaneously and after grinding in form not divided complete set (also as well as the ground in gear wheels and rings одноконусных synchronizers of other transfers). In 10 kg compressed under loading the complete set of rings двухконусного the synchronizer discrepancy of end faces And and In (pиc. 5.20) an external and internal ring from position in one plane should be within 0,1 mm.

The backlash between an end face of an external ring and an end face прямозубого a wreath on gear wheels of 3rd, 5th transfers, a backing and on primary to a shaft for new details should be within 1,1—1,5 mm.

If were replaced конусные gear wreaths of the synchronizer of 3rd, 4th, 5th transfers and a backing it is necessary polishing in gathering with a gear wheel to provide palpation of a cone concerning an internal aperture of a gear wheel no more than 0,025 mm.

Axial backlashes of gear wheels of 1st, 2nd, 3rd, 5th transfers and backing are in limits of 0,15-0,35 mm. They are provided structurally and adjustment do not demand.

The axial backlash of the block of gear wheels should be within 0,03—0,11 mm. It is provided with selection and installation of adjusting linings between an end face of an external holder of the bearing of the block and a nest end face under the bearing in forward картере.

Naves муфт switchings напрессовать on a secondary shaft in gathering with муфтами, crackers and springs of synchronizers. At statement of naves on a shaft it is necessary to pick up probably more dense nozzle.

Fig. 5.21. Installation of springs of the synchronizer

Муфты the switchings collected with naves, should have a lateral backlash in шлицах 0,01—0,05 mm; this backlash is necessary for receiving individual selection at assemblage, having provided thus easy axial moving of details. The unbent ends of both springs of synchronizers should be located in one cracker, and coils of springs should be directed every which way (fig. 5.21).

Разномерность diameters of rollers of the bearing of the forward end of a secondary shaft, and also rollers of an intermediate gear wheel of a backing should be no more than 0,005 mm.

Bearings follows напрессовывать on shaft, putting effort only to an internal ring of the bearing.

All details of a transmission should be greased by a thin layer трансмиссионного oils, grooves of heads of switching — a kolloidno-graphitic preparation or солидолом, for convenience of assemblage greasing of roller bearings of the forward end of a secondary shaft and an intermediate gear wheel of a backing, ball bearings, crackers and springs of synchronizers and other details солидолом or консталином is supposed. New bearings should be established in factory preservation.

Before assemblage without fail to grease солидолом or консталином сталебаббитовый the bearing back картера and an edge of epiploons. At assemblage of a lining and fixing bolts it is necessary to grease with a thin layer of paste "hermetic".

It is necessary to replace the damaged linings new.

At transmission assemblage it is necessary to consider the sizes of interfaced details of a transmission (tab. 5.3).

The sizes of interfaced details of a transmission, mm

Assemblage of the lever of a gear change

For assemblage of the lever of a gear change it is necessary:

- To establish on the bottom part of the lever of a gear change consistently spring, a spring saddle, a cap, a protective sealant, details of the antivibrating device of the top and bottom parts of the lever of switching, namely: запорную the plug, the bottom rubber pillow, распорную the plug, the top rubber pillow and a persistent cone;

- To insert подсобранную the bottom part of the lever of switching in top and to fix запорной the plug;

- To put on the lever a floor sealant;

- To screw on the lever the handle.

Assemblage of a primary shaft

For assemblage of a primary shaft it is necessary:

- напрессовать the bearing on a neck of a primary shaft;

- To establish spring and lock rings;

- To insert rollers into a sock of a primary shaft (14 pieces);

- To establish on a cone of a primary shaft blocking ring of the synchronizer preliminary ground in with it.

Assemblage of the block of gear wheels

For assemblage of the block of gear wheels it is necessary:

- напрессовать demountable wreaths of the block of gear wheels on an intermediate shaft. Before напрессовкой gear wheels to heat up in the furnace to temperature 150 ° C within 30 minutes, and an intermediate shaft to cool in dry ice within 30 minutes;

- To establish a lock ring;

- напрессовать on necks of an intermediate shaft ball bearings or internal holders with rollers of conic bearings, influencing thus an internal holder of the bearing.

Assemblage of an axis of an intermediate gear wheel of a backing

For assemblage of an axis of an intermediate gear wheel of a backing it is necessary:

- To insert needles into an aperture of an intermediate gear wheel of a backing (21 pieces);

- To establish an intermediate gear wheel of a backing with needles on an axis;

- To establish on an axis the axis plug;

- To turn the axis plug so that заходные apertures with a facet under bolts of fastening of an axis in the plug and an axis in a head lay in one plane, and запрессовать an elastic pin.

Assemblage of a secondary shaft

For assemblage of a secondary shaft it is necessary:

- To collect naves with crackers, springs of synchronizers and муфтами inclusions according to the instructions resulted above;

- запрессовать in a secondary shaft a pin of a persistent washer of the ball-bearing of a secondary shaft. The pin edge should settle down below a neck surface under a gear wheel of 5th transfer;

- To establish on a cone of a gear wheel of a backing blocking ring of the synchronizer preliminary ground in with it;

- To establish in an aperture of a gear wheel of a backing the needle bearing in a separator;

- To establish a gear wheel of a backing with the needle bearing and a blocking ring of the synchronizer on a secondary shaft;

- напрессовать on a secondary shaft подсобранную a nave with муфтой inclusions of 5th transfer and a backing; at напрессовке to watch, that ledges of a blocking ring of the synchronizer on a backing gear wheel have entered into nave grooves;

- To establish a lock ring of a nave of 5th transfer and a backing;

- To establish on a cone of a gear wheel of 5th transfer blocking ring of the synchronizer preliminary ground in with it;

- To establish in an aperture of a gear wheel of 5th transfer the needle bearing in a separator and распорную the plug;

- To establish a gear wheel of 5th transfer with the needle bearing and a blocking ring of the synchronizer on a secondary shaft, thus to watch, that ledges on a blocking ring have entered into nave grooves;

- To establish on a secondary shaft a persistent washer of the ball-bearing of a secondary shaft, watching that запрессованный in a shaft the pin has entered into grooves of a persistent washer; напрессовать the bearing;

- To insert into a secondary shaft a lock ball, to put on a leading gear wheel of a drive of a speedometer;

- To establish spring and lock rings;

- To establish in an aperture of a gear wheel of 1st transfer the needle bearing in a separator;

- To establish a gear wheel of 1st transfer with the needle bearing on a secondary shaft;

- To establish on a secondary shaft external, internal and average rings of the synchronizer, подсобранную a nave with муфтой inclusions of 1st and 2nd transfers, crackers and springs. At installation to watch, that:

Fig. 5.14. The Dvuhkonusnyj synchronizer of 1st — 2nd transfers: 1 — муфта; 2 — a nave; 3 — a secondary shaft; 4 — a gear wheel; 5 — a synchronizer cracker; 7 — a gear wheel of 1st transfer; 8 — a ring internal; 9 — a ring an average; 10 — a gear wreath; 11 — a ring external

• ledges of an average ring have entered into apertures of a gear wreath (fig. 5.14 see) synchronizer on a gear wheel of 1st transfer.