3.2.9. Repair of the transmission

Fig. 3.63. Removal of a plate from the leading shaft

Turn off bolts of a plate of the left case 1, and remove a plate of 2 (fig. 3.63).

Take out adjusting laying of bearings.

Fig. 3.64. Removal of a lock ring

Remove a lock ring 1 by means of the special tool (fig. 3.64).

Fig. 3.65. Bolts of clamps

Turn off bolts of clamps 1, then take out springs and steel balls (fig. 3.65).

Remove the backing light switch.

Turn off a bolt of a shaft of a backing 2 with a washer.

Fig. 3.66. Bolts of a case of the main transfer and shaft of a backing

Turn off bolts of a case of the main transfer 1 outside, and other bolts from the party of a case of coupling (fig. 3.66).

Remove the left case tapping with the plastic hammer on case ledges.

Take out a shaft of a gear wheel of a backing 1 with a washer 2, then remove a prmezhutochny gear wheel of a backing 3.

Turn off bolts of the lever of a backing 4 and remove the lever включениня a backing 5.

Fig. 3.67. Components of transfer of a backing

Take out a guide of switching of the 5th transfer and transfer of a backing 6 together with shaft of switching of the 5th transfer and transfer of a backing of 7 (fig. 3.67).

NOTE At removal of a shaft of switching of the 5th transfer and transfer of a backing 7 and a guide 6, lift a shaft of switching of overgears and establish it in the situation corresponding to inclusion of the 4th transfer that it was more convenient to remove a shaft of switching of the 5th transfer and transfer of a backing.

Fig. 3.68. Removal of the leading shaft, intermediate shaft and shaft of switching of overgears

Striking easy blows with the plastic hammer to the end of the leading shaft, nominate him assembled from the case a little, then take out the leading shaft 1, an intermediate shaft 2, a shaft of switching of overgears 3 and a shaft of switching of low gears 4 at the same time (fig. 3.68).

Remove an external ring of the left bearing of an intermediate shaft from the case.

Take out differential from the right case (for cars with the drive on two wheels).

Take out a side cover of bearing knot as follows (for cars with the drive on two wheels).

Turn off bolts of a side cover of bearing knot.

Fig. 3.69. Removal of a side cover of bearing knot

Turn a side cover of a bearing hub 1 counterclockwise against the stop and uncover, using 2 assembly shovels (fig. 3.69).

Fig. 3.70. Extraction of an external ring of the bearing of differential from the left case

Take out an external ring of the bearing of differential from the left case, using the special tool (fig. 3.70).

Fig. 3.71. Installation of the leading shaft, intermediate shaft and shaft of switching of overgears

Gather the leading shaft 5, an intermediate shaft 4, a shaft of switching of low gears 2 and a shaft of switching of overgears 3, and then install them in the right case 1 so that not to damage an epiploon vents of the leading shaft (fig. 3.71).

NOTE The right bearing of the leading shaft can be installed in the right case 1 by means of the plastic hammer. At installation be convinced that the intermediate shaft enters gearing with the main transfer.

Fig. 3.72. Installation of a shaft of switching of the 5th transfer and transfer of a backing from the 5th transfer directing to switchings and transfers of a backing to the right case

Install a shaft of switching of the 5th transfer and transfer of a backing 1 from the 5th transfer directing to switchings and transfer of a backing 2 in the right case 5. The lever of inclusion of transfer of a backing 4 needs to be attached to the lever 3 (fig. 3.72).

Fig. 3.73. Installation of an intermediate gear wheel of a backing

Establish an intermediate gear wheel of a backing 1 with the lever of inclusion of a backing 2, install a shaft of a gear wheel of a backing 3 in the right case 4 through an opening in an intermediate gear wheel, then combine "A" on a shaft with "B" in the case (fig. 3.73).

NOTE Make sure that the washer 5 was established on a shaft above a gear wheel. Make sure that between the end of the lever of inclusion of a backing and shaft of an intermediate gear wheel there is a gap of "a". Distance between the end of the lever and shaft of an intermediate gear wheel of "a": 0,5–1,0 mm.

Tighten bolts of the lever of inclusion of a backing after drawing on their carving parts of sealant for a carving.

Moment of an inhaling of a bolt of the lever of inclusion of a backing: 23 Nanometers.

Install differential in the right case (for cars with the drive on two wheels).

Fig. 3.74. Connection of cases of differential

Clear the interfaced surfaces of the right and left cases and evenly cover the interfaced surface of the left case with 1 sealant, after that connect the left case from right 2 (fig. 3.74).

Tighten case 3 bolts outside the nominal force of an inhaling.

Moment of an inhaling of a bolt of a case of the main transfer (b): 23 Nanometers.

Establish a bolt of a shaft of a backing 4, having covered its carving part with sealant, with an aluminum washer and tighten it.

Moment of an inhaling of a bolt of a shaft of a backing (c): 23 Nanometers.

Establish other bolts of fastening of the case from a case of coupling and tighten them.

Moment of an inhaling of a bolt of a case of the main transfer: 23 N · m.

Establish a side cover of bearing knot as follows (for cars with the drive on two wheels).

Fig. 3.75. Installation of an external ring of the bearing of differential

Install an external ring of the bearing of differential in the left case and press it, using the special tool and the plastic hammer (fig. 3.75).

ATTENTION You do not strike blows to a ring with the hammer. It can become the reason of damage of the bearing.

Pick up adjusting laying of the bearing of differential as follows.

Fig. 3.76. Scheme of selection of adjusting laying of the bearing of differential

Measure distance of "a" from the back surface of the left case 1 to an external ring of the bearing 2 by a depth gage (fig. 3.76).

Measure height of "b" of a cover of the side bearing by a depth gage.

Calculate a gap of "a" - "b" and choose adjusting laying according to the following table.

Install adjusting laying of the bearing of differential in the left case 3.

Fig. 3.77. Installation of laying of the bearing of differential

Apply oil on a new sealing ring of a cover of the side bearing 2 and install a bearing cover with a ring in the left case 3 (fig. 3.77).

Tighten bearing cover bolts 1 nominal force of an inhaling.

NOTE Establish a bearing cover by a tag 4 up.

Moment of an inhaling of a bolt of a cover of the bearing (a): 23 Nanometers.

Check springs (2, 4 and 5) for existence of damages and to replace them new if necessary.

Fig. 3.78. Installation of steel balls and springs

Establish steel balls 3 and springs (2, 4 and 5) for the corresponding shaft of gear shifting and tighten bolts 1 with sealant on a carving part (fig. 3.78).

Moment of an inhaling of a bolt of a clamp (a): 13 N · m.

Fig. 3.79. Installation of a new lock ring: 1 – lock ring; 2 – leading shaft; 3 – left bearing of the leading shaft

Establish a new lock ring 1 by means of the special tool (fig. 3.79).

For landing of an external ring of the left bearing of an intermediate shaft 2 use the special tool and the plastic hammer (fig. 3.79).

Fig. 3.80. Installation of an external ring of the left bearing of an intermediate shaft

Temporarily place adjusting laying 3 on an external ring of the bearing 4, establish a testing ruler on laying 1, press on a testing ruler and measure "a" (a gap between the surface of the case 5 and a testing ruler) by means of the probe 6 (fig. 3.80).

Gap between the surface of the case and the range "and": 0,08–0,12 mm.

Repeating the previous operation, pick up suitable adjusting laying which provides a necessary gap, and establish it on an external ring of the bearing.

NOTE Insert the probe 0,1 mm thick to be convinced whether really adjusting laying provides the required gap.

On hand there is following adjusting laying

Fig. 3.81. Installation of a plate of the left case: 3 – leading shaft; 5 – intermediate shaft

Establish a plate of the left case 2 having inserted its end into a flute of a guide of switching 4, then tighten bolts 1, previously cover a carving part of bolts with sealant for carvings (fig. 3.81).

NOTE After tightenings of bolts make sure that the intermediate shaft can be rotated a hand, feeling a certain loading.

Moment of an inhaling of a bolt of a plate of the left case (a): 23 Nanometers.