3.1.3. Repair

Coupling on cars with engines of fashion. 420.10-10, 421.10-10 and 4213.10
 Replacement of the coupling with the coupling switching off bearing
1. Install the car on a platform or a viewing hole for access from below to the transmission and coupling.
2. Remove from the car a box of transfers (see the head "A box of transfers").

Fig. 180. Coupling of engines 420.10-10, 421.10-10 and 4213.10: 1 – coupling switching off bearing fork; 2 – coupling switching off bearing coupling; 3 – coupling switching off bearing; 4 – casing of a press disk; 5 – press disk; 6 – lower part of a case of coupling; 7 – stopper; 8 – flywheel of a bent shaft; 9 – the conducted disk; 10 – press spring; 11 – forward bearing of a main shaft of the transmission; 12 – bent shaft; 13 – main shaft of the transmission; 14 – quencher of tortional fluctuations; 15 – coupling case; 16 – forward cover


3. Take out the coupling 2 (see fig. 180) with the bearing 3 switching off of coupling from a fork 1.
4. Wash out a neck of a forward cover of the 16th main shaft of a box of transfers and grease with a thin layer of fresh Litol-24 lubricant.
5. Insert the new coupling with the bearing of switching off of coupling into a fork.
6. Install the transmission.
 Removal and installation of clutch plates
For removal of clutch plates execute operations 1-3 of the subsection "Replacement of the Coupling with the Coupling Switching Off Bearing".
Then you carry out dismantling in the following sequence:
1. Turn off bolts of fastening and remove the lower part 6 (see fig. 180) a coupling case.
2. Turn off six bolts of fastening of a casing 4 press disks to a flywheel 8. Turn off bolts gradually and consistently on a circle, no more than two turns of a key for one time not to bend a casing support.
After removal of bolts a casing 4 with a press disk 5 assembled and the conducted disk 9 freely are taken out down.
The conducted disk and press a disk with a casing and a press spring are not subject to dismantling.
You carry out installation of disks on the car in the return order.
Before installation execute the following:
1. Wipe with the pure fabric moistened in gasoline, all surfaces of friction of disks and a flywheel.
2. Blow air of a detail of clutch plates and examine them for detection of possible defects.
3. Add lubricant to the bearing 11 of primary shaft of a box of transfers installed on cranked to a shaft.
4. Establish in the coupling case conducted and press disks and through a back opening of a case of coupling center the conducted disk concerning a flywheel by means of the mandrel entering the bearing of a bent shaft. Instead of a mandrel it is possible to use primary shaft of a box of transfers. A short part of a nave of the conducted disk has to be turned to a flywheel.
5. Combine openings on a flywheel and a casing of a press disk and wrap six bolts of fastening of a casing. Wrap bolts evenly and consistently on a circle.

Coupling on the car with the engine of fashion. 425LTRU
 Replacement of the coupling with the coupling switching off bearing
1. Install the car on a platform or a viewing ditch for access from below to a box of transfers and coupling.
2. Turn off four bolts and remove a fork of 1 switching off of coupling (fig. 183b) with a cover 9 and a frame 10.
3. Remove from the car a box of transfers (see the head "A box of transfers") together with the coupling and the bearing of switching off of coupling.

Fig. 181. Coupling of the engine 425LTRU: 1 – coupling switching off bearing fork; 2 – coupling switching off bearing coupling; 3 – coupling switching off bearing; 4 – cover; 5 – casing of a press disk; 6 – press disk; 7 – coupling case; 8 – flywheel of a bent shaft; 9 – the conducted disk; 10 – press spring; 11 – forward bearing of a main shaft of the transmission; 12 – bent shaft; 13 – main shaft of the transmission; 14 – sealing ring; 15 – quencher of tortional fluctuations; 16 – forward cover


4. Remove the coupling 2 (see fig. 181) with the bearing 3 switching off of coupling. The coupling with the coupling switching off bearing is not subject to dismantling.
5. Wash out a neck of a forward cover of the 16th main shaft of a box of transfers on which the coupling with the bearing is put, and grease with a thin layer of fresh Litol-24 lubricant.
6. Put on the coupling a forward cover of a main shaft.
7. Install the transmission.
8. Establish a coupling switching off fork.
 Removal and installation of clutch plates
For removal of clutch plates execute operations 1-4 of the subsection "Replacement of the Coupling with the Coupling Switching Off Bearing".
Then you carry out dismantling in the following sequence:
1. Turn off bolts of fastening of the working cylinder 5 (see fig. 183b) couplings to a case and put the cylinder aside, without disconnecting from it a hose 7.
2. Turn off bolts of fastening and remove a case 7 (see fig. 181) couplings.
3. Turn off six bolts of fastening of a casing of the 5th press disk to a flywheel 8 and remove a casing with a press disk 6 assembled and the conducted disk 9. Turn off bolts gradually and consistently on a circle, no more than two turns of a key for one time not to bend a support of a casing of a press disk.
The conducted disk and press a disk with a casing and a press spring are not subject to dismantling.
You carry out installation of disks on the car in the return order.
Before installation execute the following:
1. Wipe with the pure fabric moistened in gasoline, all surfaces of friction of disks and a flywheel.
2. Blow air of a detail of clutch plates and examine them for detection of possible defects.
3. Add lubricant to the bearing of primary shaft of a box of transfers installed on cranked to a shaft. Replace the sealing ring torn or lost elasticity 14.
4. Establish on the flywheel conducted and press disks and center the conducted disk concerning a flywheel by means of a mandrel, having inserted its shaft into the bearing of a bent shaft. Instead of a mandrel it is possible to use primary shaft of a box of transfers. A short part of a nave of the conducted disk has to be turned to a flywheel.
5. Establish a casing of a press disk on adjusting pins of a flywheel and wrap six bolts of fastening of a casing. Wrap bolts evenly and consistently on a circle.

Removal and dismantling of the hydraulic drive of switching off of coupling

Fig. 183. Coupling switching off drive (release bearing, fork and working cylinder): and – engines 420.10-10, 421.10-10 and 4213.10; – the engine 425LTRU; 1 – coupling switching off bearing fork; 2 – coupling switching off bearing; 3 – main shaft of the transmission; 4 – fork support; 5 – working cylinder; 6 – perepuskny valve; 7 – hose; 8 – coupling case; 9 – fork cover; 10 – cover frame


1. Disconnect a hose 7 (see fig. 183) from the working cylinder.
2. Merge liquid from a hydraulic actuator through the disconnected end of a hose.
3. Turn off bolts of fastening and remove the working cylinder.

Fig. 182. Coupling switching off drive (pedal, main cylinder and pipeline): 1 – cover; 2 – tank; 3 – main cylinder of the drive of switching off of coupling; 4 – tube of the main cylinder; 5 – protective plug; 6 – bracket; 7 – ottyazhny spring; 8 – lock-nut; 9 – fork; 10 – pedal; 11 – finger;
12 – pedal axis; 13 – arm; 14 – nut; 15, 17 – the forelock; 16 – plug; 18 – nut of fastening of a hose; 19 – spring washer; 20 – hose


4. Remove an ottyazhny spring 7 (see fig. 182) coupling switching off pedals.
5. Rasshplintuyte also take out a finger of the 11th fork of a pusher of the main cylinder.
6. Disconnect a tube 4 from the main cylinder.
7. Turn off nuts of the 14th fastening of the main cylinder and remove the cylinder.
You carry out dismantling of the main cylinder in the following order:

Fig. 184. Main cylinder of switching off of coupling: 1 – tank cover; 2,6,19 – laying; 3 – tank grid; 4 – tank case; 5 – tank union; 7,16 – the cuff is sealing; 8 – the washer is persistent; 9 – the ring is lock; 10 – pusher fork;
11 – nut; 12 – the cap is protective;
13 – pusher; 14 – piston;
15 – piston valve; 17 – piston spring; 18 – case of the main cylinder; 20 – union of the main cylinder; 21 – union


1. Remove a cover 1 (see fig. 184) and the mesh filter 3 of a filling tank. Remove the liquid remains from the cylinder, having turned it a tank down and having pressed several times a pusher of the 13th piston.
2. Take off a protective cap 12 from the cylinder case 18 and shift it along a pusher 13.
3. Remove a lock ring 9 and take out from the case 18 a pusher 13 with a persistent washer 8.
4. Take out from the case the piston 14 with sealing cuffs and a cart-vratnuyu a spring 17. In order to avoid damage of sealing cuffs for removal of the piston bring compressed air in an opening for the union 21. Unions 20 and 5 of the main cylinder with laying when dismantling should not be unscrewed if there is no dribble working liquid through them.
You carry out dismantling of the working cylinder in the following order:

Fig. 185. Working cylinder of switching off of coupling of engines 420.10-10, 421.10-10 and 4213.10: 1 – hose; 2 - piston spring; 3 – cylinder case; 4 – piston; 5 – the cuff is sealing; 6 – the cap is protective; 7 – the ring is lock; 8 – piston pusher; 9 – valve of perepuskny; 10 – the cap is protective


1. Take off a rubber protective cap 6 (fig. 185) from the working cylinder and take out a pusher 8 together with a cap.
2. Take off a cap from a pusher.
3. Remove a lock ring 7.
4. Take out the piston 4 with a sealing cuff 5 and a spring 2 of the cylinder case. In order to avoid damage of the piston and a cuff bring compressed air to an opening for a hose.
5. Remove from the piston a sealing cuff 5.
6. Turn out perepuskny the valve 9 and remove a protective cap from the valve.
Carefully wash out hydraulic actuator details in brake fluid or alcohol, blow compressed air and examine.

Note
The working cylinder of switching off of coupling on the car with the engine of fashion. 425LTRU differs from the case given only by a design.

Assessment of technical condition of details of the drive of switching off of coupling
All rubber sealing cuffs have to be soft and elastic. Hardened, inflated or with vyryvami and cracks on working surfaces of a cuff replace.
On mirrors of working and main cylinders should not be risok, sinks, zadirov and considerable wear. Small traces of corrosion and insignificant wear are allowed to be eliminated with grinding or a honingovaniye to diameter no more than 25,15 mm for the working cylinder and 22,2 mm – for the main cylinder at obligatory application only of new cuffs.

Assembly of the drive of switching off of coupling
You carry out assembly of the drive in an order, the return to dismantling. Before assembly oil a mirror of cylinders kastoro-vy or fresh brake fluid.
At assembly of the main cylinder be convinced that a returnable spring easily a cart-vrashchayet the piston in a starting position. Check with the help of a soft wire with a diameter of 0,3-0,5 mm whether the cuff compensatory otver-sty blocks that is absolutely inadmissible.
At assembly of the working cylinder be convinced that the spring easily moves the piston in the cylinder against the stop to a lock ring.
You carry out installation of a hydraulic actuator on the car in an order, the return to removal. After installation pump over a coupling hydraulic actuator.

Pumping of a hydraulic actuator of switching off of coupling
Fill the drive with liquid and pump over it for removal of air in the following order:
1. Lift a cowl of the car and turn off a cover of a tank of the main cylinder.
2. Fill a tank of the main cylinder with working liquid to level holes-malnogo (15-20 mm lower than the top edge of a tank).
3. Remove a protective cap 10 (see fig. 185) from a head of the perepuskny valve 9 of the working cylinder and put on a rubber hose a head.
4. Ship the free end of a hose in the transparent vessel with a capacity not less than 0,5 l filled on a half of height with working liquid.
5. Create pressure in system, having sharply pressed 4–5 times with an interval 1–2 with a coupling pedal.
6. Holding a pedal, unscrew on 1/2–3/4 turns perepuskny the valve, watching that the free end of a hose remained shipped in liquid. In the liquid following from a hose vials of air will be visible.
7. When liquid ceases to flow from a hose, completely wrap perepusknoy the valve at the pressed coupling pedal.
8. You watch liquid level in a tank of the main cylinder. Do not allow in pumping time lowering of the level to the bottom of a tank, in an opposite case air will get to system again.
9. Repeat operations 5-8 till that time until from a hose the liquid effluence with air stops.
10. Remove from a head perepusknogo the valve a hose and put on a protective cap.
11. Add liquid in a tank to norm.
It is impossible to add in a tank the liquid produced when pumping as it contains air. This liquid can be used only after upholding within a day and filtrations.