3.2.3. Repair

Removal and installation of a box of transfers from the car
You carry out removal in the following order:
1. Merge oil from the transmission and the transfer case.
2. Disconnect driveshafts.
3. Disconnect a flexible shaft of a speedometer.
4. Disconnect a cable of the parking brake system from the intermediate lever installed on a transmission case.
5. Weaken the nut of fastening of a cover of a cable fixed on an arm and take out a cable from a groove. Take out the forelock from the bracket located on a board of the parking brake mechanism, and release a cable.
6. Support the engine from below by means of a jack or other device.
7. Remove the frame cross-piece located under the transmission.
8. Lower the engine so that bolts of fastening of levers of the transmission and transfer case appeared lower than the level of a body floor.
9. Weaken bolts of fastening of levers of the transmission and transfer case and remove levers from shliyets of the lever of the mechanism of switching of the transmission and lever of forks of turning on of the transfer case (for the five-speed transmission).
10. Remove the working cylinder of coupling (except established on the engine 425LTRU).
11. Turn off four nuts of fastening of the transmission to a coupling case.
12. Take away the transmission together with the transfer case (unit) to an exit of a main shaft from a coupling case back.
13. Lower the unit down.
You carry out installation of the unit on the car upside-down.

Detachment of a box of transfers from a distributing box
1. Install the unit vertically on a drum of the parking brake mechanism.
2. Include direct transfer in a distributing box.
3. Turn off a nut of a hairpin and three bolts of fastening of a box of transfers to a distributing box.

Fig. 188. A detachment of a box of transfers from a distributing box


4. Lifting a box of transfers up, disconnect it from a distributing box (fig. 188).
After removal of the transmission on the transfer case there are a laying, a plate, the second laying and a persistent ring of the bearing of an intermediate shaft of the transmission (for the four-speed transmission).

Dismantling of the five-speed transmission

Fig. 189. Mechanism of switching of the five-speed transmission: 1 – fork of inclusion of I and II transfers; 2, 12, 33 – caps; 3, 16 – springs; 4 – clamp; 5 – lead of a rod of the V transfer; 6 – fork of inclusion of a backing; 7 – gear shifting lever; 8 – lever sealant; 9 – pin; 10 – lever spring; 11 – lever support; 13 – backing safety lock plunger; 14 – safety lock cover; 15 – ball; 17 – the cover is side; 18 – inclusion fork III and IV transfers; 19 – intermediate lever; 20 – plunger of the intermediate lever; 21, 25 – traffic jams; 22 – case of the V transfer; 23 – clamp ball spring; 24 – clamp ball; 26 – rod of a fork of I and II transfers; 27 – fork rod III and IV transfers; 28 – rod of the intermediate lever; 29 – the plunger is key; 30 – backing fork rod; 31 – lock bolts; 32 – lever emphasis; 34 – lock washer; 35 – fork of inclusion of the V transfer; 36 – rod of a fork of the V transfer; 37 – backing lamp switch; 38 – bolt of fastening of the lever of the transmission; 39 – transmission lever


1. Turn off bolts of fastening and remove a side cover of 17 (fig. 189) with the switching mechanism.
2. Turn off a stopper of 21 clamps of a rod of the fifth transfer, take out a spring 23 and a ball 24.

Fig. 186. Five-step box of transfers: 1 – main shaft; 2 – forward cover; 3 – cuff;
4, 18, 22, 34, 44, 47 – lock rings; 5, 13, 19, 33, 43 – bearings; 6 – forward bearing of a secondary shaft; 7 – case; 8 – coupling of the synchronizer III and IV of transfers; 9 – gear wheel of the III transfer; 10 – gear wheel of the II transfer; 11 – coupling of the synchronizer I and II of transfers; 12 – gear wheel of the I transfer; 14 – persistent ring;
15 – case of the V transfer; 16 – expansion plug; 17 – the conducted gear wheel of the V transfer; 20 – persistent ring; 21 – secondary shaft; 23 – needle bearing of a gear wheel of the V transfer; 24 – bolt of fastening of the back bearing of an intermediate shaft; 25 – transfer synchronizer V nave; 26 – basic plug; 27 – dish-shaped spring; 28, 29 – a washer; 30 – leading gear wheel of the V transfer; 31 – the blocking ring of a gear wheel of the V transfer; 32 – transfer synchronizer V coupling; 35 – screw; 36 – cover of the back bearing of an intermediate shaft; 37 – the directing plug; 38 – backing gear wheel; 39 – backing gear wheel axis; 40 – stopper; 41 – intermediate shaft; 42 – block of gear wheels of the drive of an intermediate shaft and
III transfers; 45 – cover of the forward bearing of an intermediate shaft; 46 – the blocking ring of a gear wheel of the IV transfer


3. Remove lock 22 (see fig. 186) and persistent the 20th rings of the back bearing of a secondary shaft.
4. Turn off bolts of fastening and remove a case 15 fifth transfers with the back bearing 19 of a secondary shaft.
5. Turn out a bolt 24 fastenings of the back bearing of an intermediate shaft (the bolt has the left carving) and remove a dish-shaped spring 27 and a persistent washer 28.
6. Remove from an intermediate shaft the leading gear wheel 30 fifth transfers with the needle bearing 23 and the blocking ring 31.
7. Turn out a lock bolt 31 (see fig. 189) forks of switching of the fifth transfer and remove the coupling 32 (see fig. 186) with a fork. At the same time hold crackers, balls and springs of the synchronizer.
8. By means of a stripper remove from a secondary shaft the roller bearing 13 (without internal ring) with a persistent ring 14, the expansion plug 16 and the conducted gear wheel 17 fifth transfers.
9. By means of a stripper remove from an intermediate shaft a nave of the 25th synchronizer of the fifth transfer with a persistent washer 29.
10. Turn off bolts of fastening and remove a forward cover 2. Then remove a lock ring of the 47th bearing of a main shaft.
11. Uncover 45 and 36 bearings of an intermediate shaft.
12. Using a carving opening of M8 in a back end face of axis 39 of an intermediate gear wheel of a backing, a vypressuyta an axis back also remove a gear wheel 38.
13. By means of a stripper remove back bearings 5 and 33 of primary and intermediate shaft.
14. Install a box so that the intermediate shaft was from above, move an intermediate shaft forward against the stop of the block of gear wheels 42 intermediate shafts in a case to shift forward the forward bearing.
15. Give an intermediate shaft to an exit of an internal ring from the forward bearing 43 back.
16. Install the transmission by the hatch under the switching mechanism up.
17. Take out from a transmission case a main shaft 1, the blocking ring of the 46th gear wheel of the fourth transfer and a secondary shaft assembled.
18. Remove a lock ring 44 and move an intermediate shaft back against the stop of the block of gear wheels in a case. Vypressuyte an intermediate shaft from the block of gear wheels through a forward opening of a case towards a back part of the transmission. Take out an intermediate shaft and the block of gear wheels from a case.

Dismantling of a secondary shaft

Fig. 190. Secondary shaft of the transmission assembled: 1 – secondary shaft; 2, 15, 20, 22 – a persistent washer; 3 – gear wheel of the I transfer; 4 – the blocking ring of a gear wheel of the I transfer; 5, 7, 11, 12 – a lock ring; 6 – synchronizer I and II of transfers; 8 – gear wheel of the II transfer; 9 – gear wheel of the III transfer; 10 – the blocking ring of a gear wheel of the III transfer; 13, 21 – a spline; 14 – synchronizer III and IV of transfers; 16 – expansion plug; 17 – needle bearing of a gear wheel of the III transfer; 18 – needle bearing of a gear wheel of the II transfer; 19 – the blocking ring of a gear wheel of the II transfer; 23 – needle bearing of a gear wheel of the I transfer; 24 – internal ring of the roller bearing


1. Remove an internal ring 24 (see fig. 190) the bearing, a persistent washer 2 and a gear wheel 3 first transfers with the needle bearing 23 and the blocking ring 4.
2. Remove by means of a stripper a lock ring of the 5th nave of the synchronizer of the first and second transfers and a persistent washer 22.
3. Remove the synchronizer 6 of the first and second transfers together with a gear wheel 8 second transfers, the blocking ring 19 and a persistent washer 20.
4. Remove a spline 21, a lock ring 7 and the needle bearing 18 of a gear wheel of the second transfer.
5. Remove a lock ring of the 12th nave of the synchronizer of the third and fourth transfers by means of a stripper.
6. Remove the synchronizer 14 of the third and fourth transfers together with a gear wheel 9 third transfers, the blocking ring 10 and a persistent washer 15.
7. Remove a spline 13, a lock ring 11, the expansion plug 16 and the needle bearing 17 of a gear wheel of the third transfer.

Dismantling of the mechanism of switching
1. Turn off four bolts of a support 11 (see fig. 189) the lever of switching and remove a support with the lever 7 and a podzhimny spring 10.

Fig. 191. Extraction of caps of openings of rods


2. Take four caps of 33 openings of rods on the one hand of a cover (fig. 191).
3. Turn off a stopper 25 (see fig. 189) the channel of key plungers.
4. Turn out lock bolts of 31 forks and a lead.
5. Remove a lock washer 34 rods of a fork of a backing.

Fig. 192. Vypressovka rods of forks of switching


6. Vypressuyte rods through openings in a cover where caps are removed, and remove forks, a lead and the intermediate lever (fig. 192). At vypressovke rods do not lose the sprung balls 24 (see fig. 189) clamps.
7. Take out springs 23 and balls of 24 clamps of rods.
8. Take out three key plungers from the channel and one plunger from the intermediate lever (29 and 20 respectively).
9. Turn off three bolts and uncover the 14th safety lock of a backing and a returnable spring 3.
10. Take out a plunger of the 13th safety lock. At the same time hold balls of the 15th clamp from drop-out.
11. Take out balls 15 and springs of the 16th clamp.
12. Take a cap 2 and take out a spring 3 and a clamp 4.
13. Turn off two bolts and remove an emphasis 32 levers.

Dismantling of a four-stage box of transfers
1. Turn off bolts of fastening and remove a side cover with the switching mechanism.

Fig. 187. Four-stage box of transfers: 1 – main shaft; 2 – forward cover; 3 – cuff; 4,14,17,28, 30 – lock rings;
5 – laying; 6,15,20,31 – bearings; 7 – forward bearing of a secondary shaft; 8 – case; 9 – coupling of the synchronizer III and IV of transfers;
10 – gear wheel of the III transfer; 11 – gear wheel of the II transfer; 12 – coupling of the synchronizer I and II of transfers; 13 – gear wheel of the I transfer; 16 – secondary shaft; 18 – washer; 19 – expansion ring; 21 – special bolt; 22 – dish-shaped spring; 23 – intermediate shaft; 24 – backing gear wheel axis; 25 – backing gear wheel; 26 – stopper; 27 – block of gear wheels of the drive of an intermediate shaft and the III transfer; 29 – cover


2. Using a carving opening of M8 in a back end face of axis 24 (see fig. 187) an intermediate gear wheel of a backing, vypressuyte an axis back, remove a gear wheel 25.
3. Turn off bolts of fastening and remove a cover 2 bearings of a main shaft.
4. Remove a cover of the 29th forward bearing 30 of an intermediate shaft.
5. Turn out a bolt of 21 fastenings of the back bearing of an intermediate shaft (the bolt has the left carving) and remove a dish-shaped spring 22.
6. Remove lock rings 17, 31 and a washer 18, by means of a stripper remove back bearings (6 and 15) of primary and secondary shaft for their lock rings.
7. Remove a lock ring of the back bearing 20 of an intermediate shaft.
8. Install a box so that the intermediate shaft was above, advance an intermediate shaft to an emphasis of the block of gear wheels of the 27th intermediate shaft in a case forward.
9. Move an intermediate shaft together with the back bearing 20 to an exit of an internal ring of the forward bearing 30 of rollers and the back bearing 20 of a case back.
10. Remove the back bearing 20 of an intermediate shaft by means of a stripper.
11. Install a box of transfers by the hatch under the switching mechanism up.
12. Take out from a case of a box of transfers a main shaft, the blocking ring of a gear wheel of the fourth transfer, a secondary shaft in collecting (supporting an expansion ring of the 19th gear wheel of the first transfer) and an intermediate shaft in collecting.

Dismantling of a secondary shaft
Dismantling of a secondary shaft is similar to dismantling of a secondary shaft of a five-step box.

Dismantling of the mechanism of switching

Fig. 193. Mechanism of switching of transfers of a four-stage box: 1 – lever of switching of transfers; 2 – sealant; 3, 21 – pins; 4 – lever spring; 5 – lever support; 6 – side cover of a box of transfers; 7 – safety lock cover; 8 – safety lock; 9 – safety lock spring;
10 – ball clamp; 11 – clamp spring; 12 – fork of inclusion of I and II transfers; 13 – inclusion fork III and IV transfers; 14 – fork of inclusion of a backing; 15 – screw; 16 – forelock; 17 – backing lamp switch; 18 – stopper; 19 – rod of a fork of inclusion of I and II transfers; 20 – plunger; 22 – fork rod III and IV transfers; 23 – rod of a fork of inclusion of a backing; 24 – cap


1. Unscrew four screws of a support 5 (fig. 193) of the lever of switching and remove a support with the lever 1 and a spring 4.
2. Take three caps of openings of rods from one party of a cover.
3. Turn off a stopper 18 (see fig. 193) nests of a clamp of a rod of the first and second transfers and take out a spring 9 and a ball 10.
4. Also turn out Rasshplintuyta lock bolts of forks.
5. Vypressuyte rods (see fig. 192) switching forks through openings in a cover in which caps are removed and remove forks. At vypressovke rods of the third and fourth transfers and a backing do not lose the sprung clamp ball.
6. Take out springs and balls of clamps of rods.
7. Take out two key plungers 20 (see fig. 193) through an opening of a clamp of the first and second transfers.
8. Unscrew three screws and remove a cover of the 7th safety lock and a spring 9.
9. Put forward a plunger of the 8th safety lock outside, remove a lock ring and take out a plunger. Thus hold a plunger clamp ball from drop-out.
10. Take out a spring 11 and a ball of the 10th clamp.

Assessment of technical condition of details
After dismantling carefully wash out all details of a box of transfers in kerosene, blow compressed air and examine.
 Case of a box of transfers and case of the fifth transfer. External survey reveal cracks, chips, breaks of inflows and fixing eyes, a condition of a carving in openings, lack of faces and agnails on the condensed surfaces.
Replace a case with cracks, chips and breaks. Eliminate small malfunctions.
 Gear wheels. On teeths should not be having chopped off and забоин, on a side surface of teeths – traces vykrashivaniya and a smyatiya, on face surfaces of gear wheels – zadirov.
Landing surfaces should not have the damages and wear breaking centering of details.
Gear wreaths of synchronizers without destructions of teeths have to be reliably fixed on a gear wheel.
 The main shaft should not have damages on teeths of a wreath of inclusion of the fourth transfer, a shaft vent – забоин (the conducted clutch plate has to move on them freely). Replace a worn-out shaft.
On the surface of swing of the roller bearing should not be vykrashivaniya.
 The secondary shaft should not have zadirov and deep risok on landing surfaces under gear wheels of the first, second and third transfers, chips of shliyets and vykrashivaniya on the surface of swing of the roller bearing. Replace a worn-out shaft.
 The intermediate shaft should not have damages of a carving and teeths (smyaty, vykrashivaniye). Replace a worn-out shaft and the block of gear wheels of a shaft.

Fig. 194. Completing and selection of details of synchronizers of the transmission: And – sinkh-ronizator I and II transfers; B – the synchronizer III, IV and V of transfers; 1 – the coupling (the coupling I and II of transfers is manufactured for a single whole with a backing gear wheel);
2 – nave


 Synchronizer. Check connection of the coupling 1 (fig. 194) of the synchronizer with a nave 2 and at the considerable mutual movements exceeding by two times specified in drawings in the direction, perpendicular detail axes, replace a coupling set with a nave. At selection of a new set pay attention that when moving the coupling concerning a nave on 11,5 mm the distortions in vents measured in points of B1 and B2 should not exceed 0,45 mm.
Replace the synchronizer coupling at damage or wear of teeths. Replace the blocking rings of the synchronizer if a gap between end faces of a ring and a wreath of inclusion of transfer less than 0,3 mm and a ring are deformed.
 Bearings should not have damages of separators, cracks and chips of rings, vykrashivaniya running paths of balls and rollers, and also a notable radial and axial gap. Separators of bearings should not have damages. Replace worn-out bearings.
 The side cover of a box of transfers should not have chips, cracks, damages of the condensing surfaces and openings for installation of caps.
 Rods should not be bent, and in a zone of operation of locks and clamps vykrashivaniye are not allowed. The key pin of a rod of the third and fourth transfers (and also a key pin of a rod of the intermediate lever for a five-step box) has to move freely in an opening, without dropping out of it. Pin length taking into account wear should not be less than 9,8 mm. Replace worn-out details.

Fig. 195. Control sizes of forks of switching of transfers: And – a fork of I and II transfers; B – a fork III and IV transfers; In – a fork of the V transfer; – a lead of a rod of the V transfer


 Forks should not have cracks and pognutost. Position of pads of forks concerning a groove of switching has to correspond to the sizes shown in fig. 195. If wear of grooves of switching reaches 1 mm, replace a fork.
 Other details. Persistent washers of gear wheels and a spline should not have zadirov.
Maslootrazhateli have to have the correct form and should not touch the next details.
The dish-shaped spring of a bolt of fastening of the back bearing of an intermediate shaft should not have cracks, a cover of primary shaft – cracks, breaks and damages of working and landing surfaces.
The cuff of a cover of a main shaft should not have deformations of fittings, gaps, vyryv and cracks on a working surface. The strip of wear of a working edge – more than 2 mm is allowed.
Pins in a support of the lever of switching of transfers should not be shaken in nests. The rubber sealant of the lever of switching should not have gaps and through cracks.
Replace all worn-out details.
At repair of the transmission use these tab. 11.

Assembly of the five-speed transmission
You carry out assembly of the transmission, since subassembly of its knots, in the following order.
 Assembly of a main shaft

Fig. 196. A main shaft with the ground-in blocking ring: 1 – main shaft; 2 – the blocking ring


1. Grind in on a shaft cone the blocking ring to the size of 0,8-1,25 mm, as shown in fig. 196.
2. Press against the stop the ball bearing.
3. Establish lock rings on a shaft and the bearing.
4. Put lubricant in openings of a shaft and insert rollers (14 pieces).

Fig. 197. A main shaft in collecting


The main shaft is assembled shown in fig. 197.
 Assembly of a cover of a main shaft
1. Press a cuff in a cover against the stop.
2. Fill a cuff cavity with Litol-24 lubricant.
 Assembly of the synchronizer
1. Pick up a set of the coupling and a nave of the synchronizer with the minimum gaps at free movement (see. "Synchronizer", page 85) or use the sets 469-1701117, 469-1701138 and 31601-1701096 which are picked up by manufacturer.

Fig. 198. The synchronizer coupling with a nave: 1 – coupling; 2 – nave; 3 – cracker; 4 – ball;
5 – directing springs; 6 – spring


2. Put three springs (fig. 198), three guides of a spring, three balls and three crackers in a nave and install the coupling on a nave (the coupling of the first and second transfers is manufactured for a single whole with a backing gear wheel). Establish crackers by the party with openings of smaller diameter towards the coupling.
3. At assembly of the synchronizer of the fifth transfer establish crackers by ledges towards the short basis of a nave.
 Assembly of a secondary shaft
1. Install the needle bearing 17 (see fig. 190) gear wheels of the third transfer, the expansion plug 16 of the bearing, a lock ring 11 and a spline 13.
2. Grind in the blocking synchronizer ring on a cone of a gear wheel of the third transfer to the size 0,8-
1,25 mm (fig. 199).
3. Grease the bearing 17 (see fig. 190) transmission oil, establish a gear wheel 9 third transfers with the blocking ring 10 and a persistent washer 15.
4. Install the synchronizer 14 of the third and fourth transfers and a lock ring by the 12th section to a nave spline.
5. Grind in the blocking synchronizer rings on cones of gear wheels of the first and second transfers to the size of 0,8-1,25 mm.
6. Install the needle bearing 18 of a gear wheel of the second transfer and a lock ring 7.
7. Oil the bearing 18 transmission, establish a gear wheel 8 second transfers with the blocking ring 19, a spline 21 and a persistent washer 20.
8. Install the synchronizer 6 of the first and second transfers.
9. Establish a persistent washer 22, a lock ring 5, a gear wheel 3 first transfers with the blocking ring 4 and the greased needle bearing 23 and an expansion ring 2.
10. Press an internal ring 24 roller bearings a fillet to an expansion ring.

Fig. 200. Secondary shaft assembled


The secondary shaft is assembled shown in fig. 200.
 Subassembly of a gear wheel of a backing with the bearing
1. Establish a lock ring in a gear wheel opening flute on the one hand.
2. Establish consistently persistent ring, the bearing and one more persistent ring in an opening.
3. Establish the second lock ring.
 Assembly of the mechanism of gear shifting
1. Establish in the lower nest a spring 16 (see fig. 189) and a ball of the 15th clamp of a safety lock of a backing.
2. Squeezing a clamp spring, insert a plunger of the 13th safety lock.
3. Establish a ball and a spring in the top nest. Squeezing a spring, insert a cap 12 and its raschekanta.
4. Insert into a safety lock plunger a returnable spring 3.
5. Establish a cover of the 14th safety lock, previously having applied TU 6-15-1049-91 autosealant laying on a landing surface, and wrap three bolts with spring washers.
6. Turn a cover of the 17th mechanism a big flange up and tighten an emphasis 32 backings two bolts with spring washers.
7. Insert a clamp 4 and a spring 3 into a nest from the opposite side of a plunger of a safety lock.
8. Squeezing a spring, insert a cap 2 and its raschekanta.
9. Insert into a cover from outside, opposite to a clamp, a rod of the 30th fork of a backing, install on a rod the intermediate lever 19, a fork of the 6th backing and a lock washer 34.

Fig. 201. Device for assembly of rods and clamps: and – assembly of a clamp; – installation of a rod


10. Put in a clamp nest a spring 23 and a ball 24 and, utaplivy a ball by means of a mandrel (fig. 201), establish a rod on a clamp in neutral situation.
11. Put in a nest of the intermediate lever 19 (see fig. 189) a plunger 20 with the cut-off end faces, to the vertical canal of a cover put a key plunger 29.
12. Insert into a cover from outside, opposite to a clamp, a rod of the 28th intermediate lever, establish on a rod a lead 5 and the intermediate lever 19.
13. Execute operation 10 for a rod 28.
14. Put to the vertical canal of a cover a key plunger 29.
15. Insert into a cover from outside, opposite to a clamp, a rod of the 27th fork of the third and fourth transfers, establish on a rod a fork 18.
16. Follow instructions of point 10 for a rod 27.
17. Put to the vertical canal of a cover a key plunger 29.
18. Insert into a cover from outside, opposite to a clamp, a rod of the 26th fork of the first and second transfer, establish on a rod a fork 1.
19. Execute operation 10 for a rod 26.
20. Fix forks and a lead on rods by lock bolts 31, previously having applied UG-6, UG-9 or AN-6K sealant on their carving.
21. Wrap a stopper of the 25th channel of key plungers, previously having applied sealant on its carving.
22. Insert eight caps 33 into face openings for rods, previously having applied on landing surfaces of caps sealant, and their raschekanta.
23. Grease with Litol-24 lubricant the sphere of a support 11 of the lever 7 of switching and insert the lever into a support.
24. Establish in ring deepening of a side cover of the 17th mechanism a conic spring 10. Apply sealant on the support socket plane and establish a switching support with the lever on a switching mechanism cover so that the lever entered a spring and rose between clamps of neutral situation.
25. Fix a support of the lever of switching by four bolts with spring washers, previously having applied sealant on their carving.
26. Put on the lever and a support a rubber sealant 8.
 Assembly of the transmission from subcollected knots
You carry out further assembly of the transmission in the following order:
1. Establish a transmission case by a forward end face down.
2. Install the block of gear wheels 42 (see fig. 186) an intermediate shaft in a case, through an opening of the back bearing of an intermediate shaft insert an intermediate shaft 41 into a case and press it in the block of gear wheels against the stop.
3. Turn a case, establish on an intermediate shaft a lock ring 44 and press an internal holder of the roller bearing 43.
4. Insert a collected secondary shaft into a transmission case.
5. Establish (press) a subcollected main shaft in a transmission case. At the same time you watch that the rollers established in a back opening of a shaft did not get enough sleep.
6. Establish an external ring of the roller bearing 13 of a secondary shaft with a separator and rollers.
7. Establish an intermediate shaft into place, entering gear wheels into gearing.
8. Establish an external ring of the forward bearing 43 with a separator and rollers on the forward end of an intermediate shaft.
9. Install the back bearing 33 of an intermediate shaft with a lock ring.
10. Insert backing gear wheel axis 39 into a case opening from the back privalochny plane.
11. Enclose a gear wheel of the 38th backing in a case so that axis 39 entered it from outside, an opposite flute under a switching fork.

Fig. 202. Installation of an axis of a gear wheel of a backing: 1 – axis; 2 – plate


12. Press a backing gear wheel axis against the stop in a case according to fig. 202.
13. Fix a cover 36 (see fig. 186) the back bearing of an intermediate shaft screws 35, previously having applied UG-6, UG-9 or AN-6K sealant on their carving.
14. Establish (press) a cover of the 45th forward bearing of an intermediate shaft before coincidence of end faces of a cover and a case.
15. Establish on a forward end face of a case laying so that the cut in it coincided with a masloslivny opening.
16. Establish on a main shaft a cover 2 bearings with a cuff so that masloslivny the channel coincided with an opening.
17. Fix a cover by four bolts with spring washers.
18. Install the synchronizer of the fifth transfer with a fork and a rod on an intermediate shaft (the fork fastens on a rod a conic bolt with the UG-6, UG-9 or AN-6K sealant applied on its carving).
19. Establish on a secondary shaft a persistent ring of the 14th bearing, the expansion plug 16 and the conducted gear wheel 17 fifth transfers.
20. Establish on an intermediate shaft a persistent washer 29, the basic plug 26, a gear wheel 30 fifth transfers with the bearing 23 and the blocking ring 31.
21. Establish the second persistent washer of the 28th gear wheel of the fifth transfer of an intermediate shaft, fix it by a bolt 24 with the dish-shaped spring established on it 27.
22. Press the 7th guides of the plug 37 in a back end face of a case.
23. Apply sealant on a flange of a case of the fifth transfer.
24. Install a case of the fifth transfer on the directing plugs and tighten it (previously having applied sealant on a carving of the bolts leaving in a case).
25. On a secondary shaft establish a maslootrazhatel and the two-row ball bearing 19 with a lock ring 18.
26. Establish on a secondary shaft persistent 20 and lock 22 rings of the back bearing.
27. Install in the channel of a clamp of the fifth transfer a ball 24 (see fig. 189), a spring 23 and wrap a stopper 21.
28. Apply autosealant on a flange of a side cover of the transmission.
29. Establish a side cover on a transmission case, fix it by bolts with spring washers (previously having applied sealant on a carving of bolts).

Assembly of the four-speed transmission
Assembly of the transmission is begun with subassembly of its knots in the following order.
 Assembly of a main shaft
It is carried out similar to assembly of a main shaft of a five-step box.
 Assembly of the synchronizer
It is carried out similar to assembly of the synchronizer of a five-step box.
 Assembly of a secondary shaft
1. Install the needle bearing of a gear wheel of the third transfer, the expansion plug of the bearing, a lock ring and a spline.
2. Grind in the blocking synchronizer ring on a cone of a gear wheel of the third transfer to the size 0,8-

Fig. 199. A gear wheel of the third transfer with at-tertym the blocking ring: 1 – gear wheel; 2 – the blocking ring


1,25 mm (see fig. 199).
3. Oil the bearing transmission, establish a gear wheel of the third transfer with the blocking ring, a persistent ring, install the synchronizer of the third and fourth transfers and a lock ring by a section to a nave spline.
4. Grind in the blocking synchronizer rings on cones of gear wheels of the first and second transfers to the size of 0,8-1,25 mm.
5. Install the needle bearing of a gear wheel of the second transfer and a lock ring.
6. Oil the bearing transmission, establish a gear wheel of the second transfer with the blocking ring, a persistent ring and the synchronizer of the first and second transfers.
7. Establish persistent and lock rings, a gear wheel of the first transfer with the blocking ring and the greased bearing; (maslootrazhatel) establish an expansion ring so that the pin of a secondary shaft got to a groove of an expansion ring (maslootrazhatelya).
8. Install the technological locking plug, for example from polyethylene (the locking plug will facilitate installation of a secondary shaft in collecting in a case of a box of transfers).
 Assembly of an intermediate shaft
1. Install (napressuyte) the block of gear wheels.
2. Establish a lock ring.
3. Establish (napressuyte) an internal holder of the forward roller bearing.
 Podsborka backing gear wheels with the bearing
It is carried out similar to subassembly of a gear wheel of a backing with the bearing of a five-step box.
 Assembly of a cover of a main shaft
It is carried out similar to assembly of a cover of a five-step box.
 Assembly of the mechanism of switching of transfers
1. Establish in a nest a spring 11 (see fig. 193) and a ball of the 10th clamp of a safety lock.
2. Squeezing a clamp spring, insert a plunger of a safety lock 8.
3. Insert into a safety lock plunger a returnable spring 9.
4. Establish a cover of the 7th safety lock, previously having applied sealant on a landing surface; wrap three bolts with spring washers.
5. Turn a cover a big flange up and put in nests of clamps of a spring 11 and balls 10 for a rod of the third and fourth transfers and a rod of a backing.
6. Insert into a cover from the party opposite to a clamp, a rod 23 forks of a backing, establish on a rod a fork 14 and, utaplivy a ball by means of a mandrel (see fig. 201), establish a rod on a clamp of neutral situation; also collect consistently all rods and forks. Between rods put key pins.
7. Fix forks on rods by conic bolts and a zashplintuyta bolts a wire. The Shplintovochny wire should not prevent movement of forks.
8. In an opening of a clamp of a rod of the first and second transfers put a ball 10 (see fig. 193), a spring 9 and wrap a stopper 18, previously having applied sealant on its carving. Keep in mind that the spring of the 9th clamp of a rod of the first and second transfers in a free state is longer than two other springs of clamps of rods.
9. Insert six caps 24 into face openings of the case for rods, previously having applied on landing surfaces of caps sealant, and raschekante them.
10. Grease with Litol-24 lubricant the sphere of a support of the lever of switching 1 and insert the lever into a support 5.
11. Apply sealant on the landing surfaces of laying and place laying on a switching mechanism cover.
12. Establish in ring deepening of a cover a conic spring 4. Establish a switching support with the lever on a switching mechanism cover so that the lever entered a spring, and the support the inflow closed an opening in the case.
13. Fix a support of the lever of switching by four bolts with spring washers, previously having applied sealant on a carving.
14. Put on the lever and a support a rubber sealant 2.
 Assembly of a box of transfers from subcollected knots
You carry out further assembly of the transmission in the following order:
1. Insert podsobranny an intermediate shaft into a case of a box of transfers.
2. Insert a collected secondary shaft into a case of a box of transfers and remove the technological locking plug.
3. Establish (press) the back bearing 15 (see fig. 187) a secondary shaft with the lock ring established on it 14. At a press fitting of a secondary shaft rest a mandrel against a shaft neck end face under a nave of a sinkhro-nizator. At a press fitting turn attention to correctness of installation of a persistent washer of a gear wheel of the first transfer.
4. Establish (press) podsobranny a main shaft in a case of a box of transfers so that the flute under a lock ring of the bearing 6 was drowned in a case.
5. Establish an intermediate shaft into place, having entered gear wheels into gearing.
6. Establish (press) the back bearing 20 of an intermediate shaft with the lock ring established on it to an emphasis of an internal holder of the bearing in an end face of a shaft and a lock ring in a case end face.
7. Establish an external ring of the forward bearing 30 with a separator and rollers on the forward end of an intermediate shaft.
8. Fix the back bearing of an intermediate shaft by a bolt 21 with the dish-shaped spring established on it 22.
9. Correct a main shaft that the flute under a lock ring on the bearing left a case of a box of transfers, establish a lock ring 4 and besiege a main shaft to an emphasis of a lock ring in a case.
10. Establish (press) a cover of the 29th forward bearing of an intermediate shaft before coincidence of end faces of a cover and a case.
11. Establish on a forward end face of a case laying so that the cut in it coincided with a masloslivny opening.
12. Establish on a main shaft a forward cover 2 so that masloslivny the channel coincided with a cut in laying.
13. Fix a cover by four bolts with spring washers.
14. Establish on a shaft a persistent washer 18 and a lock ring 17.
15. Insert an axis 24 gear wheels of a backing into a case opening from the party back privalochnoy the planes.
16. Enclose a gear wheel of the 25th backing in a case in such way that axis 24 entered it from the party opposite to a flute under a switching fork.
17. Press a backing gear wheel axis to an emphasis in a case according to fig. 202.
18. Apply sealant on a flange of a side cover of the transmission.
19. Establish a side cover on a transmission case, fix it by bolts with spring washers (previously having applied sealant on a carving of bolts).