2. Insert the 1/2 shift rod, install the output shaft.
3. Connect the spring clip disconnected from the reverse synchronizer pin, disengaging the reverse gear.
4. Position the 3/4 shift fork engaging the slot in the 5/3X shift shaft.
5. Remove the input shaft bearing inner race and retaining ring.
6. Partially install the input shaft, insert the 3/4 shift fork into the clutch sleeve and push the input shaft into place.
7. Move each shift rod to the neutral position, check that the lock pins are positioned as shown in Fig. 7. 6.42.
8. Insert the 3/4 shift rod, insert the lock pin. Lubricate the pin before installation.
9. Secure the 3/4 shift fork by inserting a new roll pin.
10. Install the 1/2 shift shaft.
11. Install the lock screws with new paper spacers, tighten them.
12. Clamp the output shaft with the 4th gear in a vise, calculate the thickness of the 5th gear shim by measuring the depth «A» (Pic. 6.45). The required gasket thickness will be as follows:
13. Having selected and installed the gasket, it is necessary to heat the 5th gear to a temperature of 120°C so that it can be installed on the shaft. Insert the gear so that it is against the bushing. Install bolt and flat washer, tighten bolt to specification. On late models, the bolt must be replaced.
14. Clamp the input shaft in a vise so that the shafts are vertical.
15. Lubricate the input shaft support rollers and push them in.
16. The inner ring of the bearing must be heated to 120°C and installed on the shaft, leading it down through the rollers.
17. After installing the inner ring, secure it with a circlip of suitable thickness. Select a retaining ring to ensure an axial clearance not exceeding 0.05 mm. Select the thickest circlip that will fit into the groove and provide the correct axial clearance and install it. Retaining ring thicknesses are available in 1.35, 1.40 and 1.45 mm.
18. Install the 5th gear with synchronizer hub, needle bearing and shift fork. Secure the yoke to the shaft using a new roll pin.
19. Establish a lock ring, arrange a ring of the synchronizer of 5th transfer.
20. To install the hub bushing on the 5th gear assembly, it must be heated to 120°C. Push the bushing into place, then install the inner ring on the input shaft.
21. Position new gasket, install gear retainer housing cover.
22. Position the remaining input shaft bearing inner race.
23. After installing the inner ring, install the flat gasket and mounting bolt, tighten it with the tightening torque specified in the Specifications. On late models, the bolt must be replaced.
24. Install the bolts securing the fastener of the gears to the cover of the casing, tighten them with the tightening torque specified in the Specifications. Install a new cover cap into the hole at the end of the cover.
25. Lubricate the mating surfaces of the gear carrier and gearbox with sealant. Connect the fastener of the gears to the gearbox by sliding on the dowel pins, insert the clamping bolts, and tighten them with the tightening torque indicated in Specifications.
26. Install the selector lever.
27. On late models, the selector lever and shaft assembly have been changed. The small selector shaft cover is not installed. The springs and gaskets that push the lever to the 3/4 gear mechanism have also been changed (and which prevent the possibility of direct shifting from the 5th gear to the reverse gear).
28. The last typical selector lever is attached to the shaft with a cone bolt. The cone bolt is self-locking and must be replaced when overhauled.
Visitor comments