Disassembly
Remove the 4th gear circlip.
Remove thrust washer and 4th gear with needle bearing.
Install the input shaft with the 3rd gear gear on the press and compress the 3rd gear gear, the synchronizer sliding sleeve and the hub with the synchronizer blocking rings.
When connecting the hub to the sliding clutch of the synchronizer of III and IV gears, direct the groove on the outer crown of the hub towards the gear of the IV gear, and the beveled edge of the inner splines of the hub - towards the gear of the III gear
Check the wear of the synchronizer locking wheels. To do this, press the blocking rings against the cones of the gear synchronizers and use a feeler gauge to measure the axial clearance between the end face of the blocking ring and the end face of the ring gear of the gear synchronizer, which must be at least 0.5 mm. If the gap is less, replace the synchronizer blocking rings.
Axial clearance measurement «A» between the end face of the blocking ring and the end face of the ring gear of the gear synchronizer
Press the inner ring of the rear bearing on the press.
Assembly
Connect the sliding sleeve to the 3rd and 4th gear synchronizer hub, pointing the chamfered edge of the inner splines of the hub towards the 3rd gear, and the mounting groove on the outer crown of the hub towards the 4th gear (see photo).
Slide the sliding sleeve onto the synchronizer blocking rings, aligning the dowel slots on the rings and hub. Install the retainers and springs with the spring connectors spaced 120°apart. In this case, the curved ends of the springs must be brought in and the recesses of the crackers.
Install the 3rd gear with the needle bearing.
Press the 3rd and 4th gear synchronizer onto the shaft.
Install the 4th gear with the needle bearing.
Measure the axial run-out of the 4th gear gear and install the appropriate thrust washer so that the clearance is within 0.10-0.40 mm.
Measuring the axial clearance of the gear of the IV gear of the input shaft to determine the thickness of the thrust washer
Install the rear bearing inner race with a mandrel.
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