Disassembly
Press the rear tapered roller bearing inner race together with the 1st gear sliding gear on a press.
Pressing out the inner ring of the rear tapered roller bearing of the secondary shaft together with the sliding gear of the 1st gear
Remove the 1st gear needle bearing and the 1st gear synchronizer ring.
Remove a lock ring of the synchronizer of I and II transfers.
Press the sliding clutch assembly with the hub and synchronizer blocking ring and the 2nd gear sliding gear.
Remove the first circlip of the 3rd gear gear.
Press the 3rd gear with a press.
Pressing the 3rd gear gear
Remove the second circlip of the 3rd gear gear.
Remove the 4th gear circlip.
Press the 4th gear with a Kukko 17/2 puller.
Pressing the fourth gear
Using a puller, press the inner race of the front tapered roller bearing.
Assembly
Press the inner race of the front tapered roller bearing onto the shaft.
Heat up, then use a press to press the 4th gear on the shaft with the collar towards the 3rd gear.
Pressing the 4th gear gear
Adjust the axial clearance of the 4th gear gear. To do this, slide the cooled IV gear onto the shaft until it stops, then select the most suitable retaining ring in thickness and install it in place. The axial clearance must not exceed 0.02 mm.
Measuring the axial clearance of the sliding clutch of the synchronizer of III and IV gears
Measuring the axial clearance of the 4th gear gear
Install the second circlip 2.40 mm thick of the 3rd gear.
Heat up, then using a press, press the 3rd gear gear onto the shaft until it stops with the collar towards the 2nd gear sliding gear.
Install the first retaining ring.
Measure the axial clearance of the 3rd gear gear with a feeler gauge, which should be within 0.00-0.04 mm. By selecting a retaining ring of the appropriate thickness, achieve the smallest gap.
Measuring the gap between the gears of II and III gears
Lubricate with hypoid oil and install 2nd gear needle bearing.
Check the wear of the 2nd gear synchronizer blocking ring. To do this, move the ring all the way towards the cone of the sliding gear of the 2nd gear 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 (see photo).
Install the 2nd gear sliding gear.
If the sliding sleeve has been disconnected from the hub, slide the sliding sleeve onto the hub, fit crackers into the grooves of the hub and install the springs with connectors at an angle of 120°relative to each other. The bent ends must be brought over the protrusions of crackers.
Press the hub assembly with the clutch onto the shaft so that the teeth of the reverse gear are directed towards the gear of the 2nd gear. Turn the 2nd gear synchronizer blocking ring so that the ends of the crackers fit into the grooves of the ring.
Install retaining ring.
Measure the axial clearance of the synchronizer with a feeler gauge, which should be within 0.00-0.04 mm. Achieve the smallest possible clearance by selecting a retaining ring of the appropriate thickness.
Check the wear of the 1st gear synchronizer blocking ring, proceeding in the same way as for the 2nd gear synchronizer blocking ring.
Note. Please note that the 1st and 2nd gear synchronizer blocking rings are not the same. The 1st gear synchronizer blocking ring has three teeth less at a taper angle of 110°. The 2nd gear synchronizer blocking ring is fully toothed and has a 115°taper angle.
Lubricate with hypoid oil and reinstall the 1st gear needle bearing.
Install the 1st gear sliding gear.
Using a press, press the inner race of the rear tapered roller bearing as far as it will go.
Measure the axial clearance of the sliding gear of the 1st gear with a feeler gauge, which should be in the range of 0.10-0.40 mm.
Measuring the axial clearance of the sliding gear of the 1st gear
At a deviation from norm check up adjustment of an axial backlash of the synchronizer of I and II transfers.
Pressing on the sliding clutch of the synchronizer of I and II gears, complete with the hub
Visitor comments