Disassembly
Remove the retaining ring with pliers.
Remove the 4th gear thrust washer, needle bearing and 4th gear from the shaft.
Remove the 4th gear synchronizer blocking ring, then the synchronizer retaining ring.
Compress the sliding clutch with the synchronizer blocking ring and the third gear gear on the press. Remove the 3rd gear needle bearing
Assembly
Install the needle bearing and 3rd gear on the shaft.
Check the wear of the synchronizer blocking rings, for which press the synchronizer 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 gear rim of the gear synchronizer, which must be at least 0.5 mm (see picture). If the clearance is less, replace the synchronizer blocking rings.
The arrow shows a groove for the correct connection of the hub with the sliding synchronizer clutch, which for the hub of the synchronizer clutch of I and II gears should be directed towards the gear of the first gear, and for the hub of the synchronizer clutch of III and IV gears - towards the gear of the IV gear
Install the 3rd gear synchronizer ring.
Connect the sliding sleeve to the hub of the 3rd and 4th gear synchronizer, directing the inner splines of the hub with the beveled edge towards the 4th gear (see photo). After installing the three synchronizer crackers, install the springs, placing their connectors through 120 ', while the curved ends of the springs must be inserted into the grooves of the crackers.
Press the synchronizer onto the input shaft by turning the synchronizer blocking ring
3rd gear so that the protrusions of the ring enter the grooves of the hub of the sliding clutch, and the bevelled edge of the inner splines of the hub is directed towards the gear of the 3rd gear.
Install the 4th gear synchronizer blocking ring and fix it with the circlip.
Press the 4th gear with needle bearing onto the shaft.
Slide the 3rd gear gear and synchronizer all the way into the circlip.
Measure the axial clearance of the 4th gear with a set of feelers (see photo), which should be in the range of 0.10-0.40 mm. Select an appropriate thrust washer to obtain the smallest clearance.
Install retaining ring.
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