Table of contents: Disassembly ↓ Assembly ↓
Disassembly
Remove the retaining ring using pliers.
Remove the thrust washer of the fourth gear pinion, the needle bearing and the fourth gear pinion from the shaft.
Remove the 4th gear synchronizer locking ring, then the synchronizer retaining ring.
Press the sliding sleeve with the synchronizer locking ring and the third gear pinion on a press. Remove the third gear pinion needle bearing
Assembly
Install the needle bearing and 3rd gear gear on the shaft.
Check the wear of the synchronizer locking rings, for which press the synchronizer locking rings against the gear synchronizer cones and use a feeler gauge to measure the axial clearance between the end of the locking ring and the end of the gear synchronizer ring, which should be at least 0.5 mm (see picture). If the gap is smaller, replace the synchronizer locking rings.
The arrow shows the recess for the correct connection of the hub with the sliding synchronizer clutch, which for the hub of the synchronizer clutch of the 1st and 2nd gears should be directed towards the gear of the 1st gear, and for the hub of the synchronizer clutch of the 3rd and 4th gears - towards the gear of the 4th gear
Install the 3rd gear synchronizer locking ring.
Connect the sliding coupling to the synchronizer hub of the III and IV gears, directing the internal splines of the hub with the beveled edge towards the IV gear pinion (see photo). After installing the three synchronizer crackers, install the springs, placing their connectors at 120°, while the curved ends of the springs must be inserted into the cracker recesses.
Press the synchronizer onto the input shaft by turning the synchronizer locking ring
III gear so that the projections of the ring enter the grooves of the sliding clutch hub, and the beveled edge of the internal splines of the hub is directed towards the III gear gear.
Install the 4th gear synchronizer locking ring and secure it with the retaining ring.
Press the 4th gear pinion with the needle bearing onto the shaft.
Move the 3rd gear pinion and synchronizer until they stop against the retaining ring.
Measure the axial clearance of the fourth gear pinion with a set of feeler gauges (see photo), which should be in the range of 0.10-0.40 mm. Select the appropriate thrust washer to obtain the smallest clearance.
Install the retaining ring.