Table of contents: Disassembly ↓ Assembly ↓
Disassembly
Press the 1st gear, adjusting washer and inner ring of the ball bearing on a press using a mandrel.
Remove the needle bearing with the inner sleeve and the 1st gear synchronizer locking ring.
Press out the 2nd gear pinion, needle bearing, 2nd gear synchronizer locking ring and 1st and 2nd gear synchronizer using a special puller or on a press using a mandrel.
Press off the 3rd gear retaining ring using a press or a special puller.
Press the fixed gear of the 4th gear on a press using a suitable device and remove the inner ring of the bearing with cylindrical rollers, having first removed the gear retaining ring.
Check the technical condition of the secondary shaft parts and, if necessary, replace worn or damaged parts.
Assembly
Note: Do not lubricate the III and IV gears and the secondary shaft with oil before installation.
Press the inner ring of the cylindrical roller bearing onto the secondary shaft.
Pressing on the first inner ring of the secondary shaft rear bearing using special tools on a press
Using a press, press the fourth gear pinion onto the shaft until it stops, after heating it to 120°C on a heating plate; the wide flange of the pinion should be facing the head of the main gear drive pinion.
Install the 4th gear pinion retaining ring, selecting the thickest of the rings supplied as spare parts (see subsection "Detailed technical specifications").
Heat the third gear pinion to a temperature of 120°C, press it on the press until it stops, directing the wide flange of the pinion towards the neck of the fourth gear friction wheel.
Install the needle bearing.
Install the third gear pinion retaining ring, selecting the thickest one from the supplied and spare parts rings (see subsection "Detailed technical specifications").
Install the 2nd gear pinion and the synchronizer locking ring, having first checked the axial jam between the end face of the locking ring and the end face of the synchronizer gear ring with a set of feeler gauges.
Assemble the sliding clutch and the hub of the synchronizer of the first and second gears, when installing, direct the hub opening towards the gear of the first gear. Stop the crackers and put on the synchronizer springs, placing their connectors at an angle of 120°C relative to each other and inserting the curved ends of the springs into the recesses of the crackers.
Press the synchronizer of the 1st and 2nd gears onto the shaft using a press.
Install the inner sleeve and needle bearing of the 1st gear.
Press the inner ring of the roller bearing onto the shaft using a press.
Installing the second inner ring of the secondary shaft rear bearing
Note: When replacing the bearing together with the outer ring, install a new adjusting ring, having first calculated the thickness (see "Adjusting the distance between the differential axle and the end of the drive gear").