Disassembly
Press the 1st gear gear, shim and ball bearing inner ring on a press with a mandrel.
Remove the needle bearing with the inner sleeve and the blocking ring of the 1st gear synchronizer.
Compress the 2nd gear gear, needle bearing, 2nd gear synchronizer ring and 1st and 2nd gear synchronizer using a special puller or on a press using a mandrel.
Compress the 3rd gear retaining ring using a press or a special puller.
Press the fixed gear of the IV gear on the press using the appropriate tool and remove the inner ring of the bearing with cylindrical rollers, having previously removed the gear circlip.
Check the technical condition of the output shaft parts and, if necessary, replace worn or damaged parts.
Assembly
Note. Before installation, do not lubricate the gears of III and IV gears and the output shaft with oil.
Press the inner ring of the bearing with cylindrical rollers onto the secondary shaft.
Pressing the first inner ring of the rear bearing of the secondary shaft using special tools on the press
Using a press, press the gear of the IV gear onto the shaft until it stops, preheating it to 120°C on the heating plate, when scrapped, the wide shoulder of the gear should be facing the head of the drive gear of the main gear.
Install the retaining ring of the fourth gear, choosing the thickest of the rings supplied as spare parts (see subsection «Detailed Specifications»).
Heat the third gear gear to a temperature of 120°C, press it on the press until it stops, directing the wide collar of the gear towards the neck of the fourth gear grater.
Install the needle bearing.
Install the retaining ring of the third gear gear, choosing the largest but thickest of the supplied and spare parts of the rings (see subsection «Detailed Specifications»).
Install the 2nd gear gear and the synchronizer blocking ring, having previously checked with a set of probes the axial jam between the end of the blocking ring and the end of the ring gear of the gear synchronizer.
Pick up the sliding clutch and the hub of the synchronizer of the 1st and 2nd gears, when installing the hub, direct the hub towards the gear of the 1st gear. Stop crackers and put on synchronizer springs. placing their connectors at an angle of 120°C relative to each other and leading the curved ends of the springs into the recesses of the crackers.
Press the synchronizer of I and II gears onto the shaft using a press.
Install the 1st gear inner bush and needle bearing.
Press the roller bearing inner race onto the shaft with a press.
Installation of the second inner ring of the rear bearing of the secondary shaft
Note. When replacing the bearing together with the outer ring, install a new adjusting ring, having previously calculated the thickness (cm. «Adjusting the distance between the axle of the differential and the end face of the drive gear»).
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