Adjusting washer thickness selection
Size a, mm
|
Adjusting washer thickness, mm
|
8,35–8,64
|
1,10
|
8,65–8,94
|
1,40
|
8,95–9,24
|
1,70
|
9,25–9,54
|
2,00
|
9,55–9,84
|
2,30
|
Order of execution
1. Install the differential assembly to the clutch housing.
2. Install the differential cover and tighten the bolts of its fastening to a torque of 25 Nm (2.5 kgf·m).
3. Install the axle shaft flanges and tighten the bolts of their fastening to a torque of 20 Nm (2.0 kgf·m), while securing the flanges against rotation.
4. Set axle 23 (see fig. Transmission housing type 016) reverse intermediate gear. Install the reverse intermediate gear 26, the synchronizer 25 and the spring 24 on the axle. Before installing, check the axial clearance between the end of the synchronizer 25 and the end of the reverse intermediate gear 26. It should be 0.75–2.30 mm (minimum allowable 0.20 mm). After that, insert plate 22 and fix it on the gearbox housing with bolt 19. Put spring clip 21 on synchronizer fingers 25.
5. Insert the output shaft together with the 1st and 2nd gear fork rod into the gearbox housing, while tightening the lock.
6. Insert the reverse lock 28 into the gearbox housing.
7. Screw in the bolt 5 of the lever 27 of the reverse gear.
8. Insert the reverse gear lever 27 into the gearbox housing until its threaded bushing is aligned with the bolt, then tighten the bolt 5 of the lever fastening to a torque of 35 Nm (3.5 kgf·m).
9. Engage reverse gear several times and check the ease of operation of the intermediate mechanism for engaging the reverse gear.
10. Engage reverse.
11. Install output shaft 26 (see fig. Gearbox type 016) with fork 25 for switching 1st and 2nd gears, rod 22 and leash 23 into the gearbox housing.
12. Install the input shaft into the crankcase together with the fork 28 for switching 3rd and 4th gears inserted into the groove of the coupling 32 (see fig. 3.25) synchronizer.
13. Install clips 5 (see fig. Gearbox type 016) shift forks for 3rd and 4th gears together with pin 20.
15. Fix the forks and leash with spring pins.
16. Install the fork stem thrust bolts with new cardboard spacers.
17. Lock output shaft to crankcase and measure dimension a.
18. Select shim 21 (see fig. Output shaft for gearbox 016) required thickness and then install it on the shaft (see tab. Adjusting washer thickness selection).
19. Press the pinion 22 of the 5th gear of the secondary shaft, preheating it to a temperature of 120°C. In this case, the shoulder of the gear must be facing the bearing.
20. Install washer 23 and screw bolt 24 into the end of the output shaft with a torque of 50 Nm (5.0 kgf·m).
21. Secure input shaft to crankcase.
Press on inner ring 14 (see fig. Primary shaft KP 016) cylindrical roller bearing, preheating it to a temperature of 120°C. Then install bearing 15.
22. Determine the thickness of the retaining ring 16 so that the axial clearance does not exceed 0.05 mm.
23. Install gear 28 of 5th gear with synchronizer clutch, needle bearing 29 with inner ring 30 and fork 36 on the input shaft (see fig. Gearbox type 016).
24. Fix the 5th gear fork with spring pin 37.
25. Install retaining ring 27 (see fig. Primary shaft KP 016).
26. Install the 5th gear synchronizer on the hub.
27. Press the hub 25 with the ring gear onto the input shaft, preheating it to a temperature of 120°C.
28. Press on the second inner race 22 of the bearing.
29. Install gearbox cover 41 together with gasket 40.
30. Press on the first inner race 42 of the bearing.
31. Install washer 43 and screw bolt 44 into the end of the input shaft with a torque of 50 Nm (5.0 kgf·m).
32. Tighten the cover bolts to a torque of 25 Nm (2.5 kgf·m).
33. Install new plug 45.
34. Apply a thin layer of sealant to the mating surfaces of the gearbox and clutch housings and join them together. Tighten the mounting bolts to a torque of 25 Nm (2.5 kgf·m).
35. Apply a thin layer of sealant to the mating surfaces of the clutch housing and cover 16. Install the cover and tighten the bolts 18 of its fastening.
36. Install the shift lever, while it must be installed vertically.
Visitor comments