In this article we will consider the stages of disassembling and assembling the gearbox
Disassembling the gearbox
After removing the drive shaft, remove the auxiliary cylinder assembly
Removing the gear shift cable mounting bracket (A) and the vehicle speedometer (B)
Removing the gear selector lever (C) and the switch connection (D) assembly
Removing the taillight switch (A) and the neutral switch (B)
Remove the drive shaft (A)
Disconnect the gearbox holder
Unscrew the filler cap and the driven shaft bolt
Disconnect the clutch housing (B) from the gearbox housing (A)
Remove the spring pins from the shift beam (third, fourth and reverse gear)
Remove the forks (4EA), axles (2EA) and axle support bracket
After that, remove the parts in order:
- - second output shaft;
- - input shaft;
- - first output shaft;
- - differential assembly.
Remove the reverse driven shaft assembly
Remove the magnetic plug and auxiliary cylinder
Remove the guides, outer bearing rings, mounting pin and gaskets from the clutch housing
Remove the sealing rings and guides from the clutch housing
Gearbox assembly
Install the driven shaft of the reverse gear assembly
After installing the outer race of the tapered roller bearing (B) on the differential assembly (A), measure the height with the device (C)
After installing the outer race of the tapered roller bearing (B) on both sides of the input shaft (A), measure the height
After installing the outer race of the tapered roller bearing (B) on both sides of the first output shaft (A), measure the height
After installing the outer race of the tapered roller bearing (B) on both sides of the second output shaft (A), measure the height
We install the cuffs and guides on the clutch housing (A)
We install the auxiliary cylinder assembly and the boot. Tightening torque 11.8-14.7 Nm
Fix the guides (B), outer bearing rings, mounting pins and gaskets (C) on the clutch housing (A).
Insert the rubber bushing into the auxiliary cylinder hole
Tighten the magnetic plug (A). Tightening torque 29.4-34.3 Nm
Measure the axial clearance of the reverse gear pinion (A) of the primary output shaft with a gauge (B). Standard value 0.135-0.345 mm
We measure the axial clearance of the first gear pinion (A) of the primary output shaft with a gauge (B). Standard value 0.135-0.345 mm
We measure the axial clearance of the second gear pinion (A) of the primary shaft with a gauge (B). The standard value is 0.230-0.430 mm
We measure the axial clearance of the fifth gear pinion (A) of the second output shaft with a gauge (B). Standard value 0.125-0.305 mm
We measure the axial clearance of the third gear pinion (A) of the second output shaft with a gauge (B). Standard value 0.142-0.427 mm
We measure the axial clearance of the fourth gear pinion (A) of the second output shaft with a gauge (B). The standard value is 0.230-0.430 mm
We install the driven shaft of the reverse gear (A) together with the gasket on the clutch housing (B)
Installing the differential assembly (A) with a new gasket in the clutch housing
Install the first output shaft (A) with a gasket in the clutch housing
Installing the input shaft (A) with a gasket in the clutch housing
Installing the second output shaft (A) with a gasket in the clutch housing
We install the fork (A), the switch shaft (B) and the axle support mounting bracket. Tightening torque 19.6-26.5 Nm
Fix the parts by inserting the pin into the axis (A, B). Lightly tap the spring pin.
Insert the gaskets, bushings and outer bearing rings into the gearbox housing
Apply sealant to the gearbox housing. Recommended sealant is Loktite 587 or 5060
Align the pin with the hole on the reverse driven shaft damper
Align the transmission housing (A) with clutch housing (B)
We tighten the filler cap and the bolt of the driven shaft (B). Tightening torque 29.4-34.3 Nm for the plug; 24.5-29.4 Nm for the bolt.
Fix the gearbox holder (A), thrust pin (B) and cuff (C). Tightening torque 24.5-29.4 Nm
Press the thrust pin so that it is flush with the surface of the transmission housing
Install the gear selector lever (B), first apply sealant to its surface. Tightening torque 9.8 -11.8 Nm
Install the rear light switch (A) and neutral gear (B). Tightening torque 29.4-34.3 Nm
Install the gear selector lever (A) and the lever mechanism assembly (B), arranging the parts at the same level with the yellow mark on the drive shaft (C).
Tightening torque 42.2-53.9 Nm
Install the vehicle speed sensor (B). Tightening torque 7.8-9.8 Nm
Install the gear shift cable mounting bracket assembly (A). Tightening torque 14.7-19.6 Nm.