Pic. 6.8. Output shaft details: 1 - nut; 2 - thrust plate; 3 - sliding clutch of the synchronizer of the 5th gear; 4 - sliding clutch hub; 5 – a blocking ring of the synchronizer; 6 - gear V transmission; 7 - gear bushing; 8 - thrust washer; 9 - ball bearing; 10 - thrust washer; 11 - gear IV gear; 12 – a lock ring of a nave of the synchronizer; 13 - sliding clutch of the synchronizer of III and IV gears; 14 - sliding clutch hub; 15 – gear wheel of III transfer; 16 – gear wheel of the II transfer; 17 - sliding clutch of the synchronizer of I and II gears with a gear rim in reverse; 18 - hub of the sliding clutch of the synchronizer of I and II gears; 19 - synchronizer spring; 20 - cracker; 21 - retainer; 22 - gear wheel of the 1st gear; 23 - gear wheel leading the main gear; 24 - retaining ring; 25 - cylindrical roller bearing
Details of a secondary shaft are shown on fig. 6.8.
You will need: two large flat-bladed screwdrivers, a hammer, a soft metal drift, and a set of flat feelers.
1. Remove the secondary shaft from the gearbox (see «Disassembly of the gearbox and troubleshooting of its parts»).
2. Clamp the shaft in a vise with soft metal jaws with little force.
Attention! The output shaft must be clamped in a vice with soft pads on the jaws for the inner ring of the front bearing. Tighten the vise so that the shaft can be tilted by hand, otherwise the bearing race surface may be damaged.
3. Remove the retaining ring from the front end of the shaft, which is installed under the inner ring of the front bearing.
4. Using two screwdrivers, press the front bearing inner race off the shaft. The collar of the ring is directed towards the final drive gear.
5. Opening the vise, rest the 1st gear gear on two supports. With hammer blows through a wooden gasket, press the 1st gear gear with the final drive gear from the shaft.
6. Remove the final drive gear from the shaft. Please note that the chamfer on the inside diameter of the gear is directed towards the 1st gear gear.
7. Remove the 1st gear gear from the shaft. The cone on the gear is directed towards the synchronizer.
8. Mark the blocking ring 1 with respect to the coupling 2. During operation, the teeth of the ring are run in to the teeth of the coupling, therefore, during assembly, the ring must be installed in the same position. Remove the blocking ring of the 1st gear of the synchronizer.
9. Again clamp a shaft in a vise and remove a lock ring of a nave of the synchronizer.
10. Using two large screwdrivers, applying force to the 2nd gear gear, press the 1st and 2nd gear synchronizer from the splines of the shaft.
11. Remove the synchronizer with the blocking ring 1 of the 2nd gear and mark the ring 1 with respect to the synchronizer clutch 2.
12. Remove the 2nd gear gear from the shaft. Please note that the cone on the gear is directed towards the synchronizer.
13. Turn the shaft over and use two large screwdrivers to press the rear bearing off the shaft. In this case, the open side of the bearing faces the gear of the 4th gear.
14. Remove the thrust washer.
15. Remove the 4th gear. Please note that the cone on the gear is directed towards the synchronizer.
16. Mark blocking ring 1 relative to synchronizer sleeve 2. Remove the blocking ring of the IV synchronizer gear.
17. Remove a lock ring of a nave of the synchronizer.
18. Having unclenched the vise, rest the gear of the III gear on two supports and press the synchronizer of III and IV gears from the splines of the shaft with blows of a hammer through a soft gasket.
19. Remove the synchronizer with the third gear blocking ring and mark the ring 1 with respect to the synchronizer clutch 2. Pay attention to the fact that the groove on the clutch is directed towards the 3rd gear gear.
20. Remove the 3rd gear gear. Please note that the cone on the gear is directed towards the synchronizer.
21. Thoroughly clean, rinse and dry the output shaft parts.
22. Check up a condition of a shaft. In the presence of pitting (shells) on the journals for bearings or signs of wear, the shaft must be replaced.
23. Check the condition of the gears. If there are chips and chipping of the teeth, scuffing in the internal holes or signs of wear on the working surfaces of the teeth, replace the gears. If there is significant crushing or chipping at the ends of the teeth of the spline crown, it is also necessary to replace the gears.
24. Check up ease of rotation of the bearing. If the raceways or balls are damaged and if play is found in the bearing (radial clearance in the bearing must not exceed 0.04 mm) replace the bearing.
25. Check up a condition of blocking rings of synchronizers. If there are nicks and chips on the gear rims or significant wear on the cones, replace the blocking rings.
26. Check up a backlash between gear wheels and corresponding blocking rings. To do this, firmly install the blocking ring on the cone of the corresponding gear, i.e. «grind» turn it to the cone several times, and measure the gap with a flat feeler gauge. The minimum allowable gap is 0.6 mm. If it is less, the blocking ring must be replaced.
Note. When replacing the blocking ring, also check the gap between the new ring and the gear. To do this, put the ring on the gear cone and shake it, play is unacceptable.
27. If scoring and deformation are found on the thrust rings, as well as if the retaining rings lose their elasticity, replace them.
28. Before assembly, clean the oil channels of the secondary shaft.
29. Collect a secondary shaft in an order, the return to removal. At the same time, install the old blocking rings in accordance with the previously made marks. Install the new rings so that the small protrusions on the ring (missing teeth) coincided with the grooves of the synchronizer hub where the latches are installed.
30. Press the rear shaft bearing with a suitable mandrel, applying force only to the inner race of the bearing.
31. Before installing the front bearing inner race, first install the retaining ring and only then press the bearing inner race against the retaining ring with a suitable mandrel.
32. After assembly, check the operation of the synchronizers. To do this, manually move the synchronizer clutches to the appropriate gear engagement position.