Gearbox disassembly

Before dismantling, wash the box with detergents, install it on the stand, drain the oil and remove the bottom cover with the gasket.

Remove plug 11 (see fig. 110) clutch release drive, and from the guide sleeve of the front cover of the gearbox, the clutch 10 assembly with the bearing 13 and the connecting spring.

Remove the clutch housing with gasket and transmission front cover (complete with seal and spring washer) and unscrew the reversing light switch. Then remove the speedometer drive with gasket.
Having unscrewed the fastening bolt of the shift fork of the III and IV gears, by moving the forks, turn on any two gears at the same time. This prevents the shafts from turning and allows subsequent disassembly operations.

Remove the retaining ring from the end of the output shaft, then, having unbent the lock washer, unscrew the flexible coupling flange nut a few turns to move the centering ring, and re-tighten the nut. Using A.40006/1 ejector with A.40005/4 puller, remove from the end of the secondary shaft the centering ring of the flexible coupling of the cardan shaft, the seal of the centering ring of the elastic coupling.

Unscrew the nut and remove the flange of the elastic coupling with a puller A.40005/3/9B/9C, then remove the rear cover of the gearbox by unscrewing the screw of the transverse travel limiter of the lever and moving the gear lever to the right, release it from the gear shift rods.

Remove:

• from the secondary shaft, the rear bearing and the speedometer drive gear;
• from a rod of inclusion of a backing a plug with the remote plug;
• from the axis of the intermediate reverse gear;
• with an intermediate shaft reverse gear retaining ring, pinion and spring washer;
• from the secondary shaft, the retaining ring of the reverse driven gear, pressing with a mandrel 41.7816.4069 (pic. 117) spring washer to take the load off the retaining ring;
• reverse driven gear and spring washer.

With the help of curly mandrels (screwdriver type) and rod drifts, press the front and rear intermediate shaft bearings out of the gearbox housing and remove the latter from the housing.


Remove the cover of the clamps, and from the crankcase - the reverse fork rod and the III and IV gear fork rod. Having unscrewed a bolt of fastening of a plug of switching of I and II transfers, take out a rod and a plug of switching of I and II transfers. When removing the rods, simultaneously remove the three blocking crackers.

Remove the intermediate shaft bearing retainer plate and reverse idle gear shaft. Unscrewing the screws securing the locking plate of the intermediate bearing of the secondary shaft is carried out with an impact drill screwdriver. Remove the input shaft along with the bearing and synchronizer ring and remove the needle bearing from the front end of the output shaft.

Knock out the secondary shaft from the intermediate bearing, remove the intermediate bearing and remove the secondary shaft assembly with gears, clutches and synchronizer rings from the crankcase. Then remove the synchronizer coupling of III and IV gears from the shaft.

When disassembling the input shaft, remove the retaining and blocking rings and the synchronizer spring from the rear end; having installed the shaft on the press and squeezing the spring washer with the mandrel 41.7816.4069, remove the retaining ring, and then the spring washer and bearing.

When disassembling the output shaft (pic. 118) remove from the rear side of the shaft the gear 22 of the 1st gear with the sleeve 23, the hub 16 with the sliding clutch 17 of the shift of the 1st and 2nd gears, the gear 11 of the 2nd gear together with the blocking ring 14 of the synchronizer, install the output shaft with the mandrel 41.7816.4069 (4 - fig. 119) on the press, place support half rings 1 under the gear of the III gear and, pressing the punch 3 through the mandrel on the spring washer, remove the retaining ring 5 with tongs, then the spring washer 2, the hub of the sliding clutch of the III and IV gears and the gear of the III gear.






When dismantling the gear lever and rear cover, remove the cuff 19 (pic. 120), cover 20 of the lever, then the retaining ring 14, washer 13, spring 12 and spherical washer 11. Unscrew the flange fastening nuts 16, disconnect the release spring 3 of the lever from the eye of the bolt 1 and remove the lever together with the flange, support 10 and cup 5.