Rear of the five-speed gearbox
1 - secondary shaft; 2 - reverse driven gear; 3 – a nave of the coupling of the synchronizer of V transfer; 4 - synchronizer clutch; 5 - washer; 6 - gearshift lever; 7 – a blocking ring of the synchronizer; 8 - gear and ring gear of the synchronizer of the 5th gear; 9 – oil deflector washer; 10 - bushing gear V transmission; 11 – a driving gear wheel of a drive of a speedometer; 12 - rear bearing of the secondary shaft; 13 - stuffing box; 14 – flexible coupling flange; 1 5 - nut; 16 – centering ring seal; 17 - centering ring; 18 - retaining ring; 19 - lock washer; 20 - driven gear of the speedometer drive; 21 – gear block bearing; 22 – a bolt of fastening of the block of gear wheels; 23 - block gears V transmission and reverse; 24 – a back cover of a transmission; 25 - intermediate shaft
Unscrewing the bolts of the gear block and the fork of the inclusion of V gear and reverse
1 – an intermediate gear wheel of a backing; 2 – a bolt of fastening of the block of gear wheels; 3 - plug stem; 4 – a bolt of fastening of a fork; 5 – clamp cover
Removing the reverse driven gear and the 5th gear synchronizer clutch hub
1 - intermediate shaft; 2 - driven reverse gear; 3 – an axis of an intermediate gear wheel of a backing; 4 – a nave of the coupling of the synchronizer of V transfer; 5 - secondary shaft; 6 – a rod of a fork of inclusion of I and II transfers; 7 – a rod of a fork of inclusion of III and IV transfers
Gear selector
1 - washers of the guide plate; 2 – a directing plate of the lever of a gear change; 3 – the case of the lever of a gear change; 4 - ball bearing of the lever; 5 - spherical washer; 6 - spring; 7 - thrust ring; 8 - retaining ring; 9 - gear lever; 10 - protective cover; 11 - flange; 12 - reverse blocking plate; 13 - spring; 14 - guide bar; 15 - sealing ring; A - risk
Removal of the intermediate reverse gear, V gear assembly with synchronizer and fork
1 – an intermediate gear wheel of a backing; 2 – clutch of inclusion of V transfer; 3 - gear V gear assembly with a synchronizer; 4 – fork of inclusion of V transfer and a backing
Disassembly
1. Before removing the rear cover, set the gear lever to the neutral position, unscrew the nuts securing the gear selector mechanism assembly with the mechanism.
2. Then disconnect the nuts securing the rear cover and remove it. One of the cover fastening nuts is unscrewed from the inside of the gearbox housing with the bottom cover removed.
3. When removing the rear cover, it must be fed not only back, but also rotated to prevent it from touching the reverse gear and fifth gear.
4. After removal from the secondary shaft of the inner ring of the rear bearing 12 (see fig. Rear of the five-speed gearbox) and drive gear of the speedometer drive, loosen the cover fastening bolts 5 (see fig. Unscrewing the bolts of the gear block and the fork of the inclusion of V gear and reverse) clamps and unscrew bolts 2 and 4 fastening the gear unit and the fork for engaging the fifth gear and reverse gear.
5. Remove oil deflector 9 (see fig. Rear of the five-speed gearbox) and then bushing 1 of the fifth gear.
6. Remove the rod 1 from the fork 2. At the same time, the distance sleeve 3 is removed from the rod. Then remove the gear unit 4 from the spline of the intermediate shaft.
7. Remove at the same time the intermediate gear 1 reverse from the axle (see fig. Removal of the intermediate reverse gear, V gear assembly with synchronizer and fork), gear 3 complete with clutch 2 and fork 4 from the output shaft.
8. Remove the washer 5 from the secondary shaft (see fig. Rear of the five-speed gearbox).
9. Then, using curly mandrels such as screwdrivers, remove hub 4 from the key (see fig. Removing the reverse driven gear and the 5th gear synchronizer clutch hub) fifth gear synchronizer and reverse driven gear 2.
10. Carry out further disassembly of the gearbox in the order described for the four-speed gearbox.
11. If necessary, disassemble the lever and the gear selection mechanism, for which remove the protective cover 10 (see fig. Gear selector), retaining and thrust rings 7 and 8, spring and spherical washer 5 from the gear lever.
12. Visually mark the location of the parts relative to the mark A, printed on the guide plate, so that when assembling, connect the parts in the same position.
13. Having unscrewed the nuts from the fastening bolts, separate the parts of the gear selection mechanism and remove the lever 9, its ball joint 4 and rubber sealing rings 15.
Assembly
1. The assembly of the fifth stage, reverse gear and gear selection mechanism is carried out in the reverse order of disassembly, taking into account the following.
2. Fasten the axis of the intermediate reverse gear before installing the shafts in the gearbox housing with a torque of 78 Nm (8 kgf·m).
3. Before installing the 5th gear and reverse fork rod into the crankcase, install the spacer sleeve on it.
4. Press the inner ring of the bearing onto the fifth gear and reverse gear block, and the outer ring into the socket of the rear cover.
5. Press the output shaft rear bearing onto the shaft to facilitate installation of the rear cover.
6. Reverse intermediate gear 1, gear 3 and fork 4 (see fig. Removal of the intermediate reverse gear, V gear assembly with synchronizer and fork) install at the same time.
7. When assembling the gear lever, coat the ball head or the sphere of the ball joint with LSTs-15 grease.
8. Tighten the gear block mounting bolt to a torque of 78 Nm (8 kgf·m).