9.13. Secondary shaft of the BF DOHC transmission
Secondary shaft of the BF DOHC transmission
1 – internal ring of the bearing;
2 – gear wheel of the 4th transfer;
3 – expansion plug;
4 – gear wheel of the 3rd transfer;
5 – gear wheel of the 2nd transfer;
6 – plug of a gear wheel of the 2nd transfer;
7 – needle bearing;
8 – internal ring of the synchronizer;
9 – double cone;
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10 – synchronizer ring;
11 – synchronizer 1-oy/2nd of transfers;
12 – gear wheel of the 1st transfer;
13 – internal ring of the bearing;
14 – secondary shaft;
15 – synchronizer spring;
16 – backing gear wheel;
17 – clamp cracker;
18 – synchronizer coupling nave |
Preliminary check
GAP OF THE GEAR WHEEL OF THE 1ST TRANSFER
| PERFORMANCE ORDER |
| 1. Measure a gap between a gear wheel of the 1st transfer and a gear wheel of differential. Nominal gap: 0,05–0,26 mm
Maximum permissible gap: 0,29 mm
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2. If the gap exceeds maximum permissible value, check the surface of contact of a gear wheel of the 1st transfer, a gear wheel of differential and the coupling of the synchronizer 1-oy/of the 2nd of transfers. Replace the worn-out or damaged details. |
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GAP OF THE GEAR WHEEL OF THE 2ND TRANSFER
| PERFORMANCE ORDER |
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1. Measure a gap between a gear wheel of the 2nd transfer and a gear wheel of the 3rd transfer. Nominal gap: 0,05–0,17 mm
Maximum permissible gap: 0,27 mm
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| 2. If the gap exceeds maximum permissible value, check the surface of contact of a gear wheel of the 2nd transfer, a gear wheel of the 3rd transfer and the coupling of the synchronizer 1-oy/of the 2nd of transfers. Replace the worn-out or damaged details. |
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Dismantling
BEARING AND GEAR WHEEL OF THE 4TH TRANSFER
| PERFORMANCE ORDER |
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Using a press and special OK201 172 008 adaptation, remove a gear wheel of the 4th transfer. |
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GEAR WHEELS OF THE 2ND AND 3RD TRANSFERS
| PERFORMANCE ORDER |
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1. Move gear wheels to the шестерне1st - oh transfers. |
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2. Using a press and special OK201 172 008 adaptation, remove a gear wheel of the 2nd and a gear wheel of the 3rd transfer. |
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Check
GEAR WHEELS
| PERFORMANCE ORDER |
| 1. Examine synchronizer cones on lack of wear. |
| 2. Examine a condition of a surface of teeths of gear wheels on absence of damage, wear and cracks. |
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3. Visually check a condition of a ring of the synchronizer for absence of damage, wear and cracks. |
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SYNCHRONIZER RING
| PERFORMANCE ORDER |
| 1. Visually check a condition of teeths of a ring of the synchronizer for absence of damage, wear and cracks. |
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2. Check a condition of a conic surface for absence of damage, wear and cracks. |
| 3. Establish a synchronizer ring in a gear wheel. |
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4. Measure a gap between a ring of the synchronizer and a surface of a flange of a gear wheel.
Nominal gap: 1,4–1,7 mm
Minimum admissible gap: 0,8 mm
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SYNCHRONIZER
| PERFORMANCE ORDER |
| 1. Visually check a condition of the synchronizer and its working capacity. |
| 2. Visually check a condition of teeths of a ring of the synchronizer for absence of damage, wear and cracks. |
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3. Check a condition of crackers of a clamp for absence of damage, wear and cracks. |
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4. Measure a gap between the sliding couplings of the synchronizer and forks.
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Gap, mm
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Element
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Nominal
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Maximum permissible
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1-aya/the 2nd
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0,1 – 0,35
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0,75
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3-ya/the 4th
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0,27 – 0,50
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0,80
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INTERMEDIATE GEAR WHEEL OF THE BACKING
| PERFORMANCE ORDER |
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1. Visually check a condition of teeths of a gear wheel for absence of damage, wear and cracks. |
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2. Measure a gap between the plug of an intermediate gear wheel of a backing and the lever. Nominal gap: 0,095–0,33 mm
Minimum admissible gap: 0,31 mm
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BEARING
| PERFORMANCE ORDER |
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Check the bearing for absence of damage and smoothness of rotation. |
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PRIMARY AND SECONDARY SHAFT
| PERFORMANCE ORDER |
| 1. Check surfaces of the gear wheels contacting to shaft on lack of wear and damages. |
| 2. Check vents of shaft for lack of wear and damages. |
| 3. Visually check a condition of teeths of gear wheels for absence of damage, wear and cracks. |
| 4. Check a condition of the channel for supply of lubricant for lack of a contamination. |
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5. Measure by the indicator of hour type a beating of primary and secondary shaft. Beating: 0,015 mm
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Prevention
 If replacement of a secondary shaft was made, adjust a preliminary tightness of the bearing.
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Assembly
SYNCHRONIZER COUPLING NAVE
| PERFORMANCE ORDER |
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Establish crackers of a clamp and a spring in a synchronizer coupling nave.
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Sizes of a cracker of a clamp, mm
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Element
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1
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2
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3
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| 1-aya/the 2nd | 18,0 | 4,25 | 5,0 |
| 3-ya/the 4th | 17,0 | 4,25 | 5,0 |
| 4-aya/Z.Kh | 17,0 | 4,25 | 5,0 |
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THE BEARING (FROM DIFFERENTIAL)
| PERFORMANCE ORDER |
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Using a press and special OK900 175 AA1 adaptation, install the new bearing. |
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GEAR WHEEL OF THE 1ST TRANSFER, RING OF THE SYNCHRONIZER OF THE 1ST TRANSFER AND SYNCHRONIZER 1-OY/OF THE 2ND TRANSFER
Prevention
On a ring of the synchronizer of the 2nd transfer there are no teeths in three places on perimeter to distinguish it from other rings of the synchronizer.
| PERFORMANCE ORDER |
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1. Establish a gear wheel of the 1st transfer, a ring of the synchronizer of the 1st transfer and the synchronizer 1-oy/of the 2nd transfer as it is shown in the drawing. |
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2. Combine dredging of a ring of the synchronizer with clamp crackers. |
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3. Using a press and special OK900 175 AA1 adaptation, establish a nave of the coupling of the synchronizer 1-oy/of the 2nd of transfers. |
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RING OF THE SYNCHRONIZER OF THE 2ND TRANSFER AND GEAR WHEEL OF THE 2ND AND 3RD TRANSFERS
| PERFORMANCE ORDER |
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1. Establish a ring of the synchronizer of the 2nd transfer and a gear wheel of the 2nd transfer. |
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2. Using a press and special OK900 175 AA1 adaptation, establish a gear wheel of the 3rd transfer. |
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GEAR WHEEL OF THE 4TH TRANSFER AND INTERNAL RING OF THE BEARING
| PERFORMANCE ORDER |
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1. Using a press and special OK900 175 AA1 adaptation, establish a gear wheel of the 4th transfer and an internal ring of the bearing. |
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2. Measure a gap between a gear wheel of the 1st transfer and a gear wheel of the drive of differential.
Nominal gap: 0,05–0,28 mm
Maximum permissible gap: 0,29 mm
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3. Measure a gap between a gear wheel of the 2nd and 3rd transfers.
Nominal gap: 0,10–0,22 mm
Maximum permissible gap: 0,27 mm
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4. If gaps do not correspond to demanded, sort and repeatedly collect a secondary shaft. |
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