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9.14. Secondary shaft of the TE DOHC transmission

Secondary shaft of the TE DOHC transmission

1 – bearing;
2 – the conducted gear wheel of the 4th transfer;
3 – expansion plug;
4 – gear wheel of the 3rd transfer;
5 – gear wheel of the 2nd transfer;
6 – ring of the synchronizer of the 2nd transfer;
7 – lock ring;
8 – synchronizer 1-oy/2nd of transfers;
9 – ring of the synchronizer of the 1st transfer;
10 – gear wheel of the 1st transfer;
11 – bearing;
12 – secondary shaft;
13 – clamp cracker spring;
14 – the sliding coupling of the synchronizer 1-oy/of the 2nd of transfers;
15 – clamp cracker;
16 – nave of the coupling of the synchronizer 1-oy/of the 2nd of transfers

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: 0,05–0,28 mm
Maximum permissible gap: 0,33 mm

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.

GAP OF THE GEAR WHEEL OF THE 2ND TRANSFER

PERFORMANCE ORDER
1. Measure a gap between a gear wheel of the 2nd transfer and a gear wheel of the 3rd transfer.

Nominal gap: 0,18–0,46 mm
Maximum permissible gap: 0,51 mm

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.

Dismantling

BEARING AND GEAR WHEEL OF THE 4TH TRANSFER

PERFORMANCE ORDER
Using a press and special OK201 172 008 adaptation, remove a gear wheel of the 4th transfer.

GEAR WHEELS OF THE 2ND AND 3RD TRANSFERS

PERFORMANCE ORDER
1. Remove a lock ring.
2. Move gear wheels to the шестерне1st - oh transfers.
3. Using a press and special OK201 172 008 adaptation, remove a gear wheel of the 2nd and a gear wheel of the 3rd transfer.

THE SYNCHRONIZER 1-OY/2ND OF TRANSFERS, RING OF THE SYNCHRONIZER AND THE CONDUCTED GEAR WHEEL OF THE 1ST TRANSFER

PERFORMANCE ORDER
1. Remove a lock ring.
2. Using a press, remove the synchronizer 1-oy/2nd of transfers, a ring of the synchronizer and the conducted gear wheel of the 1st transfer

BEARING

PERFORMANCE ORDER


Using a press and special OK130 171 013 adaptation, remove the bearing.

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.
3. Visually check a condition of a ring of the synchronizer for absence of damage, wear and cracks.

SYNCHRONIZER RING

PERFORMANCE ORDER

1. Visually check a condition of teeths of a ring of the synchronizer for absence of damage, wear and cracks.

2. Check a condition of a conic surface for absence of damage, wear and cracks.
3. Establish a synchronizer ring in a gear wheel.

4. Measure a gap between a ring of the synchronizer and a surface of a flange of a gear wheel.

Nominal gap: 1,5 mm
Minimum admissible gap: 0,8 mm

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.
3. Check a condition of crackers of a clamp for absence of damage, wear and cracks.
4. Measure a gap between the sliding couplings of the synchronizer and forks.
Gap, mm
Element
Nominal
Maximum permissible
1-aya/the 2nd
0,1 – 0,45
0,95
3-ya/the 4th
0,10 – 0,40
0,90
5-aya/Z.Kh.
0,10 – 0,36
0,86

INTERMEDIATE GEAR WHEEL OF THE BACKING

PERFORMANCE ORDER
1. Visually check a condition of teeths of a gear wheel for absence of damage, wear and cracks.
2. Measure a gap between the plug of an intermediate gear wheel of a backing and the lever.

Nominal gap: 0,01–0,32 mm
Minimum admissible gap: 0,5 mm

BEARING

PERFORMANCE ORDER

Check the bearing for absence of damage and smoothness of rotation.

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.

5. Measure by the indicator of hour type a beating of primary and secondary shaft.

Beating of a main shaft: 0,05 mm
Beating of a secondary shaft: 0,015 mm


Prevention

If replacement of a secondary shaft was made, adjust a preliminary tightness of the bearing.


 
Oil gap, mm

Element
Shaft (outer diameter)
Gear wheel (internal diameter)
Plug (outer diameter)
The 1st
39,445 – 39,470
39,500 – 39,525
0,03 – 0,08
The 2nd
34,945 – 34,970
35,000 – 35,025
 
3-y
35,945 – 35,970
36,000 – 36,025
 
The 4th
30,945 – 30,970
31,000 – 31,025
 
The 5th
34,000 – 34,025
33,945 – 33,970
 

SPEED SENSOR (SPEEDOMETER DRIVE MECHANISM)

PERFORMANCE ORDER
1. Visually check a condition of teeths for absence of damage, wear and cracks.
2. Check a sealing ring for absence of damage and wear.

Assembly

SYNCHRONIZER COUPLING NAVE

PERFORMANCE ORDER
Establish crackers of a clamp and a spring in a synchronizer coupling nave.

Sizes of a cracker of a clamp, mm

Element
1
2
3
1-aya/the 2nd
19,0
4,25
5,0
3-ya/the 4th
17,0
4,25
5,0
4-aya/Z.Kh.
17,0
4,25
5,0

THE BEARING (FROM DIFFERENTIAL)

PERFORMANCE ORDER

Using a press and special OK900 175 AA1 adaptation, install the new bearing.

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
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.
2. Combine dredging of a ring of the synchronizer with clamp crackers.
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.

RING OF THE SYNCHRONIZER OF THE 2ND TRANSFER AND GEAR WHEEL OF THE 2ND AND 3RD TRANSFERS

PERFORMANCE ORDER
1. Establish a ring of the synchronizer of the 2nd transfer and a gear wheel of the 2nd transfer.
2. Using a press and special OK900 175 AA1 adaptation, establish a gear wheel of the 3rd transfer.

GEAR WHEEL OF THE 4TH TRANSFER AND INTERNAL RING OF THE BEARING

PERFORMANCE ORDER
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.
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: 0,33 mm

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

4. If gaps do not correspond to demanded, sort and repeatedly collect a secondary shaft.