9.7. Dismantling, check and assembly of the fifth / reverse gear and back cover of BF DOHC

Fifth / reverse gear and back cover of BF DOHC

1 – back cover;
2 – lock-nut;
3 – coupling of the synchronizer of the reverse gear;
4 – conical plug of the reverse gear;
5 – the blocking synchronizer ring;
6 – synchronizer of the 5th transfer;
7 – fork of the 5th transfer;
8 – gear wheel of the 5th transfer;
9 – plug of a gear wheel of the 5th transfer;
10 – secondary gear wheel of the 5th transfer;
11 – clamp stopper, spring and steel ball;
12 – bolt of fastening of a shaft of transfer of a backing;
13 – transmission case;
14 – shaft of transfer of a backing;

15 - intermediate gear wheel of transfer of a backing;
16 – control unit;
17 – lever of installation of a spring;
18 – switching rod 1-oy/the 2nd transfers;
19 – switching fork 1-oy/the 2nd transfers;
20 – switching rod 5-oy/back transfers;
21 – switching rod lever 5-oy/back transfers;
22 – switching rod 3-ey/the 4th transfers;
23 – switching rod lever 3-ey/the 4th transfers;
24 – switching fork 3-ey/the 4th transfers;
25 – block of gear wheels of a secondary shaft;
26 – block of gear wheels of a main shaft;
27 – differential
Prevention

Before assembly clear a transmission case solvent.

Clear all removed details (except tight bearings) and the surfaces of consolidation by solvent and dry them compressed air.

Clear all openings compressed air and check that they are not polluted.

When using compressed air for cleaning of channels and openings, use goggles as the taken-off pollution I can cause damage to health.

Dismantling
PERFORMANCE ORDER
1. Install the transmission at the OK130 990 007 stand with OK130175011A adapter.
2. Remove the bearing and a fork of switching off of coupling.
3. Remove the probe for measurement of level of oil.
4. Remove the speed sensor.
5. Remove the backing lamp switch.
6. Remove a back cover.
Prevention

To remove a back cover, slightly knock on a back cover with the kapron hammer.

Do not reuse the unscrewed lock-nut.
7. OK201 323 021 adaptation block a main shaft of the transmission.
8. At the same time include gear wheels of the 1st and 2nd transfer in order that the main shaft of the transmission was not turned.
9. Unbend fillets of the plate fixing a lock-nut.
10. Turn off a lock-nut from main and secondary shaft and remove a conical ring of the reverse gear and the coupling of the synchronizer from a main shaft.

Prevention

Do not reuse the used cylindrical pin.
11. A thin drift and the hammer beat out a cylindrical pin of a fork of inclusion of the 5th transfer.
12. At the same time, assembled remove a synchronizer ring, a fork of inclusion of the 5th transfer, the sliding coupling of the 5th transfer, the blocking ring and the coupling of a gear wheel.
13. Remove a gear wheel of the 5th transfer from a secondary shaft.
14. Turn out a stopper of a clamp and, using a magnet, remove a spring and a steel ball.
15. Turn out a bolt of fastening of an intermediate shaft of a gear wheel of the reverse gear.
16. Remove a transmission case.
Prevention

For removal of a case of the transmission, slightly knock on it with the kapron hammer.
17. Remove a magnet.
18. Remove an intermediate shaft and a gear wheel of transfer of a backing.
19. Turn out three bolts and remove the control unit.
20. Remove the lever of installation of a spring.
21. Bring out of gearing of a gear wheel of the 1st and 2nd transfers. A thin drift and the hammer beat out a cylindrical pin of a fork of inclusion 1-oy/the 2nd transfers.
Prevention

Do not reuse the used cylindrical pin.
22. Remove a rod and a fork 1-oy/the 2nd transfers.
23. A thin drift and the hammer beat out a cylindrical pin of a fork 3-oy/the 4th transfers, remove a fork 3-oy/the 4th transfers and the switching rod lever 3-ey/the 4th transfers.
24. Remove an E-shaped lock ring of fixing of a rod 5-oy/back transfers.
25. A thin drift and the hammer beat out a cylindrical pin of a fork 5-oy/back transfers, remove a fork 5-oy/back transfers and the switching rod lever 5-oy/back transfers.
26. At the same time remove primary and secondary shaft assembled.
27. Remove differential.

Assembly

Prevention

Before installation grease an external ring of the bearing of differential.

PERFORMANCE ORDER
1. Establish differential in a transmission case.
Prevention

Make sure that did not damage an oil sealing ring at installation of a main shaft.

Before installation grease a working edge of a sealing ring.

Grease the second external ring of the bearing in a transmission case.
2. Establish assembled primary and secondary shaft in a transmission case.
3. Install a fork 3-oy/to the 4th transfers on the sliding coupling 3-ey/of the 4th of transfers, then insert a rod 5-oy/back transfers to a fork and establish a pin of fastening of a rod 5-oy/back transfers.
Prevention

At installation use a new cylindrical pin.
4. Combine the switching rod lever 5-oy/back transfers with a rod 5-oy/back transfers and fix by a cylindrical pin.
5. After installation of a rod 3-ey/the 4th transfers to a fork 3-ey/the 4th transfers, establish a fork 3-ey/to the 4th transfers to the switching rod lever 3-ey/by the 4th transfers.
Prevention

At installation use a new cylindrical pin.
6. Combine the switching rod lever 3-ey/the 4th transfers with a rod and fix by a cylindrical pin.
7. Combine a switching rod 3-ey/the 4th transfers with a switching fork 3-ey/the 4th transfers and fix by a cylindrical pin.
8. Collect a switching fork 1-oy/by the 2nd transfers with the sliding coupling 1-oy/2nd of transfers and establish a rod 1-oy/to the 2nd transfers.
Prevention

At installation use a new cylindrical pin.
9. Combine a switching rod 1-oy/the 2nd transfers with a switching fork 1-oy/the 2nd transfers and fix by a cylindrical pin.
Prevention

At installation use a new E-shaped lock ring.

10. Establish an E-shaped lock ring on a rod 5-oy/back transfers.

11. Combine in a projection the backing lever with the rod lever 5-oy/back transfers and install the backing lever on the coupling case.
12. Establish a new sealing ring on the return shaft of gear shifting.
Prevention

Establish a sealing ring so that it settled down in an external flute.
13. Insert a shaft into the lever of inclusion of a backing.
14. Establish a pin.
15. Install the lever of a spring and fix by bolts.

Inhaling moment: 7,8–11,3 N • m
16. Install the control unit and fix by bolts.

Inhaling moment: 7,8-11,3 N of m

Prevention

At installation of the control unit, consider length of bolts. (Length of a bolt of A is more than B).
17. Establish an intermediate shaft and a gear wheel of a backing.
18. Establish a magnet.
Prevention

Purify sealant from the interfaced surfaces of a case of coupling and the transmission.
19. Apply a thin film of Threebond 1216T or 1216TB sealant on the interfaced surfaces of a case of coupling and the transmission.
20. Establish a transmission case on a case of coupling and fix by bolts.

Inhaling moment: 18,6–25,5 N • m
21. Screw a bolt of fastening of an intermediate shaft of a gear wheel of the reverse gear.

Inhaling moment: 18,6–25,5 N • m
Prevention

As length of springs of clamps differs from each other, correctly choose and establish springs on the places.

Clamp spring length: 5-oy/back year it is more than 1-oy/of the 2nd, 3-ey/the 4th transfers.

Apply sealant on a clamp stopper carving.
22. Establish a steel ball and a spring and screw a clamp stopper.

Inhaling moment: 15-20 N • m

23. Establish the conducted gear wheel of the 5th transfer.
Prevention

As the form of a ring of the synchronizer differs from each other, at assembly it needs to be considered.
In a ring of the synchronizer of transfer of a backing is available admissions of teeths in three places.

Pay attention to the direction of installation of the plug of a gear wheel of the 5th transfer.
Length: A> B
24. Install the plug of a gear wheel of the 5th transfer, a gear wheel of the 5th transfer and a ring of the synchronizer.
Prevention

Establish a lubricant flute of the plug of a gear wheel of the 5th transfer from a gear wheel of the 5th transfer.
25. Establish a fork of the 5th transfer to a flute of the synchronizer of the 5th transfer.

26. Install the synchronizer.
27. Install the coupling of the synchronizer and a conical ring of the reverse gear on a main shaft.
Prevention

At installation use a new cylindrical pin.
28. Fix a fork of the 5th transfer by a cylindrical pin.
29. At the same time include gear wheels of the 1st and 2nd transfer in order that the main shaft of the transmission was not turned.
30. OK201 323 021 adaptation block a main shaft of the transmission.
Prevention

At installation use a new lock-nut.

31. Tighten a lock-nut and for fixing it from an otvorachivaniye bend fillets of the plate fixing a lock-nut.

Inhaling moment: 127–206 N • m

32. Measure by the indicator of hour type a side play of a gear wheel of the 5th transfer and the conical plug of a backing.

Side play:
Gear wheels of the 5th transfer: 0,07–0,39 mm
Conical plug of a backing: 0,1–0,25 mm

If the side play exceeds admissible limits, repeatedly sort and collect the transmission.

Prevention

Purify sealant from the interfaced surfaces of a back cover and a case of the transmission.
33. Apply a thin film of Threebond 1216T or 1216TB sealant on the interfaced surfaces of a case of the transmission and a back cover.
34. Establish a back cover taking into account the provision of deepening for the conical plug of a backing and fix by bolts.

Inhaling moment: 7,8–11,3 N • m

35. Ustanovimte a washer on the backing lamp switch also screw the switch.

Inhaling moment: 20–24,5 N • m
36. Install the speed sensor to the conducted speedometer mechanism.

Inhaling moment: 7,8-11,3 N of m

37. Install the plug on draft of gear shifting.
38. Install the bearing and a fork of switching off of coupling.
39. Remove the transmission from the OK130 990 007 stand with OK130175011A adapter.