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9.8. Dismantling, check and assembly of the fifth / reverse gear and back cover of TE DOHC

Fifth / reverse gear and back cover of TE 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 – expansion plug;
7 – fork 5-oy/reverse gear;
8 – synchronizer 5-oy/of the reverse gear;
9 – the blocking ring of the synchronizer of the 5th transfer;
10 – leading gear wheel of the 5th transfer;
11 – plug of a gear wheel of the 5th transfer;
12 – the conducted gear wheel of the 5th transfer;
13 – bolt;
14 – bolt;
15 – clamp stopper, spring and steel ball;
16 – backing lamp switch;
17 – transmission case;
18 – magnet;
19 – intermediate shaft of transfer of a backing;
20 – intermediate gear wheel of transfer of a backing;
21 – switching rod 3-ey/the 4th transfers;
22 – switching rod lever 5-oy/back transfers;
23 – pin;
24 – switching lever shaft;
25 – switching lever assembled;
26 – forks and rod of switching;
27 – ball clamp;
28 – spring;
29 – main shaft;
30 – secondary shaft;
31 – differential;
32 – coupling case;
33 – clamp cracker spring;
34 – the sliding synchronizer coupling;
35 – clamp cracker;
36 – synchronizer coupling nave;
37 – switching fork 3-ey/the 4th transfers;
38 – plug;
39 – control lever;
40 – switching fork 1-oy/the 2nd transfers;
41 – rod;
42 – rod lever

Repair

PERFORMANCE ORDER
1. You carry out dismantling to the sequences, designated by figures in the drawing.
2. Check a condition of all details and, if necessary, replace them.
3. Assembly is carried out to the sequences of the return to removal.
4. Removal and installation of separate details and knots it is given below.

Check of a side play of a gear wheel of the 5th transfer

PERFORMANCE ORDER

1. Measure by the indicator of hour type a side play of a gear wheel of the 5th transfer.

Nominal side play: 0,10–0,22 mm
Maximum permissible side play: 0,27 mm

2. If the side play exceeds maximum permissible value, check the surfaces of contact of a gear wheel of the 5th transfer and tighten the plug. If necessary, replace the worn-out and damaged details.

Otvorachivany lock-nuts

PERFORMANCE ORDER
1. Install the transmission at the OK130 990 007 stand with OK130175011A adapter.
2. OK201 323 021 adaptation block a main shaft of the transmission.
3. 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.
4. Unbend fillets of the plate fixing a lock-nut.
5. Turn off lock-nuts from primary and secondary shaft.

Removal of forks and rod of gear shifting

PERFORMANCE ORDER
1. Combine the ends of the plug with a control lever (shooter). Turn a rod counterclockwise.
2. One hand hold forks 1-oy/the 2nd transfers, the second - a fork 3-ey/the 4th transfers and lift them, at the same time moving synchronizers.
3. Lift a rod and remove a ball clamp, at the same time removing a rod from a coupling case.
4. Separate forks and rods from synchronizers.

Installation of primary and secondary shaft

PERFORMANCE ORDER
Establish primary and secondary shaft in a coupling case as it is shown in the drawing.

Installation of forks and rod of gear shifting
PERFORMANCE ORDER
1. Establish a fork and a rod of gear shifting to a gear wheel of the 2nd transfer as it is shown in the drawing.
2. Establish a nest of a spring and a spring in a backing lever shaft, then establish a ball clamp and a flat washer.
3. Establish a rod lever end face opposite to a ring and insert a rod so that the ball clamp entered a shaft. It will expose to one line a core with a rod and will combine with a coupling case opening.
4. Install synchronizers in neutral situation, and from above insert rods so that the ball clamp entered average deepening.
5. Press a ball so that it accurately entered average deepening.

Installation of the lever of a rod and rod 5-oy/back transfers

PERFORMANCE ORDER
Install the lever of a rod (1) and a rod 5-oy/back transfers (2) and fix by a bolt.

Inhaling moment: 11,8–13,7 N • m

Installation of an intermediate shaft and gear wheel of a backing

PERFORMANCE ORDER
1. Establish a gear wheel of a backing and an intermediate shaft of a gear wheel of a backing.
2. Establish a magnet on a coupling case.

3. Combine the end of the plug of the lock with a control lever and with an opening under a bolt of fastening of an intermediate shaft in the direction shown in the drawing.

Installation of a case of the transmission

PERFORMANCE ORDER

Apply a thin film of sealant on the interfaced surfaces of a case of coupling and a case of the transmission, establish a case of the transmission and fix by bolts.

Inhaling moment: 38-51H • m

Installation of the conducted gear wheel of the 5th transfer

PERFORMANCE ORDER

Establish the conducted gear wheel of the 5th transfer as it is shown in the drawing.

Installation of the synchronizer and fork 5-oy/back transfers

PERFORMANCE ORDER
Install together the synchronizer and a fork 5-oy/back transfers.

Tightening of lock-nuts

PERFORMANCE ORDER
1. 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.
2. OK201 323 021 adaptation block a main shaft of the transmission.

Prevention

At installation use a new lock-nut.


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

Inhaling moment: 128-196 N of m

4. 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.

Nominal side play: 0,10–0,22 mm
Maximum permissible side play: 0,27 mm