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;
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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
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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. |
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Check of a side play of a gear wheel of the 5th transfer
| PERFORMANCE ORDER |
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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
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| 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. |
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Otvorachivany lock-nuts
| PERFORMANCE ORDER |
| 1. Install the transmission at the OK130 990 007 stand with OK130175011A adapter. |
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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. |
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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. |
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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. |
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4. Separate forks and rods from synchronizers. |
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Installation of primary and secondary shaft
| PERFORMANCE ORDER |
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Establish primary and secondary shaft in a coupling case as it is shown in the drawing. |
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Installation of forks and rod of gear shifting
| PERFORMANCE ORDER |
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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. |
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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. |
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5. Press a ball so that it accurately entered average deepening. |
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Installation of the lever of a rod and rod 5-oy/back transfers
| PERFORMANCE ORDER |
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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
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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. |
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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. |
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Installation of a case of the transmission
| PERFORMANCE ORDER |
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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
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Installation of the conducted gear wheel of the 5th transfer
| PERFORMANCE ORDER |
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Establish the conducted gear wheel of the 5th transfer as it is shown in the drawing. |
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Installation of the synchronizer and fork 5-oy/back transfers
| PERFORMANCE ORDER |
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Install together the synchronizer and a fork 5-oy/back transfers. |
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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.
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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
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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
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