6.2.4. Dismantling of the transmission and troubleshooting of its details

Prevention
If in the course of repair of the transmission one of the following details was replaced at least: a case of coupling or the transmission, the case of differential or bearings of differential, it is necessary to pick up an adjusting ring of bearings of differential.

It will be required to you: a face key (head) "on 10", "on 13", "on 32", keys "on 10" and "on 17", the big screw-driver, small beards, the hammer, pincers for removal of lock rings, an impact driver.
1. Remove the transmission from the car (see. "Removal and installation of the transmission"). Clear it of dirt and wash up outside.
2. Take out the index (probe) of level of oil from the transmission.
3. Install the transmission on a coupling case vertically, a key "on 10" turn out a bolt 1 (under its head the flat washer is established) and two nuts 3 (under them spring washers are established) fastenings of an arm of a cable of coupling. Remove an arm 2 cables of coupling from the transmission.
4. A key "on 10" turn off the remained four nuts of fastening of a back cover.
5. Having hooked the screw-driver inflow on a cover, remove a back cover.
6. A key "on 10" turn out a bolt of fastening of a fork of the V transfer (under a head of a bolt the spring washer is established).
7. Record transmission shaft from a provorachivaniye. For this purpose include the V transfer, having moved the synchronizer coupling together with a fork down so that vents of the coupling entered gearing with a gear wheel, then include III or IV transfer, having moved a rod of the choice of transfers.
8. Raskontrite and a head "on 32" turn off a nut of fastening of a main shaft. For this purpose it is necessary to make big effort as the nut is tightened by the big moment.
9. Previously расконтрив, a head "on 32" turn off a nut of fastening of a secondary shaft. For this purpose it is necessary to make effort as the nut is tightened by the big moment.
10. Having raised screw-drivers the conducted gear wheel of the V transfer (thereby having pressed a synchronizer nave from a shaft), remove it together with the synchronizer and a fork from a secondary shaft.

Prevention
You watch that the coupling of the synchronizer did not descend from a nave as the sprung fixing balls of the synchronizer can be scattered.

11. Remove a persistent plate from the synchronizer. Then take out a fork from a synchronizer coupling groove.
12. Remove a gear wheel of the V transfer from the synchronizer with the blocking ring 1. Mark the blocking ring 1 concerning the coupling 2 and remove it. At operation teeths of a ring are earned extra to coupling teeths therefore at assembly the ring should be established in the same situation. If it is not supposed to disassemble the synchronizer, connect it by a wire or a rope that it was not scattered.

13. Remove the plug from a secondary shaft.
14. Remove the leading gear wheel of transfer from a main shaft. Pay attention as it is established.
15. By means of an impact driver turn out four screws (under them spring washers are established) fastenings of a plate of bearings and remove a plate of 1 bearings. Then remove a persistent washer 2 from a secondary shaft.
16. Remove lock rings of bearings of both shaft, raising shaft a hand.
17. A key "on 13" turn off three stoppers of clamps and carefully take balls of clamps with springs.
18. Having turned off a backing clamp stopper, remove a sealing ring, and then take a clamp spring.
19. Having inclined a box, take a clamp ball.
20. Turn off twelve nuts and turn out a bolt of fastening of cases of the transmission. Pay attention to under what nuts are established the holder 1 and a transport eye 2. Under nuts and a bolt spring washers are established. Remove the cap 3 inserted instead of one of drives.
21. Inserting the screw-driver into grooves (three special grooves on perimeter of cases), separate a transmission case from a coupling case.
22. Raise a transmission case a little, turn it counterclockwise so that inflow of 1 case came out from under a gear wheel, and remove a transmission case from a coupling case.
23. A key "on 10" turn out bolts of fastening of forks of switching I and II, III and IV transfers.
24. Raise a little a rod of switching of I and II transfers that it left a support 3, and turn it counterclockwise that the head of 1 rod left gearing with a blocking bracket 2. Bring a fork 4 rods out of a groove of the coupling of the synchronizer and remove a rod with a fork. Needlessly it is not recommended to remove forks from rods not to mix them at assembly.
25. Having turned a switching rod III and IV transfers, bring its head out of gearing with the lever of the choice of transfers. Then raise a little a rod that it left a support, and, having brought a rod fork out of a synchronizer coupling groove, remove a rod with a fork.
26. Having turned a rod of inclusion of the V transfer, bring its head out of gearing with a blocking bracket. Remove a rod, having brought it out of a support.
27. Take out an axis of an intermediate gear wheel of a backing.
28. Shift an intermediate gear wheel of a backing against the stop in the mechanism of the choice of transfers, turn it on 30-40 ° and, having brought out of shaft gear wheels, remove an intermediate gear wheel.
29. Slightly shaking, take out at the same time primary and secondary shaft.
30. Take out differential from a coupling case.
31. A key "on 10" turn out three bolts of fastening of the mechanism of the choice of transfers (under heads of bolts spring washers are established). Remove the mechanism of the choice of transfers.
32. Take out a magnet from a coupling case.
33. A key "on 10" turn off a nut of fastening of the sensor of speed and remove the sensor.
34. Replace the sealing ring of the sensor of speed torn or lost elasticity.
35. Turn out the backing light switch from a transmission case. Under it the metal sealing ring is established.
36. For a vypressovka of the forward bearing of a secondary shaft there is a special stripper. At its absence to a vypressuyta the bearing by means of the screw-driver.
37. Remove the oil pan established under the bearing.
38. For a vypressovka of the forward bearing of a main shaft there is also a special stripper. At its absence make adaptation in the form of a hook of a rigid wire. Insert the device in one of two grooves of a case and get a hook under the bearing. Then by means of the screw-driver (having enclosed wooden whetstone) to a vypressuyta the bearing from a case, putting effort to the opposite end of the screw-driver blows of the hammer and serially rearranging a hook in grooves.
39. Press new forward bearings of shaft against the stop in a case of coupling with the help of a suitable mandrel.
40. Hook the screw-driver an edge of a protective cover of a rod of the choice of transfers and shift it from the basic plug of a rod.
41. A key "on 10" turn out a bolt 3 fastenings of the lever 2 choice of transfers. Having shifted a rod 1, remove the lever of the choice of transfers. Then take out a rod of the choice of transfers from a coupling case.
42. In need of replacement of the hinge of a rod shift from it a protective cover and turn out a bolt of fastening of the hinge. The bolt is recorded by special TB-1324 glue. Before a vvorachivaniye of a bolt clear it of old glue and put new. Replace the protective cover of the hinge of a rod torn or lost elasticity.
43. For replacement of a case of coupling remove from it the bearing (see. "Replacement of the bearing of switching off of coupling") and a coupling switching off fork (see. "Replacement of a fork of switching off of coupling"), a vypressuyta epiploons (see. "Replacement of epiploons of the transmission").
44. Examine cases of coupling and the transmission, and also a back cover. On them there should not be cracks and chips. On privalochny surfaces there should not be забоин, рисок, dents, etc. Remove small damages with a grinding skin. At strong damages replace defective parts.
45. Check seats under bearings in cases of coupling and the transmission. On these surfaces there should not be wear tracks or damages. Otherwise replace cases.
46. Check a condition of roller bearings. At damage of paths of swing, a separator or rollers and at detection of a side play (the radial gap in the bearing should not exceed 0,07 mm) replace the bearing.
47. Check a condition of rods of gear shifting. With teases, agnails or the developed holes under clamps replace the bent rods. Replace forks if they are bent or worn-out their pads.
48. Check epiploons of half shafts. They should not be jarred on, have anguishes. The working edge has to be equal, without vyrov, dents and flows of rubber. The spring of an epiploon should not be broken and stretched. Replace defective epiploons.
49. Check and if necessary replace epiploons of a main shaft and a rod of the choice of transfers (see. "Replacement of epiploons of the transmission").
50. Replace the damaged or strongly pressed out laying.
51. Clear a magnet of particles of wear of details. If on a magnet there were cracks or its magnetic properties weakened, replace a magnet.
52. Carefully clear privalochny surfaces of cases of coupling and the transmission, and also a back cover of old sealant.
53. Collect the transmission as it should be, the return to dismantling, taking into account the following.
54. Before installation of shaft enter teeths of their gear wheels into gearing and in such situation establish in a coupling case.
55. Pay attention to how establish forks on gear shifting rods: 1 – a rod with a fork of switching of I and II transfers, 2 – a rod with a switching fork III and IV transfers.
56. Plentifully oil all rubbing details gearbox.
57. Do not forget to establish into place a magnet.
58. Before installation of a case of the transmission on a case of coupling and a back cover apply sealant on their privalochny surfaces on all perimeter.