6.2.5. Repair of a secondary shaft

Fig. 6.8. Details of a secondary shaft: 1 – nut; 2 – persistent plate; 3 – the sliding transfer synchronizer V coupling; 4 – a nave of the sliding coupling; 5 – the blocking synchronizer ring; 6 – gear wheel of the V transfer; 7 – gear wheel plug; 8 – persistent washer; 9 – ball bearing; 10 – persistent washer; 11 – gear wheel of the IV transfer; 12 – lock ring of a nave of the synchronizer; 13 – the sliding coupling of the synchronizer III and IV of transfers; 14 – a nave of the sliding coupling; 15 – gear wheel of the III transfer; 16 – gear wheel of the II transfer; 17 – the sliding coupling of the synchronizer I and II of transfers with a gear wreath of a backing; 18 – a nave of the sliding coupling of the synchronizer I and II of transfers; 19 – synchronizer spring; 20 – cracker; 21 – clamp; 22 – gear wheel of the I transfer; 23 – gear wheel leading main transfer; 24 – lock ring; 25 – roller cylindrical bearing

Details of a secondary shaft are shown in fig. 6.8.
It will be required to you: two big screw-drivers with flat edges, the hammer, a drift from soft metal, a set of flat probes.
1. Take out a secondary shaft from the transmission (see. "Dismantling of the transmission and troubleshooting of its details").
2. Clamp a shaft in a vice with slips on sponges from soft metal with small effort.

Prevention
The secondary shaft needs to be clamped in a vice with soft slips on sponges for an internal ring of the forward bearing. Tighten a vice so that the shaft could be inclined by effort of a hand, differently it is possible to damage a bearing racetrack surface.

3. Remove the lock ring established under an internal ring of the forward bearing from the forward end of a shaft.
4. By means of two screw-drivers press an internal ring of the forward bearing from a shaft. The fillet of a ring is directed to the leading gear wheel of the main transfer.
5. Having unclenched a vice, rest a gear wheel of the I transfer on two support. Blows of the hammer through wooden laying press from a shaft a gear wheel of the I transfer with the leading gear wheel of the main transfer.
6. Remove the leading gear wheel of the main transfer from a shaft. Pay attention that the facet on the internal diameter of a gear wheel is directed to a gear wheel of the I transfer.
7. Remove a gear wheel of the I transfer from a shaft. The cone on a gear wheel is directed to the synchronizer.
8. Mark the blocking ring 1 concerning the coupling 2. At operation teeths of a ring are earned extra to coupling teeths therefore at assembly the ring should be established in the same situation. Remove the blocking ring of the I transfer of the synchronizer.
9. Again clamp a shaft in a vice and remove a lock ring of a nave of the synchronizer.
10. By means of two big screw-drivers, having made effort for a gear wheel of the II transfer, press the synchronizer I and II of transfers from shliyets of a shaft.
11. Remove the synchronizer with the blocking ring of 1 II transfer and mark a ring 1 concerning the coupling 2 synchronizers.
12. Remove a gear wheel of the II transfer from a shaft. Pay attention that the cone on a gear wheel is directed to the synchronizer.
13. Turn a shaft and by means of two big screw-drivers press the back bearing from a shaft. At the same time the open party of the bearing is turned to a gear wheel of the IV transfer.
14. Remove a persistent washer.
15. Remove a gear wheel of the IV transfer. Consider that the cone on a gear wheel is directed to the synchronizer.
16. Mark the blocking ring 1 concerning the coupling 2 synchronizers. Remove the blocking ring of the IV transfer of the synchronizer.
17. Remove a lock ring of a nave of the synchronizer.
18. Having unclenched a vice, rest a gear wheel of the III transfer on two support and blows of the hammer through soft laying press the synchronizer III and IV of transfers from shliyets of a shaft.
19. Remove the synchronizer with the blocking ring of the III transfer and mark a ring 1 concerning the coupling 2 synchronizers. Pay attention that the groove on the coupling is directed to a gear wheel of the III transfer.
20. Remove a gear wheel of the III transfer. Pay attention that the cone on a gear wheel is directed to the synchronizer.
21. Carefully clear, wash out and dry up details of a secondary shaft.
22. Check a condition of a shaft. In the presence of pitting (sinks) on necks under bearings or wear tracks the shaft needs to be replaced.
23. Check a condition of gear wheels. In the presence of chips and a vykrashivaniye of teeths, zadir in internal openings or wear tracks on working surfaces of teeths replace gear wheels. In the presence at end faces of teeths of a shlitsevy wreath considerable a smyatiya or chips it is also necessary to replace gear wheels.
24. Check ease of rotation of the bearing. At damage of paths of swing or balls and at detection of a side play in the bearing (the radial gap in the bearing should not exceed 0,04 mm) replace the bearing.
25. Check a condition of the blocking rings of synchronizers. In the presence забоин and chips on gear wreaths or considerable development on cones replace the blocking rings.
26. Check a gap between gear wheels and the corresponding blocking rings. For this purpose densely establish the blocking ring on a cone of the corresponding gear wheel, i.e. "grind in" it to a cone, having several times turned, and the flat probe measure a gap. Minimum admissible gap makes 0,6 mm. If it is less, the blocking ring needs to be replaced.

Note
When replacing of the blocking ring also check a gap between a new ring and a gear wheel. For this purpose put on a ring a cone of a gear wheel and shake it, the side play is inadmissible.

27. At detection of zadir and deformation on persistent rings, and also at loss of elasticity of lock rings replace them.
28. Before assembly clean oil channels of a secondary shaft.
29. Collect a secondary shaft as it should be, the return to removal. At the same time establish the old blocking rings according to earlier made tags. Establish new rings so that small ledges on a ring (there are no teeths) coincided with synchronizer nave grooves where clamps are established.
30. Press the back bearing of a shaft by means of a suitable mandrel, putting effort only to an internal ring of the bearing.
31. Before installation of an internal ring of the forward bearing at first establish a lock ring and only then a napressuyta by means of a suitable mandrel an internal ring of the bearing against the stop in a lock ring.
32. After assembly check operation of synchronizers. For this purpose move couplings of synchronizers manually to the provision of inclusion of the corresponding transfers.