If adjustment of an axial side play of primary and secondary shaft and differential was not made, execute adjustment as it is described.

You carry out assembly of the transmission in the following order:

check that internal and external surfaces of cases of the transmission and coupling were pure;

if it is necessary, replace the starter shaft plug for what by means of a stripper press the old plug from a shaft and by means of a mandrel (a piece of a pipe of suitable diameter) press the new plug and grease it. The plug can be replaced, without removing the transmission;

arrange a coupling case so that the party with which coupling is established appeared below;

grease bearings of differential and establish differential by a speedometer drive gear wheel, in a case;

install a secondary shaft in the transmission. Check that on hairpins of fastening of a support of the bearing sealing rings were established, and a flat part of a support was directed to a backing gear wheel;

install a main shaft in the transmission;

establish into place a kosozuby gear wheel of a backing then establish a backing shaft. Enter teeths of a pryamozuby gear wheel of a backing into gearing with the corresponding gear wheel on secondary to a shaft;

having established forks of turning on of the reverse gear over a pryamozuby gear wheel of a backing, combine an opening in the holder of a fork with a carving opening in a case and screw the holder of forks a bolt, having tightened it the required moment;

Fig. 8.43. Arrangement of screws of fastening of the holder of a shaft of a backing: 1 – cross; 2 – longitudinal

establish laying and the holder of a shaft (fig. 8.43) of gear wheels of a backing;

install the main unit of forks of gear shifting, at the same time tips of forks have to be established in flutes of the sliding rings of synchronizers;

temporarily turn out a carving hairpin of M8x100 in the holder of a shaft of the reverse gear and combine selector plates. Forks of gear shifting have to enter flutes of the sliding couplings;

establish a magnet in a nest in a transmission case;

apply a thin film of sealant on the interfaced surfaces of cases of the transmission, combine cases of the transmission and coupling and screw bolts, having tightened them the regulated moment;

after assembly of a case of the transmission install screws of the holder of a shaft of a backing for what screw at first the cross screw 1 (see fig. 8.43 ). turn out the carving hairpin screwed in a transmission case and screw the longitudinal screw 2. Tighten screws in the sequence at first the screw 2, and then the screw 1. Togkh-otvertka is for this purpose necessary. Use only new screws;

Fig. 8.44. Installation of the directing plug of the release bearing

install the directing plug (fig. 8.44) of the release bearing and fix it by bolts, having tightened them the required moment. At installation of the directing plug of the release bearing, it is necessary to establish a new sealing ring;

Fig. 8.45. Alignment of axes of forks by means of the screw-driver and a pin

for alignment of axes of forks (fig. 8.45) and installation of pins of forks of inclusion of transfers install the screw-driver in a window of the transmission and orient the switching mechanism that it was possible to establish pins;

Fig. 8.46. Installation of a shaft of the mechanism of the choice of transfers: 1 – shaft; 2 – dredging on the case; 3 – ledge

establish a shaft of the mechanism of the choice of transfers (fig. 8.46) to neutral situation and establish a shaft so that the ledge on it was placed in dredging on the case. Move a shaft so that the finger of a shaft was established in an opening of levers of forks of inclusion of transfers, and tighten bolts of fastening of a shaft the regulated moment;

establish the cover closing the mechanism of gear shifting and tighten bolts of fastening of a cover the regulated moment;

establish a cover of a shaft of the mechanism of the choice of transfers;

install the transmission by a coupling case down;

establish the conducted gear wheel of the fifth transfer, previously its heating to 100 °C;

install the needle bearing of the leading gear wheel of the fifth transfer then establish a gear wheel and a ring of blocking of the synchronizer on a main shaft;

establish a spring on a ring of blocking of the synchronizer;

Fig. 8.47. Slanted teeths on the sliding coupling of the synchronizer have to be directed to a gear wheel of the 5th transfer

establish a nave of the synchronizer and the sliding synchronizer coupling so that slanted teeths on the sliding coupling were directed to a gear wheel of the fifth transfer (fig. 8.47) ;

establish washers on the conducted and conducting gear wheels of the fifth transfer and fix them by bolts, previously having applied the means interfering their otverchivaniye on a carving of bolts. When tightening bolts of fastening of gear wheels of the fifth transfer block gear wheels from a provorachivaniye, simultaneous inclusion of the fifth transfer and transfer of a backing;

Fig. 8.48. Elements of the mechanism of inclusion of the fifth transfer: 1 – fork of inclusion of the fifth transfer; 2 – lever of movement of a fork of the fifth transfer; 3 – spring; 4 – synchronizer ring; 5 – the sliding synchronizer coupling; 6 – gear wheel; and – the gap equal to 1,2 mm

establish and adjust the provision of a fork of 1 (fig. 8.48) of inclusion of the fifth transfer. Previously establish tips of forks of the fifth transfer to a flute of the sliding coupling of the synchronizer and screw pins of a fork of inclusion of the fifth transfer;

Fig. 8.49. Adjustment of provision of a fork of inclusion of the fifth transfer: And – probes 1,2 mm thick; 1 – bolt of fastening of the lever. The arrow specified the direction a fork otzhatiya at adjustment

having included the fifth transfer, insert from two opposite sides between the sliding coupling of the synchronizer and a gear wheel of the fifth transfer two probes 1,2 mm thick and, having pressed a back part of a fork of inclusion of the fifth transfer in the direction from a transmission case, tighten a bolt of fastening of the lever of movement of a fork of the fifth transfer (fig. 8.49) ;

clear the transmission case surface interfaced to a cover of the fifth transfer, establish laying and a cover of the fifth transfer and fix a cover by bolts, having tightened them the regulated moment;

install the speedometer drive block;

if there is a need, establish new sealing rings of differential;

Fig. 8.50. Installation of new spring lock rings on a drive flange

establish new lock rings on drive flanges, apply a layer of lubricant on working edges of sealing rings of differential and install drive flanges in the transmission before accurate fixing them by lock rings (fig. 8.50) ;

install the lever of switching off of coupling and the release bearing;

establish a support of fastening of the transmission;

establish an arm of fastening of cables of gear shifting.