3.2. Transmission

Possible malfunctions of the transmission, their reason and ways of elimination


       PREVENTION
On cars with engines of fashion. 2106 VAZ-21074-1700010 or Izh-2126-1700010-80 transmissions can be installed. Because of design features a main shaft of the transmission for the engine of fashion. Is longer than 2106, than for the engine of fashion. 331.

Features of a design of the transmission of fashion. 2126
The transmission consists of primary, secondary, intermediate shaft, a case, a back cover and the mechanism of gear shifting.

Fig. 3.26. Transmission: 1 – main shaft; 2 – cracker; 3 – lever of inclusion of a backing; 4 – speedometer drive reducer; 5 – bolt of fastening of a reducer of a speedometer; 6 – washer; 7 – laying of the top cover; 8 – bolt of fastening of the top cover; 9 – the blocking ring of the third and fourth transfers; 10 – nave of the third and fourth transfers; 11 – gear wheel of the third transfer; 12 – nave of the fifth transfer; 13 – coupling of the fifth transfer; 14 – gear wheel of the fifth transfer; 15 – gear wheel of the second transfer; 16 – the bearing is roller; 17 – the blocking ring of the second transfer; 18 – backing coupling gear wheel; 19 – gear wheel of the first transfer; 20 – persistent washer; 21 – bearing of a secondary shaft back; 22 – nave of the first and second transfers; 23 – spline; 24 – gear shifting mechanism; 25 – expansion plug; 26 – gear wheel leading speedometer drive; 27 – cuff; 28 – lock ball; 29 – nut; 30 – secondary shaft; 31 – lock ring; 32 – the aligning ring; 33 – sealant; 34 – lock washer; 35 – flange of the elastic coupling; 36 – mud-reflector; 37 – washer; 38 – bolt of an intermediate shaft back; 39 – bolt; 40 – nut; 41 – bearing of an intermediate shaft back; 42 – ball; 43 – the cover is back; 44 – laying of a back cover; 45 – the gear wheel is intermediate; 46 – the bearing is roller; 47 – lock ring; 48 – axis of an intermediate gear wheel; 49 – intermediate shaft; 50 – the ring is lock; 51 – coupling of the third and fourth transfers; 52 – transmission case; 53 – washer; 54 – bolt of an intermediate shaft forward; 55 – bearing of an intermediate shaft forward; 56 – bearing of a main shaft; 57 – bearing roller secondary shaft; 58 – lock ring of the bearing


The main shaft 1 (fig. 3.26) is made for a single whole with a gear wheel of continuous gearing. It rotates in two ball bearings, forward – is pressed in a nest of an end face of a bent shaft, the back bearing 56 is placed in a forward wall of a case 52 transmissions, is drawn in by a dish-shaped spring and condensed with the epiploon located in a coupling case.
The intermediate shaft 49 is made in the form of the block of gear wheels and leans on two bearings.
The forward bearing 55 roller, is installed on intermediate to a shaft and fixed on it by a washer 53 and a bolt 54. The back bearing 41 ball two-row, is fixed on a shaft by a washer 37 and a bolt 38 and is fixed in a case by the 52nd back cover 43.
The secondary shaft 30 is installed in two bearings. The forward roller bearing 57 is located in boring of a main shaft, the back bearing 21 – in a back wall of a case of a box, fixed by means of a back cover and a persistent washer 20 and condensed with the cuff 27 located in the same cover.
On secondary to a shaft gear wheels of 11 and 14 third and fifth transfers are freely placed, gear wheels of 19 and 15 first and second transfers are established on a shaft on needle bearings. All gear wheels are in continuous gearing with the corresponding wreaths of the block of gear wheels of an intermediate shaft 49.
On the forward end of a secondary shaft – three vent on which naves of the sliding couplings of synchronizers of the third, fourth and fifth transfers fasten. The nave of the synchronizer of the first and second transfers is fixed on a shaft by a spline 23. The gear wheel of a backing 18 is executed on the sliding coupling of the synchronizer of the first and second transfers. On a back neck of a shaft the leading gear wheel of the 26th drive of a speedometer, a flange of the elastic coupling 35 of the driveshaft напрессован on vents of a shaft is placed and it is fixed by a nut 29 with a lock washer 34.
The intermediate gear wheel of the 45th backing is established on the roller bearing on the axis 48 pressed in openings of a case of the transmission and recorded from turn by a ball 42. At inclusion of a backing the gear wheel 45 at the same time enters gearing with teeths of gear wheels of a backing on intermediate to a shaft and the corresponding wreath of the block of gear wheels that provides torque transmission from an intermediate shaft on a secondary shaft.
Synchronizers of all transfers of the forward course consist of naves 10, 12, 22, the sliding couplings 13, 18, 51, the blocking rings of 9, 17 and spring cutting rings.
The sliding coupling connects to a secondary shaft of the transmission through the nave which is rigidly connected with shaft.
The blocking ring connects to a nave through three ledges at an end face of a nave and three grooves on a gear wreath of the blocking ring. The spring cutting ring established between the blocking ring and a nave of the synchronizer, the three ledges passing through grooves on a nave interacts with the sliding coupling.
At transfer inclusion the coupling through a spring ring draws in the blocking ring to a conical surface of a gear wheel of the included transfer, there is a coupling of cones of a gear wheel and the blocking ring. The ring which turned on a limited corner concerning a nave blocks further advance of the coupling of the synchronizer until there is a full alignment of relative speeds of a gear wheel of the included transfer and secondary shaft. Thereby unaccented inclusion of transfer is provided.

Fig. 3.27. Mechanism and drive of gear shifting: 1 – the cover is top; 2 – ball; 3 – spring; 4 – clamp stopper; 5 – laying of a spherical support; 6 – cup guide; 7 – pin; 8 – gear shifting lever; 9 – the support is spherical; 10 – the washer is spherical; 11 – lock ring; 12 – flange of fastening of a cover; 13 – washer; 14 – nut; 15 – lever cover; 16 – basic washer; 17 – lever spring: 18 – collar of an internal cover; 19 – the cover isolating; 20 – a collar of the isolating cover; 21 – bracket of an ottyazhny spring; 22 – ottyazhny spring; 23 – the cover is protective; 24 – the washer is spring; 25 – lock bolt; 26 – the laying isolating; 27 – fork of the first and second transfers; 28 – locking plug; 29 – damper plug; 30 – the plug is remote; 31 – persistent pillow of a damper; 32 – lever core; 33 – control lever handle; 34 – lever cover; 35 – frame; 36 – screw; 37 – the washer is spring; 38 – rod of the first and second transfers; 39 – head plunger; 40 – head of a rod of the first and second transfers; 41 – stopper of rods; 42 – pusher; 43 – rod of the third and fourth transfers; 44 – head of a rod of the third and fourth transfers; 45 – rod of the fifth transfer; 46 – head of a rod of the fifth transfer; 47 – backing rod head; 48 – washer; 49 – lock bolt; 50 – backing rod; 51 – backing fork; 52 – the laying isolating; 53 – the cover is protective; 54 – screw; 55 – washer; 56 – fork of inclusion of the fifth transfer; 57 – fork of inclusion of the third and fourth transfers; 58 – backing light switch; 59 – laying of the top cover


The mechanism of gear shifting is placed in the top cover of 1 (fig. 3.27), enter it:
1) compound lever of gear shifting 8, 28, 29, 30, 31, 32;
2) four rods 38, 43, 45, 50 on which forks of gear shifting 27, 51, 56, 57 are fixed;
3) clamps 2, 3, 4 rods;
4) castle device 2, 42 of rods. Transfers switch by means of a core 32 levers of the gear shifting 8 removed through a body floor to the right of a driver's seat.
The core of the lever of gear shifting is supplied with the damping device absorbing vibrations and providing smooth inclusion of transfers.
For prevention of spontaneous switching off of transfers the clamps consisting of balls 2 and springs 3 serve. The blocking device consisting of two pushers of 42 and three balls 2 protects a box from simultaneous inclusion of two transfers. By means of a spring the 22nd lower head of the lever of switching always settles down in neutral situation in a head 44 rods of inclusion of the third and fourth transfers.
On the left side of the mechanism of switching the backing light switch 58 settles down.
The nominal sizes, admissions and landings of knots and details of the transmission are given in tab. 3.4.

Table 3.4  the Nominal sizes, admissions, gaps and tightnesses in the main interfaced details of the transmission and its drive

Removal of the transmission.
1. Install the car on a viewing ditch or the elevator and you will hang out one or both back wheels.
2. Disconnect a wire from the - plug of the rechargeable battery.
3. Remove a floor tunnel casing.
4. Pressing a core 32 down (see fig. 3.27) the lever, the screw-driver or any other pointed tool take out an elastic ring from a flute on a core of the lever and remove a core.
5. Disconnect wires from the backing light switch.
6. Remove the isolating cover 19.
7. Disconnect a protective cover 23 on the floor tunnel.
8. Disconnect a collar of a reception pipe of the muffler.
9. Turn off nuts of fastening of a reception pipe of the muffler to a final collector and remove a pipe.
10. Remove the working cylinder of the drive of coupling.
11. Remove a starter.
12. Turn off nuts and remove an arm of safety of the driveshaft.
13. Turn off a cap nut and disconnect a flexible shaft of a speedometer from a speedometer reducer.
14. Turn off nuts of bolts of fastening of the elastic coupling to a flange and, scrolling the driveshaft, take out bolts.
15. Lower and take aside the forward driveshaft with the coupling.
16. Turn off nuts of bolts of fastening of a pillow of a back engine mount to a cross-piece, then nuts of fastening of a cross-piece to a body and remove it, supporting the transmission from below.
17. Put a jack or other suitable support under a transmission case.
18. A hinged face key turn off nuts of fastening of a case of coupling to the block of cylinders.
19. Remove the transmission together with a coupling case, having displaced it to a back part of the car so that to take a main shaft of the transmission from the forward bearing in an end face of a bent shaft and from a nave of the conducted clutch plate.

       PREVENTION
At removal or installation of the transmission it is strictly forbidden to opirat the end of a main shaft of a box on a persistent flange of a press spring of coupling not to deform connecting plates of coupling.

Installation of the transmission
1. By means of a mandrel center the conducted clutch plate.
2. Lift a hydraulic jack the transmission to the level of the engine and move it along the car so that the main shaft entered vents of the conducted clutch plate and the forward bearing. If vents of a main shaft do not get to the corresponding grooves of a shlitsevy opening of a nave, it is recommended, slowly turning a secondary shaft of the transmission by the included direct transfer, to slightly give the transmission forward until the shaft the shlitsevy part does not enter a nave and the box does not reach the correct position.
3. Supporting the transmission from below, wrap the top nuts of fastening of a case of coupling to the block of cylinders.
4. Establish a starter.
5. Establish and attach to a cover of the back bearing of the transmission a pillow assembled with a cross-piece of a back engine mount. Then attach a cross-piece to a body.
6. Connect the elastic coupling of the driveshaft to a flange of the transmission and fix by bolts with nuts.
7. Establish an arm of safety of the driveshaft and fix it by nuts.
8. Establish and attach a flexible shaft of a speedometer to the speedometer drive.
9. Install the working cylinder of the drive of coupling on a coupling case.
10. Establish from below a reception pipe of the muffler.
11. Attach a collar a reception pipe to the transmission.
12. Fill in in the transmission oil to the level of a control opening.
13. Establish in a gear shifting lever core a persistent pillow 31 (see fig. 3.27), the top plug 29 of a damper, the remote plug 30, the lower plug of a damper and the locking plug 28.
14. Install a core on the lever and press it down to calling of pads of the remote plug a lever flute.
15. Connect wires to the backing light switch.
16. Establish a protective cover 23.
17. Establish a protective cover 19.
18. Establish a floor tunnel casing.

Repair of the transmission
Dismantling of the transmission
1. Remove the transmission from the car.
2. Carefully clear outside the transmission.
3. Install the transmission on the stand.
4. Turn out a stopper of a drain opening and merge oil from the transmission.
5. Turn off bolts of fastening of the transmission to a case of coupling and remove a case with laying (together with an epiploon and a spring ring).
6. Turn off a bolt 5 (see fig. 3.26) and remove a reducer 4 drives of a speedometer.
7. Turn off bolts 8 and remove the top cover with the mechanism of switching 24.
8. By means of nippers remove a lock ring 31 from the end of a secondary shaft of the transmission.
9. Unbend a lock washer 34 nuts of a flange of the elastic coupling, turn off a nut 29 on several turns to shift 32 elastic couplings aligning a ring, and again wrap a nut. By means of a stripper remove the aligning ring of the elastic coupling of the driveshaft from the end of a secondary shaft.
10. Remove from the end of a secondary shaft a sealant 33 the aligning rings of the elastic coupling, turn off a nut 29 and by means of a stripper remove a flange of the 35th elastic coupling.
11. Turn off nuts of fastening of a cover 43 back bearings of a secondary shaft of the transmission and uncover together with a cuff of the 27th secondary shaft.
12. Remove the leading gear wheel of the 26th drive of a speedometer.
13. Remove the conical expansion plug 25.
14. Include at the same time two transfers that shaft relatively each other were not turned.
15. Turn off lock bolts of 54 and 38 forward 55 and back 41 bearings of an intermediate shaft of the transmission.
16. Shift an intermediate shaft 49 back as far as it is possible, previously having switched off transfers.
17. Take out a lock ring of the back bearing of 41 intermediate shafts, then for a pro-point on the bearing take out an external ring from a transmission case together with a half of an internal ring.
18. Take out balls with a separator and by means of a stripper press the second half of an internal ring of the bearing from a shaft.
19. Take out the forward bearing 55 of an intermediate shaft from a transmission case.
20. Fix a stripper by nuts on the hairpins intended for fastening of a cover of the back bearing of a secondary shaft and shift a secondary shaft 30 in a box. Then, having returned back a shaft, remove a lock ring from the back bearing of 21 secondary shaft.
21. By means of a stripper press the bearing for a pro-point from a secondary shaft.
22. Take out a main shaft 1 together with the bearing from a transmission case, holding a secondary shaft.
23. Take out a secondary shaft from a transmission case.
24. Vypressuyte by means of a stripper axis 48 of an intermediate gear wheel of a backing also remove an intermediate gear wheel of the 45th backing.
25. Remove the lever 3 inclusions of a backing with a cracker 2 from the axis pressed in a transmission case.
26. Take out an intermediate shaft 49 of the transmission.
Dismantling of the mechanism of gear shifting
1. Turn out the switch of light of a backing 58 (see fig. 3.27).
2. Remove a stamped lower cover 53, having unscrewed screws 54.
3. Establish all rods in neutral situation.
4. Take out a bracket 21 on the right side on a cover of the mechanism of switching and separate from it a spring 22 levers of gear shifting.
5. Turn off three nuts of the 14th fastening of the lever of gear shifting and take out the lever 8 of a cover.
6. Remove the directing cup 6.
7. Turn off traffic jams of 41 rods on a back wall of a cover of the mechanism of gear shifting.
8. Turn off lock bolts 49 and 25 on heads of rods and forks of gear shifting.
9. Remove a fork of the 57th inclusion of the third and fourth transfers.
10. Take out a clamp of the third and fourth transfers (a ball 2 with a spring 3), having turned out previously carving stopper 4.
11. Through a cap opening in a back wall of a cover take out a rod of 43 third and fourth transfers and remove a head of 44 third and fourth transfers.
12. Take out a pusher 42 of a rod.
13. Moving the rods which remained in a cover, take out balls of stoppers from a nest of a rod of the third and fourth transfers.
14. Similarly take out rods of inclusion of the fifth transfer of the 45, first and second transfers 38 and a backing 50.
15. Sort a head of the 40th rod of the first and second transfers, having beaten out a drift a lock pin and having taken out a plunger 39 with a spring.
Dismantling of a main shaft of the transmission
1. Mark the blocking ring 9 (see fig. 3.26) that at assembly to put it on the former place.
2. Take out the bearing 57 of boring of a main shaft.
3. Remove a lock ring of the 58th bearing from the leading shaft.
4. Press the bearing 56 from a main shaft.
Dismantling of a secondary shaft of the transmission
1. Remove a persistent washer 20 (see fig. 3.26).
2. Remove a gear wheel 19 first transfers.
3. Remove the blocking ring of the first transfer and mark it concerning the synchronizer coupling.
4. Remove the needle bearing of a gear wheel of the first transfer.
5. Remove a lock ring of a nave 22 synchronizers of the first and second transfers.
6. Remove the synchronizer (a nave 22 with cutting spring rings and the backing coupling gear wheel 18) and take out a spline 23.
7. Remove 17 second transfers blocking a ring and mark it concerning the synchronizer coupling.
8. Remove a gear wheel 15 second transfers.
9. Remove the second lock ring of a nave of the synchronizer of the first and second transfers.
10. Remove the needle bearing 16 of a gear wheel of the second transfer.
11. Remove a lock ring of a nave of the synchronizer of the third and fourth transfers from other end of a shaft.
12. Remove the synchronizer of the third and fourth transfers (a nave 10 with the sliding coupling 51 and cutting spring rings).
13. Remove the blocking ring of the third transfer and mark it concerning the synchronizer coupling.
14. Remove the second lock ring of a nave of the synchronizer of the third and fourth transfers.
15. Remove a gear wheel 11 third transfers.
16. Remove a lock ring of a nave of the synchronizer of the fifth transfer.
17. Remove the synchronizer of the fifth transfer (a nave 12 with the sliding coupling 13 and a cutting spring ring).
18. Remove the blocking ring of the fifth transfer.
19. Remove a gear wheel 14 fifth transfers.
Dismantling of an intermediate  gear wheel of a backing
1. Remove a lock ring of the 47th bearing.
2. Take out the bearing 46 of a gear wheel with a separator assembled.
Dismantling of the lever of gear shifting
1. Remove an ottyazhny spring 22 (see fig. 3.27) from the lever.
2. Remove a cover of the 15th lever of gear shifting.
3. Remove a flange of the 12th fastening of a cover.
4. Remove a lock ring 11 and a basic washer of the 16th spring of the lever of gear shifting.
5. Remove a spring of the 17th lever of gear shifting.
6. Remove a spherical washer of the 10th lever of gear shifting.
7. Remove the directing cup of the 6th lever of gear shifting.
Check of technical condition
Before survey of a detail of the transmission carefully clear. Carefully, not to damage a surface of details, remove all deposits and clear openings and vents of possible pollution. Wash out to remove all remains of lubricant, and to an obduyta a stream of compressed air of a detail, then accurately and carefully wipe them. Especially carefully blow bearings. For their protection from damage the stream of compressed air should be directed so that to avoid bystry rotation of rings.
Case and covers
On a case there should not be cracks, on the surface of boring under bearings – wear or damages.
On the surface of interface to a coupling case, a cover of the mechanism of gear shifting and a cover of the back bearing of a secondary shaft there should not be damages which can become the reason of a divergence of axes and insufficient tightness, so, oil leak.
At detection of these damages remove roughnesses a file. If details are considerably damaged or worn-out, replace them new.
Epiploons
Check epiploons and be convinced of absence of damage, wear and roughnesses on their working edges. At detection even of insignificant defect replace epiploons new.
Shaft
On working surfaces and vents of a secondary shaft damages and excessive wear are not allowed. The flange of the elastic coupling has to slide freely without jammings on vents. On the surfaces of swing of rollers on the forward end of an intermediate shaft, on the forward end of a secondary shaft and under gear wheels there should not be roughnesses and zadir.
Check a beating of secondary and primary shaft, turning them manually. Check the surfaces of swing of rollers in a pro-point of a main shaft. Check an intermediate shaft. At detection of a vykrashivaniye or excessive wear of teeths replace an intermediate shaft.
The surface of an axis of an intermediate gear wheel of a backing has to be without jamming traces. Insignificant roughnesses on surfaces can be eliminated with a fine-grained skin.
The deformed shaft can be corrected on a small press if deformation is insignificant and all measures will be taken not to damage working surfaces. Otherwise replace a shaft new.
Gear wheels
On gear wheels damages or excessive wear of teeths are not allowed. Pay special attention to a condition of end faces of teeths of wreaths. The contact spot between teeths of gear wheels in gearing has to extend to all working surface which has to be without wear tracks. Check a gearing gap between gear wheels which assembly size has to be 0,1 mm; maximum permissible gap of 0,2 mm. The assembly axial gap between a fillet of a secondary shaft and gear wheels of the third and fifth transfers has to be 0,05–0,1 mm, a maximum permissible gap of 0,15 mm. At wear it is more admissible a gear wheel replace new.
Bearings
Ball or roller bearings have to be in a perfect state, their axial gap should not exceed 0,5 mm, and radial – 0,05 mm. Having pressed fingers an internal ring to external, turn one of them in both directions, swing at the same time has to be smooth, without jammings. On a surface of separators, rollers and racetracks of rings of bearings damages are not allowed. Replace defective bearings new.
Rods and forks
Deformation on forks of gear shifting is not allowed. Rods have to slide freely without considerable gap in cover openings.
Check a condition of pushers of rods, springs and balls of clamps, at detection of traces of jamming replace them, and also the springs of clamps which lost elasticity.
Synchronizers
Check whether there are no traces of jammings on naves and the sliding couplings of synchronizers, especially on the surfaces of sliding of couplings. Pay special attention to a condition of end faces of teeths of couplings. Excessive wear of a surface of the blocking rings is not allowed. The possible roughnesses interfering free movement of details can be eliminated with a velvet file. On details zaboina and cracks are inadmissible. Replace worn-out details new.
Assembly of the transmission
1. Clear and wash out transmission details.
2. The bearing 56 (see fig. 3.26) also establish to Napressuyta on the forward end of a main shaft a lock ring.
3. By means of nippers establish a lock ring of the 58th bearing.
4. Establish on the forward end of a secondary shaft a gear wheel by the 14th heel of transfer, the lock ring of the fifth transfer blocking a ring, a nave of the 12th synchronizer of the fifth transfer with a cutting spring ring assembled, a lock ring. At assembly of a secondary shaft grease seats of a shaft and details with gearbox oil.
5. Install the sliding coupling 13 of the synchronizer of the fifth transfer.
6. Establish a gear wheel 11 third transfers, the lock ring blocking a ring of 9 third and fourth transfers, a nave of the 10th synchronizer of the third and fourth transfers with spring rings in collecting (the unbent ends of rings have to be directed towards a gear wheel of the corresponding transfer), a lock ring and the sliding coupling of 51 synchronizers of the third and fourth transfers.
7. Install on the back end of a secondary shaft the bearing 16 of a gear wheel of the second transfer, a lock ring of a nave of the synchronizer, a gear wheel 15 second transfers blocking a ring 17 second transfers, a spline 23, the synchronizer of the first and second transfers with spring cutting rings in collecting (the unbent ends of rings have to be directed towards a gear wheel of the corresponding transfer), a gear wheel of the 18th backing, the lock ring of a nave of the synchronizer of the first and second transfers, the bearing of a gear wheel of the first transfer blocking a ring of the first transfer, a gear wheel 19 first transfers, a persistent washer 20.
8. Enter an intermediate shaft 49 into openings for bearings through the top cavity of a case and put it on necks under bearings.
9. Install the lever 3 inclusions of a backing with a cracker 2 assembled on the axis pressed in a case.
10. Establish an intermediate gear wheel of the 45th backing with the bearing assembled on axis 48 of an intermediate gear wheel, having pressed the last in a transmission case assembled with a lock ball 42.
11. Enter a secondary shaft the back end into a transmission case opening under the back bearing of a secondary shaft.
12. Grease the bearing 57 with jellied lubricant and install it in boring of a main shaft.
13. Establish a main shaft with the bearing assembled in a transmission case opening.
14. Install the forward end of a secondary shaft in the bearing on primary to a shaft and by means of a mandrel a napressuyta the back bearing of 21 secondary shaft with a lock ring assembled on the back end of a shaft and in a transmission case.
15. Lift an intermediate shaft for the aligning openings by means of mandrels, to a napressuyta the forward roller bearing 55 assembled with a lock ring and the back bearing of 41 intermediate shafts assembled with a lock ring and fix by bolts with persistent washers both bearings on intermediate to a shaft.
16. Establish a case of coupling with an epiploon, a spring ring in collecting and with laying, fix it by bolts.
17. Install the expansion plug 25 on a secondary shaft.
18. Establish the leading gear wheel of the 26th drive of a speedometer with a lock ball 28.
19. Establish and fix by nuts a cover 43 back bearings of a secondary shaft with a cuff of the 27th secondary shaft assembled.
20. Establish a flange of the 35th elastic coupling on vents of a secondary shaft, a lock washer 34, then wrap a nut 29 and stop it, having bent a lock washer.
21. Establish on a secondary shaft a sealant 33 the aligning rings of the elastic coupling, aligning 32 and lock 31 rings.
22. Grease details of the mechanism of gear shifting with liquid gearbox oil, grooves of heads of switching – colloidal and graphite medicine or solid oil.
23. Collect a head 40 (see fig. 3.27) a rod of the first and second transfers.
24. Establish a spring and a lock pin in a head.
25. Insert a rod of 38 first and second transfers to a cover, establish a head and a fork of inclusion of 27 first and second transfers and fix them on a rod, having wrapped lock bolts 25 with spring washers 24.
26. Insert a ball 2 and a spring 3 clamps of a rod of inclusion of the first and second transfers, wrap a stopper 4, establish a rod in neutral situation.
27. Insert a rod of 43 third and fourth transfers with a finger of the blocking device assembled into a cover, watching that the ball and a finger did not drop out of the nests.
28. Establish a head 44 and a fork of the 57th inclusion of the third and fourth transfers and fix them on a rod, having wrapped lock bolts.
29. Insert a ball and a spring of a clamp of a rod of inclusion of the third and fourth transfers, wrap a stopper and establish a rod in neutral situation.
30. Establish a rod 45, the blocking device, a head 46, a fork 56, a clamp of the fifth transfer is similar to a rod of the third and fourth transfers.
31. Establish a ball 2 blocking devices of a rod of the 50th inclusion of a backing, insert a rod of inclusion of transfers of a backing to a cover, watching that the blocking ball did not drop out of a nest in a cover.
32. Establish a head 47 and a fork of 51 inclusion of a backing and fix them on a rod, having wrapped lock bolts with spring washers.
33. You will insert a ball and a spring of a clamp of a rod, wrap a stopper and establish a rod in neutral situation.
34. Screw the backing light switch 58.
35. Screw traffic jams 41 in a back wall of a cover, having greased them previously with sealant.
36. Establish a protective cover 53 mechanisms of gear shifting with laying 52 and fix by screws 54 with spring washers 55.
37. Collect the gear shifting lever, grease a spherical support 9 with jellied lubricant, insert the lever 8, establish from above a spherical washer 10, a spring 17, a basic washer 16 and a lock ring 11.
38. On the top cover establish the laying directing a cup 6, laying of the 5th spherical support, laying under a flange of the 12th fastening of a cover.
39. Connect an ottyazhny spring to the lever of gear shifting 22.
40. Install the lever in a cover, through a side window in a cover extend an ottyazhny spring by means of a hook or a loop and connect to it a bracket 21.
41. Establish a flange 12 isolating a cover and fix the lever by nuts 14 with washers 13.
42. Put on a cover of the 15th lever a flange of a cover and establish the isolating cover 19.
43. Establish laying of the 59th top cover.
44. Install the gear shifting mechanism in a box, having checked correctness of installation of forks in gear shifting couplings, and fix the mechanism by means of bolts.
45. Establish a reducer 4 (see fig. 3.26) a speedometer, fix it by a bolt 5.
46. Fill in oil in a transmission case to a control opening and wrap a stopper.

Features of a design of the transmission VAZ

Fig. 3.28. Transmission: 1 – main shaft; 2 – a forward cover with the directing plug; 3 – epiploon of a main shaft; 4 – spring washer; 5 – adjusting ring of the bearing; 6 – transmission case; 7 – сапун; 8 – needle bearing of a secondary shaft; 9 – persistent washer of a spring of the synchronizer; 10 – gear wreath of the synchronizer IV of transfer; 11 – the sliding coupling of the synchronizer III and IV of transfers; 12 – nave of the coupling of the synchronizer III and IV of transfers; 13 – lock ring of the synchronizer; 14 – the blocking synchronizer ring; 15 – synchronizer spring; 16 – gear wheel and gear wreath of the synchronizer III of transfer; 17 – gear wheel and gear wreath of the synchronizer II of transfer; 18 – secondary shaft; 19 – gear wheel and gear wreath of the synchronizer I of transfer; 20 – plug of a gear wheel of the I transfer; 21 – intermediate bearing of a secondary shaft; 22 – lock plate of the intermediate bearing; 23 – flange; 24 – protective cover; 25 – spring; 26 – gear shifting lever; 27 – gear shifting lever core; 28 – elastic pillow of a damper; 29 – rubber plug of a damper; 30 – expansion plug of a damper; 31 – locking plug of a damper; 32 – cuff; 33 – spherical washer; 34 – spherical support of the lever; 35 – gear shifting lever case; 36 – the directing plate; 37 – flange of the elastic coupling of cardan transfer; 38 – nut; 39 – a sealant of the aligning ring; 40 – the aligning ring; 41 – lock ring; 42 – epiploon of the back bearing of a secondary shaft; 43 – back bearing of a secondary shaft; 44 – expansion plug; 45 – maslootrazhatelny washer; 46 – block of gear wheels of the V transfer and backing;
47 – transfer synchronizer V nave; 48 – intermediate gear wheel of a backing; 49 – back bearing of an intermediate shaft; 50 – gear wheel of the I transfer of an intermediate shaft; 51 – the sliding coupling of the synchronizer I and II of transfers; 52 – gear wheel of the II transfer of an intermediate shaft; 53 – gear wheel of the III transfer of an intermediate shaft; 54 – stopper of a bulk and control opening; 55 – intermediate shaft; 56 – gear wheel of continuous gearing of an intermediate shaft; 57 – forward bearing of an intermediate shaft; 58 – tightening washer of the bearing of an intermediate shaft; 59 – bolt of a tightening washer; 60 – gear wheel of continuous gearing of a main shaft; 61 – back bearing of a main shaft; 62 – lock ring


The five-speed transmission consists of three shaft: primary 1 (fig. 3.28), intermediate 55 and secondary 18 with gear wheels and synchronizers; axes with an intermediate gear wheel of the 48th backing and the mechanism of gear shifting. Shaft and gear wheels of the transmission are placed in a cast aluminum case 6 and in a back cover.
The main shaft 1 rotates in two ball bearings, one of which is located in an end face of a bent shaft of the engine, another – in a forward wall of a case of the transmission. The back bearing 61 is kept on a shaft by a lock ring 62 and the spring dish-shaped washer established between an internal ring of the bearing and a lock ring. In a flute of an external ring of the bearing 61 the adjusting ring 5 which is clamped between a forward wall of a box and a case of coupling is located. Between a forward cover 2 and an external ring of the bearing 61 the spring dish-shaped washer 4 is established. Such fixing of the back bearing holds a shaft from axial movement.
On a forward part of a main shaft vents which it connects to the conducted clutch plate are cut. For a single whole with shaft 1 the kosozuby gear wheel 60 which is in continuous gearing with a gear wheel of the 56th intermediate shaft is made. The Pryamozuby wreath of the 10th synchronizer of the fourth transfer soldered by copper to a main shaft 1 connects to the coupling 11 at inclusion 1V of transfer.
The intermediate shaft 55 represents the block of four gear wheels which the forward end leans on the two-row ball bearing 57, and the back end – on the roller bearing 49.
On vents of an intermediate shaft the block of 46 gear wheels of the fifth transfer and backing fastens a coupling bolt. The back end of the block leans on the roller cylindrical bearing located in a nest of a back cover.
The secondary shaft 18 rotates in three roller bearings. The forward needle bearing 8 is located in a nest of a main shaft. The intermediate bearing 21 is in a back wall of a case of the transmission. It is fixed in a nest by a lock plate 22 which fastens to a back wall of a case screws. Between a plate and a case the adjusting ring of the intermediate bearing is clamped. The bearing is installed on a shaft between the plug 20 and a gear wheel of a backing which fastens on a shaft a spline together with a nave of the coupling of the synchronizer of the fifth transfer. Behind a nave the persistent washer and the plug on which the conducted gear wheel of the fifth transfer rotates are located. Between the plug of this gear wheel and the expansion plug 44 the maslootrazhatelny washer 45 is established. The back end of a secondary shaft is established on the roller cylindrical bearing 43 and at the exit from a cover is condensed with an epiploon 42. On vents of a shaft the flange of the 37th elastic coupling fastens. All details located on secondary to a shaft are drawn in by a nut 38 on which cylindrical corbel the rubber sealant 39 is located, on the end of a shaft there is an aligning ring 40.
On the thermoprocessed necks of a secondary shaft gear wheels of 16 and 17 third and second transfers rotate. The gear wheel 19 first transfers rotates on the steel thermoprocessed plug 20 which is put on a shaft. Each of these gear wheels has two wreaths. Kosozuby wreaths are in continuous gearing with gear wheels of an intermediate shaft 55, and pryamozuby wreaths connect at inclusion of transfers to couplings 11 and 51 of synchronizers and through them, and also through naves of synchronizers transfer torque to a secondary shaft. The conducted gear wheel of the fifth transfer is in continuous gearing with a big wreath of the block of 46 gear wheels. With a small wreath of the block the intermediate gear wheel 48 enters gearing at inclusion of transfer of a backing.
On two corbels of a secondary shaft about three deep grooves which ledges of naves of the sliding couplings of synchronizers enter that provides their rigid connection with shaft are cut.
The synchronizer of the third and fourth transfers consists of a nave 12, the sliding coupling 11, two blocking rings 14, springs 15 and wreaths. One blocking ring of the synchronizer connects an internal wreath to a pryamozuby wreath of a gear wheel 16 third transfers. The ring is kept on a gear wheel wreath by a lock ring 13. Between the blocking ring and a basic washer of a gear wheel the spring 15 which draws in the blocking ring 14 to a lock ring 13 is established. Other ring of the synchronizer in the same way connects to a wreath of the 10th synchronizer of the fourth transfer of a main shaft of the transmission.
Each blocking ring has a conic surface with a small carving on which nestles at transfer inclusion a conical part of the sliding coupling 11. At the time of contact of the coupling with a ring the oil film on a carving of a ring is broken off therefore friction between a ring and the coupling increases.
The sliding coupling 11 has vents, outside inside – a ring pro-point for a gear shifting fork. The coupling is located on vents of the nave 12 which is rigidly connected with a secondary shaft. At inclusion of the third or fourth transfer the sliding coupling, moving on vents of a nave 12, 16 third transfers or with a wreath of the 10th main shaft enter gearing with a small wreath of a gear wheel and connect them through a nave 12 to a secondary shaft 18. At the same time the torque from a main shaft 1 or a gear wheel 16 is transferred to a secondary shaft through synchronizer details. Synchronizers of the first, second and fifth transfers have the similar device.
The intermediate gear wheel of the 48th backing rotates on a motionless axis on the ceramic-metal plug. One end of an axis fastens to a case partition a nut with a dish-shaped spring washer, other its end is established in a nest of a back cover.

Removal and installation
1. Install the car on a viewing ditch or the elevator, put an emphasis under forward wheels and you will hang out the back bridge with one or from two parties.
2. Turn on the parking brake and install the gear shifting lever in neutral situation.
3. Disconnect wires from the rechargeable battery.
4. Remove an external cover of the lever of gear shifting, then remove a plastic cover and a sealant.
5. Press down a core of the 27th lever, the screw-driver or any other pointed tool take out the locking plug 31 of a flute on a core of the lever and remove a core.
6. Disconnect a suspension bracket of pipes and mufflers in a back part of the car, and then a pipe of mufflers from a reception pipe. Disconnect a collar of fastening of a reception pipe to the transmission. A key 02.7812.9500 turn off nuts of fastening of a reception pipe of mufflers to a final collector and lower a pipe down.
7. Turn off four bolts of fastening of a cover of a case of coupling.
8. Disconnect a "mass" wire from a case of coupling and a wire from the backing lamp switch.
9. Remove the working cylinder from a coupling case, without disconnecting a hose from the cylinder. It will exclude loss of brake fluid and need of the subsequent pumping of the hydraulic drive of coupling.
10. Remove an arm of safety of the driveshaft.
11. Turn off a nut and disconnect a flexible shaft of a speedometer from the speedometer drive.

Fig. 3.29. Elastic coupling of connection of the driveshaft with the transmission: 1 – bolts of fastening of a flange of the driveshaft to the elastic coupling; 2 – nuts of bolts of fastening of a flange of a secondary shaft of the transmission to the elastic coupling; 3 – A.70025 adaptation; 4 – elastic coupling; 5 – cross-piece of a back engine mount


12. Put on a collar of A.70025 the elastic coupling 4 (fig. 3.29) and tighten it. It will facilitate removal and the subsequent installation of the elastic coupling. Turn off nuts 2 and, scrolling the driveshaft, take out bolts of fastening of the elastic coupling 4 to a flange of a secondary shaft of the transmission. Lower and take aside the forward driveshaft with the coupling.
13. Turn off a hinged face key 02.7812.9500 bolts of fastening of a starter to a case of coupling and remove a starter.
14. Disconnect a support of a back engine mount from a cross-piece, and then remove a cross-piece, supporting the transmission from below.
15. Put under a transmission case a special support on the hydraulic elevator. A hinged face key of A.55035 turn off bolts of fastening and remove the transmission together with a coupling case, having displaced it to a back part of the car so that to take a main shaft of the transmission from the forward bearing and a nave of the conducted clutch plate.

       PREVENTION
At removal or installation of the transmission not to an opirayta the end of a main shaft on a persistent flange of a press spring of coupling not to deform connecting plates of coupling.

16. Installation of the transmission is carried out upside-down. Before installation apply a thin film of LSTs-15 lubricant (Litol-24) on the shlitsevy end of a main shaft and center a mandrel of A.70081 the conducted clutch plate.

Repair of the transmission
Dismantling
1. Wash up outside the transmission.
2. Turn off traffic jams of drain and bulk openings and merge oil from the transmission.
3. Remove from the directing plug the coupling switching off coupling assembled with the bearing and a connecting spring.
4. Remove a cover of a fork of switching off of coupling from a case, accurately hooking a cover the screw-driver, and remove a fork with a cover, having turned it on 90 °.

Fig. 3.30. Coupling case interior. Black shooters specified nuts of fastening of a case of coupling to the transmission; the white arrow specified an opening in a forward cover for production of oil from a transmission case that there was no oiling of clutch plates


5. Turn off seven nuts of fastening of a case of coupling (fig. 3.30), remove spring washers.
6. Remove a coupling case, having disconnected it from the transmission.
7. Remove laying and a spring washer.
8. Turn off ten nuts of fastening of the lower cover to a case (under nuts spring washers are established) and uncover a case. Then accurately separate laying from a case and remove it from hairpins.

Fig. 3.31. Removal of the drive of a speedometer from a case


9. Turn off a nut of fastening of the case of the drive of a speedometer to a case (under a nut the spring washer is established) and remove the speedometer drive from a case (fig. 3.31).

Fig. 3.32. Weakening of an inhaling of the switch of a lamp of a backing and its removal from a case


10. Having turned the transmission, weaken an inhaling of the switch of a lamp of a backing and remove it from a case (fig. 3.32).

Fig. 3.33. Gear shifting drive: 1 – inclusion fork III and IV transfers; 2 – rod of a fork of inclusion of I and II transfers; 3 – inclusion fork rod III and IV transfers; 4 – fork of inclusion of I and II transfers; 5 – rod of a fork of inclusion of the V transfer and backing; 6 – blocking crackers; 7 – cover of clamps; 8 – spring of clamps; 9 – ball of clamps; 10 – fork of inclusion of the V transfer and backing; 11 – head of a rod of a fork of inclusion of the V transfer and backing; 12 – block of gear wheels of the V transfer and backing; 13 – axis of an intermediate gear wheel of a backing; 14 – intermediate gear wheel of a backing; 15 – a washer of the directing plate; 16 – the directing plate; 17 – gear shifting lever case; 18 – spherical support; 19 – spherical washer; 20 – spring; 21 – persistent washer; 22 – lock ring


11. Turn off a bolt of fastening of a fork of 1 (fig. 3.33) of switching of the third and fourth transfers.
12. Include the first transfer by the lever of gear shifting and at the same time the fourth, having shifted the screw-driver the synchronizer coupling.

Fig. 3.34. Removal of a lock ring


13. Remove a lock ring from the end of a secondary shaft (fig. 3.34).
14. Unbend a lock plate of a nut of fastening of a flange of the elastic coupling.
15. Turn off on several turns a nut 38 (see fig. 3.28) to shift the aligning ring of the 40th elastic coupling, and again wrap a nut.

Fig. 3.35. Removal of the aligning ring of the elastic coupling of the driveshaft


16. A stripper press the aligning ring of the elastic coupling (fig. 3.35).
17. Remove a sealant 39 (see fig. 3.28) the aligning ring.
18. Turn off a nut 38 and remove a lock washer.

Fig. 3.36. Removal of a flange of the elastic coupling stripper of A.40005/3/9B/9C: 1 – flange of the elastic coupling; 2 – stripper of A.40005/3; 3 – level of a stripper of A.40005/3; 4 – bolts of fastening of adaptation to a flange


19. By means of a stripper remove a flange of 1 elastic coupling (fig. 3.36).
20. Install the gear shifting lever in neutral situation and shift a cuff 32 (see fig. 3.28) from a flange 23 mechanisms of control of the transmission for simplification of access to fastening nuts.

Fig. 3.37. Removal of the mechanism of gear shifting


21. Turn off three nuts of fastening of a flange 23 to a case (under nuts spring washers are established) and remove the gear shifting lever assembled with the mechanism of switching (fig. 3.37).
22. Turn off outside of five nuts of fastening of a back cover (under nuts spring washers are established). The right top nut cannot be turned off up to the end in a starting position of a cover.
23. Turn off the nut of fastening of a back cover located from the inside of a case.

Fig. 3.38. Removal of a back cover and case


24. Separate a back cover and a case, having removed a cover on the greatest possible distance, and turn off finally right top nut (fig. 3.38).
25. Having taken away a back cover back and having turned approximately on 20 ° clockwise (to exclude its zadevaniye for the block of gear wheels of a backing and the fifth transfer), remove it from a box case.
26. Remove an internal ring of the back bearing of a secondary shaft and the leading gear wheel of the drive of a speedometer.

Fig. 3.39. Removal of a cover of clamps


27. Turn off two bolts of fastening of a cover of clamps, uncover also laying of a cover (fig. 3.39).
28. Take out from openings of a spring of clamps. Then, having turned the transmission, take out balls of clamps.
29. Remove a ball clamp of the leading gear wheel of the drive of a speedometer and a maslootrazhatelny washer 45 (see fig. 3.28).

Fig. 3.40. Otvertyvaniye of bolts of fastening of the block of gear wheels and fork of inclusion of the V transfer and backing: 1 – intermediate gear wheel of a backing; 2 – bolt of fastening of the block of gear wheels; 3 – fork rod; 4 – bolt of fastening of a fork; 5 – cover of clamps


30. Turn off a bolt of 2 (fig. 3.40) of fastening of the block of gear wheels of the fifth transfer, previously having included two transfers, and take out a bolt.
31. Turn off a bolt 4 fastenings of a fork of inclusion of the fifth transfer and a backing.

Fig. 3.41. Removal of a rod of a fork of inclusion of the V transfer and backing: 1 – rod of a fork of inclusion of the V transfer and backing; 2 – fork of inclusion of the V transfer and backing; 3 – remote plug


32. Pull on yourself a rod of 1 (fig. 3.41) of inclusion of the fifth transfer and a backing and take out it from a case and a fork of inclusion.
33. Remove from shliyets of an intermediate shaft the block of 4 gear wheels of the fifth transfer and backing with the bearing.

Fig. 3.42. Removal of the plug of a gear wheel of the V transfer


34. Remove the plug of a gear wheel of the fifth transfer (fig. 3.42) from a secondary shaft.

Fig. 3.43. Removal of an intermediate gear wheel of a backing, gear wheel of the V transfer assembled with the synchronizer and a fork: 1 – intermediate gear wheel of a backing; 2 – coupling of inclusion of the V transfer; 3 – gear wheel of the V transfer and backing; 4 – fork of inclusion of the V transfer and backing


35. Remove at the same time a backing gear wheel, a gear wheel of the fifth transfer assembled with the coupling of the synchronizer and a fork of inclusion of the fifth transfer (fig. 3.43).

Fig. 3.44. Removal of the conducted gear wheel of a backing and a nave of the coupling of the synchronizer V of transfer: 1 – intermediate shaft; 2 – the conducted backing gear wheel; 3 – axis of an intermediate gear wheel of a backing; 4 – transfer synchronizer V coupling nave; 5 – secondary shaft; 6 – rod of a fork of inclusion of I and II transfers; 7 – inclusion fork rod III and IV transfers


36. Remove a synchronizer nave, the blocking ring and a gear wheel of a backing (fig. 3.44) from a secondary shaft.
37. Vypressuyte with the help a small beard the back bearing 49 (see fig. 3.28) an intermediate shaft easy blows to an external ring.
38. Remove from an intermediate shaft the remote plug and an external ring of the back bearing with rollers. Then remove an internal ring of the back bearing.
39. Remove a lock ring of the forward bearing 57 of an intermediate shaft.
40. Turn off a bolt of the 59th fastening of the forward bearing of an intermediate shaft, having included at the same time two transfers (first and fourth), and remove a bolt with spring and tightening 58 washers.
41. Install the screw-driver between an external ring of the bearing 57 and a gear wheel of a shaft and, working as the lever, a vypressuyta an external ring of the bearing with balls and a forward internal ring. Then press a back internal ring of the bearing, accurately working with the screw-driver as the lever.

Fig. 3.45. Extraction of an intermediate shaft from a transmission case


42. Take out an intermediate shaft from a case, inclining it, as shown in fig. 3.45.
43. Turn the transmission and take out a blocking cracker 6 (see fig. 3.33) a rod of inclusion of the third and fourth transfers.

Fig. 3.46. Withdrawal of an intermediate blocking cracker


44. Put forward a rod 3 forks of inclusion of the third and fourth transfers so that it was possible to take out an intermediate blocking cracker from its opening, and take out a cracker by means of the screw-driver (fig. 3.46).
45. Remove a rod and a fork of inclusion of the third and fourth transfers.
46. Turn off a bolt of fastening of a fork 4 (see fig. 3.33) inclusions of the first and second transfers and take out a rod 2 forks of inclusion of the first and second transfers from a case.
47. Turn the transmission and take out a blocking cracker of the 6th rod of a fork of inclusion of the first and second transfers.
48. Remove a fork of inclusion of the first and second transfers.

Fig. 3.47. Extraction of a main shaft from a transmission case


49. Take out a main shaft assembled from the transmission (fig. 3.47).
50. Remove the needle bearing 8 (see fig. 3.28) from the forward end of a secondary shaft.

Fig. 3.48. Otvertyvaniye of screws of fastening of a lock plate of the intermediate bearing of a secondary shaft drill screw-driver. The arrow showed the direction of the shock course of a holder of the screw-driver at blow by the hammer


Fig. 3.49. Fastening of an axis lock plate


51. Weaken an inhaling of three screws of fastening of a lock plate of the intermediate bearing of a secondary shaft (fig. 3.48) and remove screws with lock washers. Remove a lock plate. Then turn off a nut of fastening of an axis of an intermediate gear wheel of a backing and remove an axis. As the option an axis can fasten a lock plate. In this case for removal of an axis develop a lock plate so that to bring her out of a groove of an axis of an intermediate gear wheel of a backing (fig. 3.49).
52. Remove a lock ring of the intermediate bearing 21 (see fig. 3.28) a secondary shaft.
53. Remove a spline from a secondary shaft.
54. Remove the intermediate bearing 21 from a secondary shaft, working with the screw-driver as the lever.

Fig. 3.50. Extraction of a secondary shaft from a transmission case


55. Give a secondary shaft back and take out it from a case the forward end (fig. 3.50) up.
56. In need of replacement to a vypressuyta the back bearing 43 (see fig. 3.28) a secondary shaft from a back cover of the transmission easy blows of the hammer to an external ring of the bearing.
Repair of a main shaft

Fig. 3.51. Details of a main shaft: 1 – lock ring; 2 – spring washer; 3 – bearing;
4 – main shaft; 5 – synchronizer spring; 6 – the blocking synchronizer ring; 7 – lock ring; 8 – bearing


1. Establish a shaft in a vice and remove a lock ring of 7 (fig. 3.51), holding the blocking synchronizer ring.
2. Remove the blocking ring 6 and a spring of the 5th synchronizer.
3. Oboprite a shaft on an external ring of the bearing and, without clamping in a vice, remove an adjusting ring 5 (see fig. 3.28).
4. Remove a lock ring 1 (see fig. 3.51) from a shaft.
5. Remove from a shaft a spring washer 2.
6. Press the bearing 3 from a shaft, putting effort only to an internal ring of the bearing.
7. Check technical condition of details (see. "Check of technical condition") also collect a shaft upside-down.
Repair of a secondary shaft

Fig. 3.52. Details of a secondary shaft: 1, 5, 15, 18, 30, 45 – a lock ring; 2 – spring washer;
3 – nave of the synchronizer of the third and fourth transfers; 4 – coupling of the synchronizer of the third and fourth transfers; 6 – the blocking ring of the third transfer; 7, 13, 20, 32 – a synchronizer spring; 8, 12, 21 – a washer; 9 – gear wheel of the third transfer; 10 – secondary shaft; 11 – gear wheel of the second transfer; 14 – the blocking ring of the second transfer; 16 – coupling of the synchronizer of the first and second transfers; 17 – nave of the synchronizer of the first and second transfers; 19 – the blocking ring of the first transfer; 22 – gear wheel of the first transfer; 23 – plug of a gear wheel of the first transfer; 24 – intermediate bearing of a secondary shaft; 25 – spline; 26 – backing gear wheel; 27 – nave of the synchronizer of the fifth transfer; 28 – spring washer; 29 – coupling of the synchronizer of the fifth transfer; 31 – the blocking ring of the fifth transfer; 33 – gear wheel of the fifth transfer; 34 – plug of a gear wheel of the fifth transfer; 35 – maslootrazhatelny washer; 36 – leading gear wheel of the drive of a speedometer; 37 – back bearing of a secondary shaft; 38 – epiploon; 39 – flange of the elastic coupling; 40 – lock washer; 41 – nut; 42 – sealant spring; 43 – sealant; 44 – the aligning ring


1. Establish a shaft in a vice and remove the coupling 4 (fig. 3.52) of the synchronizer of the third and fourth transfers from a shaft.
2. Remove a lock ring of 1 nave of the synchronizer of the third and fourth transfers.
3. Remove from a shaft a spring washer 2.
4. Shift the screw-driver a nave 3 synchronizers of the third and fourth transfers and remove it.
5. Remove from a shaft a gear wheel 9 third transfers assembled with the blocking ring of the 6th synchronizer.
6. Turn a shaft and by means of the screw-driver press the plug 23 gear wheels of the first transfer.
7. Remove from a shaft a gear wheel 22 first transfers assembled with the blocking ring of the 19th synchronizer, the coupling 16 of the synchronizer of the first and second transfers, a nave of the 17th synchronizer of the first and second transfers, a gear wheel 11 second transfers assembled with the blocking ring 14.
8. Remove lock rings 15 and 18 from gear wheels of the first and second transfers, holding the blocking synchronizer rings.
9. Remove blocking a ring 14 and 19, gradually weakening effort of pressing, and a spring of the 13 and 20 synchronizer.
10. Check technical condition of details (see. "Check of technical condition") also collect a secondary shaft upside-down, taking into account the following features:

Fig. 3.53. Installation of couplings of synchronizers


11. Install couplings of synchronizers so that ring pro-points (are shown by shooters) were turned to each other (fig. 3.53).
12. Press the plug of a gear wheel of the first transfer against the stop.
13. Measure by the flat probe an assembly gap between an end face of a gear wheel of the first transfer and a fillet of the plug, and also between end faces of gear wheels of the second and thirds of transfers. The gap has to be 0,05–0,10 mm. Maximum permissible gap of 0,15 mm. If the gap exceeds maximum permissible, replace worn-out details.
14. Establish a spring conic washer so that its cone was turned outside.
Repair of the mechanism of gear shifting

Fig. 3.54. Details of the lever and mechanism of gear shifting: 1 – gear shifting lever; 2 – laying; 3 – spherical support; 4 – spherical washer; 5 – spring; 6 – ring; 7 – lock ring; 8 – flange; 9 – cuff; 10 – protective cover; 11 – handle; 12 – lever core; 13 – persistent pillow; 14 – elastic plug; 15 – remote plug; 16 – locking plug; 17 – gear shifting lever case; 18 – sealing ring; 19 – a washer of the directing plate; 20 – the directing level; 21 – springs; 22 – the directing plate; 23 – blocking plate of a backing


1. Remove a cuff of 9 (fig. 3.54) from the gear shifting mechanism.
2. Remove the screw-driver a protective cover 10.
3. Turn off three nuts of coupling bolts of the case 17 of the lever of switching and a guide of a plate 22, remove bolts and spring washers.
4. Remove a blocking plate 23 backings and the lower washer of the 19th guide of a plate.
5. Having hooked the screw-driver the directing levels 20, take out them and springs 21 of the directing switching lever plate.
6. Remove the directing plate 22, the top washer of the 19th guide of a plate, three rubber sealing rings 18 from the switching lever case, then remove the switching lever case 17.
7. Remove from the switching lever a flange 8 and laying 2 flanges.
8. Fix the gear shifting lever in a vice and remove a lock ring 7.
9. Having released the lever from a vice, remove from the lever a persistent ring 6, a spring 5 and a spherical washer 4.
10. Remove from the switching lever a spherical support 3 with laying 2.
11. Check technical condition of details and collect the gear shifting mechanism upside-down, previously having greased with jellied lubricant the spherical surfaces of the lever of switching and a spherical support of the lever.
Check of technical condition
Cleaning
Before survey carefully clear transmission details. Remove with a brush or a scraper all deposits, clean openings; then wash out to remove the oil remains.
Of a detail a stream of compressed air and accurately wipe with Obduyte them. Especially carefully blow bearings, directing a stream of compressed air so that there was no bystry rotation of rings.
Case and covers
On a case there should not be cracks, and on the surface of boring for bearings – wear or damages.
On the surfaces of interface to a coupling case, back and lower covers there should not be damages causing oil leak. Smooth insignificant damages a file. If details are too damaged or worn-out, replace them new.
Check a condition of a forward cover and be convinced that the main shaft at rotation does not concern it. If not coaxiality of a shaft and cover is found, replace the damaged details. Check whether the drain opening for oil in a cover is littered (it is shown by an arrow in fig. 3.30). Clear a stopper of a drain opening.
Epiploons
Check epiploons and be convinced of absence of damage, unacceptable wear and roughnesses on working edges. Wear of working edges of epiploons on width is allowed no more than 1 mm. At detection even of insignificant defect replace epiploons new.
Shaft
On working surfaces and on vents of a secondary shaft damages and excessive wear are not allowed. On the surfaces of swing of needles on the forward end of a shaft there should not be roughnesses and zadir.
Check a condition of a surface of swing of needles in an opening of a main shaft.
Examine an intermediate shaft: the vykrashivaniye or excessive wear of teeths is not allowed.
The surface of an axis of a gear wheel of a backing has to be absolutely smooth, without jamming traces. The size of an assembly gap between an axis and the plug of an intermediate gear wheel of a backing of 0,056-0,09 mm, a maximum permissible gap of 0,15 mm. The gap is defined by a difference of the measured diameter of an axis and an opening of the plug of a gear wheel. At new details diameter of an axis is equal to 19,079-19,094 mm, and the internal diameter of the pressed plug – 20,05–20,07 mm.
Eliminate insignificant roughnesses on surfaces with a fine-grained skin. At big damages and deformations replace a shaft new.
Gear wheels
On gear wheels there should not be damages or excessive wear of teeths. Pay special attention to a condition of end faces of teeths on wreaths of synchronizers.
The spot of contact of gearing of teeths of a gear wheel has to settle down on all surface – smooth and without wear tracks. Check a gap in gearing between teeths of gear wheels which assembly size has to be 0,10 mm; maximum permissible gap of 0,20 mm.
Assembly gaps between plugs and gear wheels of the first and fifth transfers and between a secondary shaft and gear wheels of the second and third transfers have to be 0,05–0,10 mm; maximum permissible gap of 0,15 mm.
At wear it is more admissible a gear wheel replace new.
Bearings
Ball or roller bearings have to be in a perfect state. Their radial gap should not exceed 0,05 mm.
Having pressed fingers an internal ring to external, turn one of them in both directions, swing at the same time has to be smooth. On a surface of balls or rollers and on paths of swing of rings of damage are not allowed. Replace the damaged bearings new. When replacing the forward bearing of a main shaft use a pusher of A.40006; at the same time the flywheel can be not removed.
Rods and forks
Deformation of forks of gear shifting is not allowed. Rods have to slide freely without considerable gap in case openings.
Check a condition of blocking crackers of rods, springs and balls of clamps. Replace the details having traces of jamming or wear new.
Naves, couplings and the blocking rings of synchronizers
Check whether there are no jamming traces on naves of couplings, especially on the surfaces of their sliding. Pay special attention to a condition of end faces of teeths of couplings.
Excessive wear of a surface of the blocking rings is not allowed. They should be replaced if they rest an end face against the synchronizer coupling. Eliminate the possible roughnesses interfering free sliding with a "velvet" file. Replace strongly worn-out details new.
Assembly
Collect the transmission upside-down taking into account the following.
1. If the axis of an intermediate gear wheel of a backing fastens a nut, then establish an axis before installation of shaft in a case of the transmission and wrap a nut the moment of 78 N · m (7,8 kgfs · м).
2. An internal ring of the bearing of the block of gear wheels of the fifth transfer and a backing to a napressuyta on the block of gear wheels, and external – in a nest of a back cover.
3. The back bearing of a secondary shaft to a napressuyta on a shaft for simplification of installation of a back cover.
4. An intermediate gear wheel 1 (see fig. 3.43) a backing, a gear wheel 3 and a fork 4 establish at the same time.
5. At assembly of the lever of gear shifting cover with LSTs-15 or Litol-24 lubricant a spherical head or the sphere of a spherical support.
6. A bolt of fastening of the block of gear wheels tighten the moment of 78 N · m (7,8 kgfs · м).
7. At installation of a case of coupling with a forward cover of the transmission the opening in a forward cover has to be located as it is shown in fig. 3.30.
8. Before installation cover a working edge of epiploons with Litol-24 lubricant.
9. At installation of epiploons and bearings use the following mandrels – 41.7853.4028, 41.7853.4032, 41.7853.4039.