Disassembly
1. Using a special tool (09432-21201), remove the circlip.
2. Using a special tool (09432-21300), remove the front bearing.
3. Using a special tool (09432-33200), remove the inner race, spacer, fourth gear, needle bearing, bearing bush, synchronizer rings, third and fourth gear synchronizer hub and clutch, and third gear.
Examination
1. Check the surface of the drive shaft at the location of the needle bearing for damage and excessive wear (plot "A").
2. Check the splines for damage and wear.
Needle bearing
1. Assemble the needle bearing with the shaft or bearing sleeve and gear wheel and make sure they turn smoothly without excessive noise or play.
2. Check the bearing cage for deformation.
Synchronizer ring
1. Check gear teeth for damage or breakage.
2. Check the inner surface for damage, wear and tear.
3. Slide the synchronizer ring towards the gear clutch and check the clearance "A". If the gap deviates from the normal value, replace the ring.
- Limit value - 0.5 mm
Synchronizer Hub and Clutch
1. Connect the clutch and synchronizer hub and check that they slide smoothly.
2. Check that there is no damage to the inner, front, and rear surfaces of the coupling.
3. Check the wear of the end surfaces of the hub (in contact with each gear).
Warning. Replace hub and synchronizer sleeve as a set.
Cracker and synchronizer spring
1. Check up wear of the central ledge of a synchronizer cracker.
2. Check the spring for looseness, deformation and breakage.
Gear wheels
1. Check helical gear teeth and coupling for damage and wear.
2.. Check the timing cone for surface roughness, damage and wear.
3. Check the inner, front and rear surfaces of the gear for damage and wear.
Assembly
1. Assemble the hub and the synchronizer sleeve so that they are located as shown in the figure.
2. There are six missing teeth on the circumference of the synchronizer sleeve. Install the coupling on the hub so that the tooth located between the two corresponding teeth touches the synchronizer cracker.
3. Install the synchronizer springs so that their protrusions rest on the grooves of the synchronizer crackers.
Warning. When installing the synchronizer springs, make sure that the front and rear springs are not in the same direction.
4. Using a special tool (09432-33300), install the 3rd and 4th gear synchronizer on the input shaft.
Warnings:
1. When installing the synchronizer, make sure that the three synchronizer cotters are correctly located in the corresponding cutouts of the synchronizer ring.
2. After installing the synchronizer, check the smoothness of rotation of the third gear gear.
5. Using a special tool (09432-33300), install the ball bearing.
6. Install the needle bearing and fourth gear on the drive shaft.
7. Install the ring and spacer on the drive shaft.
- 1) With a special tool (09432-33300) install the ball bearing.
- 2) Install the snap ring.