Pic. 3.30. Input shaft: 1 - retaining ring; 2 - washer; 3 - bearing; 4 - intermediate conical bushing; 5 - intermediate inner ring; 6 - synchronizer ring; 7 - synchronizer clutch; 8 - cracker; 9 - synchronizer hub; 10 - synchronizer ring; 11 - intermediate gear of the fifth gear; 12 - needle bearing; 13 - the inner ring of the bearing of the intermediate gear of the fifth gear; 14 - needle bearing; 15 – an intermediate gear wheel of the fourth transfer; 16 - synchronizer ring; 17 - retaining ring; 18 - synchronizer clutch; 19 - synchronizer ring; 20 - intermediate gear of the third gear; 21 - needle bearing; 22 - input shaft; 23 - bearing
Examination
Pic. 3.31. Measuring the clearance between the 3rd idle gear and the 4th idle gear
Measure the clearance between the 3rd idle gear and the 4th idle gear (pic. 3.31).
If the clearance is greater than the maximum, check the contact surfaces of the third idle gear, the fourth idle gear and the synchronizer clutch (3 gears - 4 gears). Replace damaged parts.
Pic. 3.32. Measuring the clearance between the 4th idle gear and the 5th idle gear
Measure the clearance between the 4th idle gear and the 5th idle gear (pic. 3.32).
If the gap is greater than the maximum allowable, check the contact surfaces of the fourth idle gear, the fifth gear idle gear, the synchronizer clutch (3 gears - 4 gears) and synchronizer clutch (5 gears). Replace damaged parts.
Disassembly
Remove the 5th synchro clutch assembly, 5th synchro ring and 5th idle gear using SST.
Pic. 3.33. Disassembly of 3rd and 4th gear components
Remove the synchronizer clutch (3 gears - 4 gears) assembly, third gear synchronizer ring and third gear idler using SST (pic. 3.33).
Assembly
Pic. 3.34. Installing a new bearing
Install new bearing using SST (pic. 3.34).
Pic. 3.35. Installing 5th gear components
Install the 5th gear synchronizer ring, 5th idle gear and new bearing using SST (pic. 3.35).