Pic. 3.36. Output shaft: 1 - spacer sleeve; 2 - retaining ring; 3 – an intermediate gear wheel of the fifth transfer; 4 – an intermediate gear wheel of the fourth transfer; 5 – an intermediate gear wheel of the third transfer; 6 – an intermediate gear wheel of the second transfer; 7 - needle bearing; 8 - spacer sleeve; 9 – an internal ring of the synchronizer; 10 - outer synchronizer ring; 11 - synchronizer ring; 12 - synchronizer spring; 13 - intermediate gear; 14 - synchronizer clutch; 15 - synchronizer spring; 16 - synchronizer ring; 17 - outer synchronizer ring; 18 – an internal ring of the synchronizer; 19 – an intermediate gear wheel of the first transfer; 20 - needle bearing; 21 - the outer ring of the bearing; 22 - tapered bearing; 23 - output shaft
Examination
Pic. 3.37. Measuring clearance between output shaft and bearing
Measure clearance between output shaft and bearing (pic. 3.37).
If the gap is greater than the maximum allowable, check the contact surfaces of the third idler gear, the output shaft first idler gear and the synchronizer clutch (1 gear - 2 gears) assembled. Replace damaged parts.
Pic. 3.38. Measuring the clearance between the 2nd idle gear and the 3rd idle gear
Measure the clearance between the 2nd idler gear and the 3rd gear idler (pic. 3.38).
If the gap is greater than the maximum allowable, check the contact surfaces of the second idle gear, the third idle gear and the synchronizer clutch (1 gear - 2 gears) assembled. Replace damaged parts.
Disassembly
Pic. 3.39. Removing 5th gear components
Remove the 5th gear bearing and idler using SST (pic. 3.39).
Pic. 3.40. Removing the synchronizer clutch
Remove the synchronizer clutch (1 gear - 2 gears) assembly, first gear synchronizer ring and first gear idler using a press (pic. 3.40).
Assembly
Pic. 3.41. Assembly of 1st and 2nd gear components
Assemble the 1st idler gear, 1st gear synchronizer ring and synchronizer clutch (1 gear - 2 gears) assembled as picture shown (pic. 3.41).
Pic. 3.42. Pressing in the synchronizer clutch
Press in the synchronizer sleeve (1 gear - 2 gears) complete (pic. 3.42).
Measure the clearance between the first idler gear and the differential drive gear.
Measure the clearance between the 2nd idler gear and the 3rd gear idler.