Disassembly
1. Remove the clamping ring with a special tool (09432-21201).
2. Remove the tapered roller bearing, first gear, bearing bush and needle bearing using the special tool (09432—33100).
Warning:
- 1. Do not reuse bearings that have been removed from the shaft
- 2. Replace tapered roller bearing inner and outer races as a set
- 3. Remove the 1st-2nd gear synchronizer assembly, 2nd speed gear, needle bearing as one piece using the special tool (09432-33100).
- 4. Remove the tapered roller bearing using the special tool.
Examination
Intermediate shaft
1. Check the outer surface of the layshaft where the needle bearing is mounted for excessive wear or damage.
2. Check that the shaft splines are not damaged or worn.
Needle bearing
1. Assemble the needle bearing with the shaft or bearing sleeve and the gear wheel and check if it rotates smoothly without noise or wobble.
2. Check the needle bearing cage for deformation.
Synchronizer ring
1. Check the synchronizer teeth for damage and breakage.
2. Check if the inner surface is not damaged, worn or damaged threads.
3. Press the synchronizer ring in the direction of the clutch gear and check the gap between their ends. If the gap out of range, replace the ring.
- Limit value: 0.5mm
Sleeve and hub of the synchronizer
1. Assemble the synchronizer sleeve with its hub and check for smooth movement.
2. Check for damage to the bushing on its inner front and rear surfaces.
3. Check the wear of the end surfaces of the hub (in contact with each gear).
Warning. Replace hub and synchronizer bushings as a set.
Synchronizer key and spring
1. Check up wear of the central ledge of a synchronizer cracker.
2. Check the spring for looseness, deformation or breakage.
Transfers
1. Check the helical gear teeth and synchronizer clutch for damage and wear.
2. Check the synchronizer cone for surface defects, damage or wear.
3. Check the gear bore, front and rear ends for damage and wear.
Assembly
1. Install the tapered roller bearing on the intermediate shaft using the special tool (09432—33300).
Warning. When installing the bearing, press only on the inner ring.
2. Install the first synchronizer ring, taking into account the label identification.
3. Combine the hub and sleeve of the first-second speed synchronizer.
4. The synchronizer sleeve has teeth interrupted in six places.
Assemble this bushing and hub so that the center tooth «T» between two interrupted groups of teeth came into contact with the key (cracker) synchronizer.
5. Install the synchronizer spring so that its protrusion fits into the groove in the synchronizer key.
Warning. When installing the synchronizer springs, make sure that the front and rear springs are not located in the same direction.
6. Install the needle bearing, 2nd speed gear, 1st/2nd speed synchronizer assembly onto the countershaft using the special tool (09432-33300).
Warning:
- 1. When installing the synchronizer assembly, make sure that the synchronizer keys are correctly installed in the corresponding grooves of the synchronizer ring.
- 2. After installing the synchronizer assembly, check that the third speed gear rotates smoothly.
7. Install the needle bearing, first gear, bearing bush together using the special tool (09432—33300), as it shown on the picture.
8. Install the tapered roller bearing using the special tool (09432—33300).
Warning. When installing the bearing, press only on the inner ring.
9. Install the clamping ring.