Transmission housing assembly
1 - front of the crankcase (clutch housing); 2 - intermediate bearing plate; 3 - the middle part of the crankcase; 4 - back cover; 5 – stopper of check of level of oil; 6 - centering sleeve of the intermediate bearing plate; 7 - release bearing guide sleeve
Assembly of gears and gearbox shafts
1 - input shaft; 2 - secondary shaft; 3 – an axis of a gear wheel of a reverse gear; 4 - reverse gear; 5 - synchronizer hubs; 6 – a stopper of the plug of synchronizers; 7 - balls and springs of the synchronizer sleeve; 8 - synchronizer rings; 9 - spring fixing rings; 10 - sleeve synchronizer 1-2 gears; 11 - sleeve synchronizer 3-4 gears; 12 - 5th gear synchronizer sleeve; 13 - bearings of the secondary and primary shafts; 14 - plate; fixing the input shaft bearing; 15 - plate; protecting the output shaft bearing; 16 - support lining; 17 – the needle bearing of a gear wheel of 5th transfer; 18 – a nut of a secondary shaft; 19 - differential box with main gear drive gear; 20 - side gears; 21 - satellites; 22 - the axis of the satellites; 23 – differential basket; 24 - differential bearings; 25 - differential sealing rings; 26 - worm gear wheel of the speedometer drive; 27 - gear with speedometer drive shaft
Gear numbers are shown in black circles (AR - reverse gear).
1. Remove the clutch release bearing at the front of the transmission.
2. Remove the speedometer drive shaft by unscrewing the bolt of its fastening to the box crankcase.
3. Place the gearbox with the front of the crankcase on a holder of the appropriate height (minimum 80 mm).
4. Remove the rear of the crankcase by unscrewing the appropriate mounting bolts.
5. Remove the 5th gear fork pin.
6. Engage 5th gear by moving the synchronizer sleeve.
7. Engage 2nd gear to secure the gearbox shafts.
8. Unscrew the nut at the end of the output shaft.
9. Set the gearshift mechanism to neutral position.
10. Remove the synchronizer assembly from the end of the output shaft ("hub-sliding sleeve") 5th gear together with the forks without disconnecting the synchronizer hubs from the sliding sleeve.
11. Remove the 5th gear from the output shaft along with the treadmill, needle bearing and support pad.
12. Remove the o-ring, spring washer and 5th gear from the end of the input shaft.
13. Remove the two plates that fix the bearings of the input and output shafts by unscrewing two screws each.
14. Remove the middle part of the gearbox housing by unscrewing the appropriate bolts connecting it to the front of the housing (clutch housing).
15. Remove the axle, bushing and reverse gear.
16. Press with your finger on the reverse gear forks at the height of their axis, remove the axle of the forks and the reverse gear forks.
17. Knock out the cotter pin from the selector shaft, pull out the shaft and its seal.
18. Remove the selector axle spring with two washers, as well as the selector with the cage.
19. Remove the gear units with both shafts upwards from the crankcase, as well as the fork assembly with axles.
20. Remove the intermediate bearing plate by unscrewing the appropriate bolts connecting it to the front of the crankcase (clutch housing).
21. Remove the cotter pin and reverse fork lock spring from the front of the gearbox housing.
22. Remove differential.
23. Remove the selector lever assembly from the front of the crankcase by knocking out the cotter pin from the outer selector lever and pulling it out, remove the seal and the inner selector lever along with the shaft of the selector lever assembly.
24. Discard from the front of the crankcase (clutch housing) differential seal and remove the four dowel sleeves.
25. Remove the differential tapered bearing outer race.
26. Unbolt the release bearing guide bushing from the front of the crankcase (clutch housing) and remove the bushing together with the gasket.
27. Remove the differential sealing ring from the middle part of the gearbox housing, as well as the outer ring of the differential tapered bearing (second differential bearing).
28. Clean crankcase connection surfaces.