Determining the thickness of the adjusting ring installed between the speedometer drive gear and the output shaft rear bearing
measure distance «WITH» between the end face of the secondary shaft rear bearing pressed into the seat of the rear cover of the gearbox and with the plane of the rear cover connector without a seal.
Using the formula D=A+B, determine the distance between the rear end of the speedometer drive gear and the plane of the rear cover connector without a gasket, where:
- D is the distance between the back end of the speedometer drive gear and the plane of the rear cover connector without a gasket;
- A - the distance between the front end of the drive gear of the speedometer drive and the plane of the rear cover connector without a gasket, equal to 22 mm;
- B is the thickness of the speedometer drive gear.
Using the formula X = CD, determine the thickness of the adjusting ring installed between the speedometer drive gear and the output shaft rear bearing, where:
- X is the thickness of the adjusting ring;
- C - the distance between the end face of the rear bearing of the secondary shaft and the plane of the rear cover connector without a gasket;
- D is the distance between the rear end of the speedometer drive gear and the plane of the rear cover connector without a gasket.
Determining the thickness of the adjusting ring mounted on the input shaft front bearing
Press the front input shaft bearing into the housing of the gearbox housing, placing a 1 mm thick ring on the clutch side. Measure the depth of the gearbox housing, i.e. the distance between the mating surface of the gearbox housing and the end of the bearing. Determine the thickness of the adjusting ring, based on the value obtained and the markings on the input shaft (see photo).
Install the selected adjusting ring on the input shaft and press the front shaft bearing out of the gearbox housing housing.
Determination of the thickness of the adjusting ring mounted on the rear bearing of the intermediate shaft
Measure the distance between the mating surface of the gearbox housing and the countershaft bearing circlip.
Insert the countershaft with pressed-on bearings into the rear cover of the gearbox and measure the distance between the split plane of the rear cover with the seal installed and the front countershaft bearing.
The difference between the measurement results will be equal to the thickness of the adjusting rings. If it is equal to or greater than 0.4 mm, install shims at both ends of the intermediate shaft.
On vehicles from model year 1978
Measure the distance between the mating surface of the gearbox housing and the bearing circlip.
Measure the distance between the mating surface of the transmission rear cover and the bearing housing.
Add up the measurements and add to them the thickness of the rear cover gasket equal to 0.2 mm.
Subtract from the obtained value the length of the intermediate shaft, measured between the ends of the bearings, and the value of the maximum axial clearance of the intermediate shaft, equal to 0.2 mm, thereby determining the thickness of the adjusting ring.
Assemble the gearbox in the reverse order of disassembly. When doing so, keep the following in mind:
- after installing the reverse fork rod retainer ball in the rear cover, install the axle with the reverse idler gear;
- install the shafts in the rear cover in the following order: intermediate shaft, primary and secondary shaft assemblies; at the same time, the bearings must enter all the way into the sockets of the cover;
- after installing the shafts in the rear cover, measure the sinking of the rear bearing of the secondary shaft in the rear cover, i.e., the distance between the cover split plane and the bearing separator. Install an oil seal on the bearing and measure the collar height. The difference between the measurement results gives the thickness of the installed adjusting rings;
- on cars since 1978, install the detent ball, reverse fork stem and reverse gear lever;
- after installing the flange on the secondary shaft, tighten the nut, having previously applied Loctite type sealant to the thread, and lock it by bending the plate washer;
- to facilitate pressing the front bearing of the intermediate shaft, the gearbox housing should be heated,
- when connecting the gearbox housing to the rear cover, screw in two mounting bolts and insert the dowel pins into the sockets, then tighten the mounting bolts crosswise;
- after connecting the gearbox housing to the rear cover, press the input shaft front bearing into the housing of the gearbox housing using drift 23 1000 and install the adjusting rings and the retaining ring;
- after pressing the front shaft bearing, measure the sinking of the bearing separator relative to the plane of the gearbox housing. Measure the height of the collar on the clutch release bearing guide bush. The difference in the measurement results determines the thickness of the installed adjusting rings;
- before installing the front crankcase cover, apply Curil K2 type sealant to the mating surfaces;
- after completion of work, pour oil into the gearbox housing.