Add the results of measurements and subtract the sum from the height of the rear output shaft bearing, thus determining the thickness of the installed adjusting ring.
Warning. The gears are matched in pairs, so if one of them is damaged, this pair of gears is replaced.
Install the parts on the output shaft in the following order: 2nd gear gear, bearing, synchronizer blocking ring, 1st and 2nd gear synchronizer sliding sleeve (annular groove towards the gear wheel of the 1st gear), synchronizer blocking ring (heating it up and pressing it all the way), 1st gear gear, 1st gear needle bearing, reverse gear (directing a wide lubricated surface towards the 1st gear gear), bearing bush and shims (with mandrel 38x45 mm), adjusting ring, speedometer drive gear (heating it up and pressing it all the way), 3rd gear bearing, 3rd gear with synchronizer blocking ring, 3rd and 5th gear synchronizer sleeve hub, adjusting ring and snap ring (ensuring their seamless installation), 4th gear bearing, 4th gear and input shaft with synchronizer blocking ring.
Screw in a headless bolt to center the gear clusters.
Heat up the internal cavity of the rear cover at a temperature of 80-100°C to facilitate the pressing of the rear bearings of the secondary and intermediate shafts.
Warning. When heating, direct the flame of the burner so that it does not touch the plastic driven gear of the speedometer drive.
Install the output shaft flange on Loctite-type locking adhesive, lubricate the thread of its fastening nut with the same adhesive and tighten it to a torque of 11 kgf·m.
Establish a rod and a fork of switching of I and II transfers.
Install the fork and reverse gear rod, replace the spring and detent ball.
Establish locking balls of locks of I and II transfers and a backing, then insert a rod.
Insert the pin into the shift fork of 1st and 2nd gears.
Install the reverse gear lever parallel to the gearbox housing and slide the lever into the recess until it stops.
Establish a rod and a fork of switching of III and IV transfers and a rod of a choice of transfers. Take away the leash and shift the stem of the shift fork of III and IV gears further forward.
Insert the detent balls and lock balls and push the shift rods all the way in with the hole at the end of the selector rod in a vertical position.
Insert the locking pins into the shift fork stems, insert the longest pin into the selector stem.
Install stem caps.
Tighten the hex socket head bolts securing the output shaft rear bearing cap.
Connect the gearbox housing to the rear cover and tighten the mounting bolts.
Press the front bearing of the intermediate shaft into the crankcase seat, then the rear bearing of the input shaft with an adjusting washer of the same size until it stops against the retaining ring.
Using a special tool, check that the fourth gear synchronizer block ring (see photo) is in an unattached state.
Establish an adjusting ring and an adjusting ring of the back bearing of an input shaft.
Determine the thickness of the adjusting rings of the input shaft rear bearing and the intermediate shaft front bearing as the difference between the protrusion of the bearings relative to the plane of the gearbox housing and the depth of the bearing seat in the front case cover.
Install the front cover of the gearbox housing and adjusting rings with a thickness determined by the specified method. Note that the top three front cover mounting bolts are longer than the others.