Withdrawal
Disconnect from a secondary shaft an input shaft with the roller bearing.
Remove the 5th gear with needle bearing.
Take out a lock ring. Remove spacer. When installing, select the spacer so that the gap is 0-0.9 mm.
Press out the third gear with guide and sliding sleeve.
Press out the bearing bush and second gear.
Remove the needle bearing and synchronizer ring.
Remove retaining ring.
Press out the first gear with guide and sliding sleeve.
Remove the needle bearing.
Remove the reverse gear snap ring.
Remove the needle bearing.
Examination
Check the synchronizer rings.
Install the synchronizer rings. Measure the gaps between the synchronizer ring and the transmission gear with a feeler gauge.
The gap is from 1st to 5th gear 1.0-1.3 mm. The minimum size is 0.8 mm. Reverse travel 0.5-0.6 mm.
The minimum size is 0.4 mm.
Assembly
Install the needle bearing, reverse gear and synchronizer ring.
Slide the guide and sliding sleeve onto the input shaft gearing.
Caution: The circlip in the guide sleeve must face the reverse gear.
Press in the guide
Attention: When pressing, make sure that the spouts on the synchronizer ring coincide with the recesses in the guide sleeve.
Insert sliding clutch into reverse gear.
Install the guide sleeve without play using the circlip. Retaining rings from 1.7 to 2.0 mm should be used.
Install retaining ring.
Fit the needle bearing, first gear and synchronizer ring.
Put on gearing of a secondary shaft directing and sliding couplings.
Attention: For clutches with different teeth, the protruding side must face the second gear.
Press in the guide sleeve with the bushing.
Attention: Pay attention to the installation position of the synchronizer ring (notches).
Insert sliding clutch into first gear. Install the guide sleeve without play. Side rings are available.
Attention: Bearing sleeve collar on input shaft must protrude slightly.
Check that the retaining ring is installed correctly.
Heat the bearing race with warm air to 80°C and put it on the secondary shaft.
Install the needle bearing, third gear and synchronizer ring.
Put on the guide and sliding sleeves with the working edge to the fourth gear.
Press in the guide sleeve.
Attention: Pay attention to the installation position of the synchronizer ring (notches).
Install spacer and circlip.