1. Remove the transmission and install on the holding KM-444-B adaptation together with basic KM-489 adaptation.

2. Remove a switching lever casing from a transmission case (do not sort it).

3. Remove a back case with secondary and primary shaft from a transmission case (do not sort them).

4. Remove differential from a transmission case (do not sort it).

5. Remove the bearing of switching off of coupling and the directing basic plug.

6. Remove the conducted speedometer drive gear wheel.

7. Remove the following elements:

– turn off a coupling casing plate from a transmission case;

– KM-304 adaptation remove both basic plugs of the separating clutch lever.

1. Tighten a coupling casing plate on a transmission case.

Fig. 8.90. Use of KM-304 device for installation of basic plugs of the separating clutch lever

2. Install by KM-304 adaptation both basic plugs of the separating clutch lever (fig. 8.90). Grooves on plugs have to settle down in dredging in a transmission case. Apply a thin film of a disulfide of molybdenic paste on inside of plugs.

3. Establish differential.

4. Establish a back case, secondary and primary shaft on a transmission case.

5. Tighten a plate of a casing of the mechanism of switching to a transmission case.

6. Establish the conducted speedometer drive gear wheel.

7. Install the directing basic plug of coupling and the bearing of switching off of coupling.

8. Install the transmission and fill in in it oil.

Fig. 8.91. Arrangement of a bolt of fastening of the lever mechanism of switching

1. Weaken a bolt of fastening of the lever mechanism of switching and separate the lever mechanism from the transmission (fig. 8.91).

Fig. 8.92. Arrangement of hinged connection of the lever mechanism

2. Remove pins from hinged connection on the lever mechanism of switching (fig. 8.92).

Fig. 8.93. Arrangement of bolts of fastening of a casing of the mechanism of switching

3. Turn off bolts of fastening of a casing of the mechanism of switching and remove its (fig. 8.93).

4. Switch the transmission to the 2nd transfer.

5. Lift the car and fix on support.

6. Turn off a casing of differential and merge oil from the transmission.

7. Turn off a stopper from a back case.

Fig. 8.94. Arrangement of a lock ring of fastening of a main shaft

8. Turn out the screw with a cylindrical head of fastening of a main shaft. Before it remove a lock ring (fig. 8.94).

Paint note the adjusting provision of a main shaft of the transmission in the block of gear wheels.

Fig. 8.95. Use of KM-556-1-A device for extraction of a power shaft from the transmission

9. KM-556-1-A adaptation get power shafts from the transmission (fig. 8.95).

10. Turn out the switch of lamps of a backing.

11. Remove a back case with secondary and primary shaft and sort it. Turn off a transmission case from a back case. Turn off a bearing board with secondary and primary shaft from a transmission case, take and screw on adjusting KM-552 adaptation.

12. Unscrew the basic bearing with the shaking lever from a back case and remove it.

13. KM-161-A devices and a hook of KM-161-2 remove the synchronizer of the 5th transfer from a secondary shaft. For this purpose at the same time include two transfers (for example, a gear wheel of the 3rd transfer and a gear wheel of a backing). Before it remove a lock ring from a forward part of the synchronizer.

14. Remove the following elements from a secondary shaft: gear wheel of the 5th transfer (small), needle bearing of the 5th transfer, lock ring of persistent washers and both half of persistent washers. The needle bearing can be slightly curved.

15. Making effort from below, remove a gear wheel of the 5th transfer (big) from the block of gear wheels. Before it remove a lock ring from a gear wheel.

16. Unscrew the basic bearing with a safety lock from a gear wheel.

17. Remove 4 stoppers of the persistent lever of switching from a back case.

18. Turn off a crossing point of pins from a back case and remove it. For this purpose at the same time include the 2nd and 5th transfers (with the leading gear wheel of switching).

19. A core beat out pins of a fork of switching of the 3rd and 4th transfers and a fork of switching of a gear wheel of a backing.

20. Remove rods and forks of switching of the 3rd and 4th transfers and a gear wheel of a backing from a back case.

21. Take the leading gear wheel of switching of the 5th transfer from a back case.

22. KM-443-A adaptation remove both lock rings of fastening of a secondary shaft and a main shaft to a back case.

23. Remove secondary and primary shaft together with an intermediate gear wheel of a backing, a fork and a rod of switching for the 1st and 2nd transfers from a back case.

24. Sort a secondary shaft of the transmission.

25. Using the corresponding punch, remove the ball bearing, a pro-masonry washer, the axial needle bearing and a gear wheel of the 1st transfer. Previously remove a lock ring.

26. Remove the needle bearing of the 1st transfer.

Remove a lock ring and a vypressuyta the synchronizer of the 1st transfer and gear wheel, and also a gear wheel of the 2nd transfer.

27. Remove the needle bearing of the 2nd transfer.

28. Remove both half of a persistent washer, a gear wheel of the 3rd transfer and the needle bearing.

29. Remove a lock ring and a washer and a vypressuyta the synchronizer 3rd and 4th of transfers, and also a gear wheel of the 4th transfer.

Remove the needle bearing of the 4th transfer, both half of a persistent washer and the roller bearing.

1. Clean all removed details and check for wear, teases, and replace damages and formation of hair cracks if necessary. Replace lock rings, springs of synchronizers and blocks of sliding.

2. Grease the basic contacting surfaces of all rotating details and the surfaces of sliding with oil for the transmission.

3. All synchronizers, the sliding blocks, springs of synchronizers, rings of synchronizers and a washer are interchanged.

4. Collect a secondary shaft of the transmission. Install the roller bearing, both half of a persistent washer, the needle bearing and a gear wheel of the 4th transfer. Establish a synchronizer ring on a cone of a gear wheel of the 4th transfer. KM-514 adaptation press the synchronizer 3rd and 4th of transfers and fix by a lock ring with a washer.

       PREVENTION

Previously heat the synchronizer to temperature of 100 °C.

Install the needle bearing and a gear wheel of the 3rd transfer.

Establish a synchronizer ring on a game of a gear wheel of the 3rd transfer.

Establish both half of a persistent washer, the needle bearing and a gear wheel of the 2nd transfer. Establish a synchronizer ring on a cone of a gear wheel of the 2nd transfer. KM-514 adaptation press the synchronizer 1 and 2nd of transfers and fix by a lock ring.

       PREVENTION

Previously heat the synchronizer to temperature of 100 °C.

Install the needle bearing and a gear wheel of the 1st transfer.

Install the axial needle bearing in a forward part of a gear wheel of the 1st transfer.

KM-311 adaptation to a vypressuyta also fix a pro-masonry washer and a clip of the ball bearing by a lock ring.

5. Collect and establish a back case. Insert pins of fastening of the persistent lever of the drive, a secondary shaft, a main shaft, a fork of switching of the 1st and 2nd transfers and an intermediate gear wheel of a backing into a back case.

Fix secondary and primary shaft by lock rings.

Insert a rod and the fork of switching of transfer of a backing conducting a gear wheel of the 5th transfer and a fork and rods of switching of the 3rd and 4th transfers to a back case. Tighten a plate of fixing of pins on a back case the moment of 7 N • m. Tighten the basic bearing and a safety lock to a back case the moment of 30 N • m. Insert 4 stoppers for persistent oil-tight pins into a back case. Install knot of a back case on KM-554 adaptation.

KM-466-Z adaptation press a gear wheel of the 5th transfer (big) to the block of gear wheels and fix it by a new lock ring.

Establish a gear wheel of the 5th transfer (small) and a ring of the synchronizer on a secondary shaft. KM-334 adaptation press the synchronizer for the 5th transfer on a secondary shaft. Screw the basic bearing with the shaking lever on a back case, having tightened bolts the moment of 22 N • m. Carefully insert completely collected back case into a case of the transmission and fix by bolts, having tightened their moment 15 N • m.

6. Manually, carefully insert or pull a main shaft of the transmission in vents of the conducted clutch plate and the block of gear wheels.

Fig. 8.96. Centering of the conducted clutch plate

7. Center the conducted clutch plate (fig. 8.96). Combine the tags put on primary to a shaft and the block of gear wheels before removal.

Fig. 8.97. Use of KM-564 device for a bolt vvertyvaniye with a cylindrical head in a main shaft of the transmission

8. KM-564 adaptation screw a bolt with a cylindrical head in a main shaft of the transmission and press a shaft against the stop in the block of gear wheels (fig. 8.97).

9. Fix a main shaft by a new lock ring.

10. Screw a bolt of an oil-tight casing in a persistent casing with the condensing connection. After installation of a casing the distance between a forward part of a plate and a back case should not exceed 4 mm.

11. Install the switch of lamps of a backing.

12. Screw a switching mechanism casing on a transmission case. Paste a sealant on a transmission case antifrictional lubricant.

13. Adjust the mechanism of switching of the transmission.

14. Fill in oil in an opening for a bulk stopper.

Actions for sealing are carried out with the transmission case established on the car.

1. Turn off a speedometer drive cable from a transmission case.

2. Remove a speedometer drive gear wheel. Turn off the holding plate. The screw-driver remove a sealing ring.

3. Replace a sealing ring and a rubber sealing ring.

4. Establish a speedometer drive gear wheel. Tighten bolts of fastening of the holding plate the required moment. Grease speedometer drive gear wheel teeths with lubricant.

5. Connect a speedometer drive cable.

Fig. 8.98. Arrangement of a bolt of fastening of the lever mechanism of switching

1. Weaken a bolt of fastening of the lever mechanism of switching and separate the lever mechanism from the transmission (fig. 8.98).

Fig. 8.99. Arrangement of bolts of fastening of a casing of the mechanism of switching

2. Turn out bolts of fastening of a casing of the mechanism of switching to a case of the transmission and remove its (fig. 8.99).

3. Paste a new sealant to a transmission case antifrictional lubricant.

       PREVENTION

The casing is not screwed finally into place in a transmission case until the last consolidation is established.

1. Lift the car and fix on support. Turn out a bolt of fastening of a casing to a back case.

Fig. 8.100. Arrangement of a lock ring of fastening of a main shaft

2. Turn off a bolt with a cylindrical head from a main shaft. Before it remove a lock ring (fig. 8.100). Note paint the adjusting provision of a main shaft of the transmission in the block of gear wheels.

Fig. 8.101. Use of KM-556-1-A device for extraction of a main shaft from the transmission

3. KM-556-1-A adaptation remove a main shaft of the transmission (fig. 8.101). Vents of coupling are uncoupled therefore you do not put in action coupling after this operation.

4. Turn out the switch of lamps of a backing.

5. Turn off bolts of fastening of a back case to a transmission case.

6. Remove a back case with secondary and primary shaft from a transmission case.

       PREVENTION

Oil will follow from the transmission.

7. Replace consolidation of a back case.

8. Establish a back case on a case of the transmission and fix it by bolts.

9. Paste a new sealant to a transmission case antifrictional lubricant.

10. Screw the switch of lamps of a backing. Manually, carefully insert or pull a main shaft of the transmission in vents of the conducted clutch plate and the block of gear wheels.

Fig. 8.102. Centering of the conducted clutch plate

11. Center the conducted clutch plate (fig. 8.102).

12. Combine the tags put on primary to a shaft and the block of gear wheels before removal.

Fig. 8.103. Use of KM-564 device for a bolt vvertyvaniye with a cylindrical head in a main shaft of the transmission

13. KM-564 adaptation screw a bolt with a cylindrical head in a main shaft of the transmission and press a shaft against the stop in the block of gear wheels (fig. 8.103).

14. Fix a main shaft by a new lock ring.

15. Screw a bolt of an oil-tight casing in a persistent casing with the condensing connection.

16. Screw a switching mechanism casing on a transmission case.

17. Adjust the lever mechanism of switching of the transmission.

       PREVENTION

Oil will follow from the transmission.

1. Turn off a differential box from a transmission case.

2. Replace a transmission sealant.

3. Install a differential box on a transmission case. Paste a new sealant on a transmission case antifrictional lubricant.

1. Remove both forward wheels.

Fig. 8.104. Use of KM-507-B device for a vypressovka of spherical hinges from rotary fists

2. KM-507-B adaptation to a vypressuyta spherical hinges from rotary fists (fig. 8.104).

3. KM-460-2-A and KM-460-1 devices take power shafts from the transmission.

       PREVENTION

The slanted party of KM-460-2-A adaptation has to be always turned to the transmission.

Oil will follow from the transmission.

Fig. 8.105. Use of KM-519 device for installation of a sealing ring in a transmission case

4. Establish by KM-519 adaptation the corresponding sealing ring in a case of the transmission (fig. 8.105). Turn a spring support in one party as far as the brake hose will allow.

5. Establish both power shafts in a transmission case. Then the screw-driver press a lock ring before installation it in a flute.

       PREVENTION

Do not allow an overload of a lock ring. When the lock ring is established in a flute, check quality of installation of a power shaft a tension manually in the widest point of connection.

Quality of installation of a power shaft cannot be checked by a shaft pulling.

6. Tighten the spherical hinge to a rotary fist a koronchaty nut and fix by the forelock.

7. Cross-wise tighten bolts of fastening of a wheel the moment of 90 N • m.

8. Fill in oil in the transmission. Level of oil has to be at the level of the lower edge of a test opening.

1. Lift the car and fix on support. Remove both forward wheels.

2. Unscrew a differential casing from a transmission case (oil will follow).

3. KM-507-B adaptation to a vypressuyta spherical hinges from rotary fists (see fig. 8.104).

4. KM-460-2-A and KM-460-1 devices take power shafts from the transmission.

       PREVENTION

The slanted party of KM-460-2-A adaptation has to be always turned to the transmission.

Oil will follow from the transmission.

5. Note the provision of a basic ring on a ring and a case of the transmission.

6. Check an axial gap of conic roller bearings.

7. KM-520 adaptation turn off a basic ring from a transmission case.

8. Unscrew a basic flange and remove differential.

9. Using KM-524-A adaptation, fix a differential case in a vice.

10. Beat out the leading gear wheel of the drive of a speedometer from a box of differential and throw out it.

1. Using KM-525 adaptation, establish a new leading gear wheel of the drive of a speedometer in a differential box so that it was latched on the place.

       PREVENTION

Previously heat a gear wheel of a speedometer and KM-525 adaptation to temperature of 80 °C on a water bath.

2. Insert differential into a transmission case.

3. KM-520B adaptation, return a basic ring to a transmission case. When performing this operation follow rules of adjustment of conic roller bearings in differential.

4. Screw a differential box on a transmission case.

5. Establish both power shafts in a transmission case. Then the screw-driver press a lock ring before installation it in a flute.

       PREVENTION

Do not allow an overload of a lock ring. When the lock ring is established in a flute, check quality of installation of a power shaft a tension manually in the widest point of connection.

Quality of installation of a power shaft cannot be checked by a shaft pulling.

6. Tighten the spherical hinge to a rotary fist a koronchaty nut, tighten its moment • m also fix 70 N by the forelock.

7. Cross-wise tighten bolts of fastening of a wheel the moment of 90 N • m.

8. Fill in oil in the transmission. Level of oil has to be at the level of the lower edge of a test opening.