4-2-6-razborka-i-sborka-ryada-uzlov-korobki-peredach.html
4.2.6. Dismantling and assemblage of some transmission knotsPrimary shaft of a transmission
Dismantling
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Fig. 4.79. Details of primary and secondary shaft: 1 — a lock ring of a primary shaft; 2 — a gear ring of the synchronizer of the fifth transfer; 3 — муфта the synchronizer of the fifth transfer; 4 — a spring of the synchronizer of the fifth transfer; 5 — a synchronizer cracker; 6 — a nave of the synchronizer of the fifth transfer; 7 — a gear ring of the synchronizer of the fifth transfer; 8 — a gear wheel of the fifth transfer of a primary shaft; 9 — the bearing of the fifth transfer of a primary shaft; 10 — the plug of a gear wheel of the fifth transfer of a primary shaft; 11 — the left bearing of a primary shaft; 12 — a gear wheel of the fourth transfer of a primary shaft; 13 — a cogwheel of the synchronizer of the fourth transfer; 14 — the bearing of the fourth transfer of a primary shaft; 15 — муфта the synchronizer of 3-4 transfers; 16 — a spring of the synchronizer of 3-4 transfers; 17 — a cracker of the synchronizer of 3-4 transfers; 18 — a nave of the synchronizer of 3-4 transfers; 19 — a cogwheel of the synchronizer of the third transfer; 20 — a gear wheel of the third transfer of a primary shaft; 21 — the bearing of the third transfer of a primary shaft; 22 — a primary shaft; 23 — the right bearing of a primary shaft; 24 — an epiploon of a primary shaft; 25 — a bolt of fastening of a shaft of a gear wheel of a reverse gear; 26 — a shaft of a gear wheel of a reverse gear; 27 — a reverse gear gear wheel; 28 — a nut of a secondary shaft; 29 — a gear wheel of the fifth transfer of a secondary shaft; 30 — an adjusting lining of the bearing of a secondary shaft; 31 — the left bearing of a secondary shaft; 32 — a gear wheel of the fourth transfer of a secondary shaft; 33 — the plug of gear wheels of 3-4 transfers of a secondary shaft; 34 — a gear wheel of the third transfer of a secondary shaft; 35 — a gear wheel of the second transfer of a secondary shaft; 36 — a cogwheel of the synchronizer of the second transfer; 37 — the bearing of a gear wheel of the second transfer of a secondary shaft; 38 — a lock ring of the synchronizer of 1-2 transfers; 39 — муфта the synchronizer of 1-2 transfers; 40 — a spring of the synchronizer of 1-2 transfers; 41 — a cracker of the synchronizer of 1-2 transfers; 42 — a nave of the synchronizer of 1-2 transfers; 43 — a cogwheel of the synchronizer of the first transfer; 44 — a gear wheel of the first transfer of a secondary shaft; 45 — the bearing of the first transfer of a secondary shaft; 46 — a secondary shaft; 47 — the right bearing of a secondary shaft
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Details of primary and secondary shaft are resulted on fig. 4.79.
Remove a transmission.
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Fig. 4.80. Use of adaptation DW09921-57810 for removal of the right bearing (1) primary shaft
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Arrange the right bearing of 1 primary shaft on stripper DW09921—57810 and remove it ( fig. 4.80).
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Fig. 4.81. Use of adaptation DW09921-57810 for removal of the plug (1), the left bearing (2) and gear wheels of the fifth transfer (3)
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Arrange a gear wheel of the fifth transfer on bearing DW09921-57810 stripper, выпрессуйте a shaft and remove the plug 1 ( fig. 4.81) gear wheels of the fifth transfer, the left bearing 2 and a gear wheel of the fifth transfer 3.
Remove the bearing of a gear wheel of the fourth transfer.
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Fig. 4.82. Removal of a gear ring and a wave spring of the synchronizer of the fourth transfer
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Remove a gear ring and a wave spring of the synchronizer of the fourth transfer ( fig. 4.82).
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Fig. 4.83. Removal of a lock ring of the synchronizer of the third-fourth transfers
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Remove a lock ring of the synchronizer of the third-fourth transfers ( fig. 4.83).
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Fig. 4.84. Use of adaptation DW09921-57810 for removal of a nave (1) synchronizers of the third-fourth transfers in gathering and gear wheels of the third transfer and a gear ring of the synchronizer (2)
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Arrange a gear wheel of the fifth transfer on bearing DW09921-57810 stripper, выпрессуйте a shaft and remove a nave 1 ( fig. 4.84) the synchronizer of the third-fourth transfers in gathering and a gear wheel of the third transfer and a gear ring of the synchronizer 2.
Disassemble a nave of the third-fourth transfers in a following order:
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Fig. 4.85. Removal of a nave (1) third-fourth transfers, муфты the synchronizer and a cracker (2) and springs of the synchronizer (3)
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- Remove муфту the synchronizer and a cracker 2;
- Remove springs of the synchronizer 3.
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Fig. 4.86. Removal of the bearing (1) gear wheels of the third transfer of a primary shaft
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Remove the bearing 1 ( fig. 4.86) gear wheels of the third transfer of a primary shaft.
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Fig. 4.87. Backlash measurement between a gear ring of the synchronizer with a gear wheel
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Combine a gear ring of the synchronizer with a gear wheel and measure a backlash as is shown in fig. 4.87. Rating value of a backlash of 1,0 mm, maximum permissible value — 0,5 mm. If the measured size less maximum permissible, replace a gear ring of the synchronizer.
Check up cone combination. At abnormal work of the synchronizer connection between an internal surface of a gear ring and a cone is considered partially defective despite a correct backlash between a gear wheel and a gear ring. Therefore the cone and an internal surface of a gear ring should be checked up. The internal surface of a gear ring should be smooth. A surface of black colour the abnormal; if check difficult, execute check after drawing of lead minium. The cone can have wavy deterioration.
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Fig. 4.88. Places of measurement of width of a groove of a cracker of a gear ring of the synchronizer
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Check up width of a groove of a cracker of a gear ring of the synchronizer ( fig. 4.88). Nominal and maximum permissible sizes of width are resulted in tab. 4.8. If the width exceeds maximum permissible size, replace a gear ring of the synchronizer.
Check up deterioration of a gear ring of the synchronizer, if necessary, replace it.
Table 4.8 of Size of width of a groove of a cracker of a gear ring of the synchronizer
Gear wheel
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Width of a groove of a cracker, mm
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The nominal
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Maximum permissible
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1st transfers
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8,2
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8,6
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2nd, 3rd, 4th transfers
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9,6
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10,0
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5th transfers
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9,4
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9,8
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Fig. 4.89. Crackers (1) and springs (2) synchronizers
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Check up on absence of deterioration a cracker of the synchronizer 1 ( fig. 4.89).
Check up on absence of easing, damages or breakage of a spring 2.
Assemblage
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Fig. 4.90. Installation of the bearing (1) gear wheels of the third transfer and a gear ring (2) synchronizers of the third transfer
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Apply a thin film трансмиссионного oils and establish the bearing 1 ( fig. 4.90) gear wheels of the third transfer and a gear ring 2 synchronizers of the third transfer.
Collect a nave of the synchronizer of the third-fourth transfers in a following order:
- Establish synchronizer springs in a nave;
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Fig. 4.91. Installation of a nave of the synchronizer of the third-fourth transfer: 1 — a nave; 2 — муфта; And and In — выступание a spring and a synchronizer cracker
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- Establish a synchronizer cracker. In case of assemblage муфты the synchronizer and a nave, observance of condition А=В ( fig. 4.91) is necessary ;
- Establish a nave 1 in муфту 2.
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Fig. 4.92. Use of a hammer and tool DW09940-53111 for installation of a nave of the synchronizer of the third-fourth transfers in gathering (1) on a primary shaft
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Using a hammer and tool DW 09940—53111, establish a nave of the synchronizer of the third-fourth transfers in gathering 1 ( fig. 4.92) on a primary shaft.
Arrange the longest part of a flange of a nave in a direction to a gear wheel of the third transfer and combine a cracker and a flute on a gear ring. At repressing gear wheel teeths can be damaged.
Establish a lock ring of the synchronizer of the third-fourth transfers ( fig. 4.83 see ). Combine a flute on a gear ring with a cracker of a nave and establish a gear ring of the synchronizer of the fourth transfer and a wave spring.
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Fig. 4.93. Installation on a primary shaft of the bearing (1) and gear wheels (2) fourth transfers
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Establish the bearing 1 ( fig. 4.93) the fourth transfer of a primary shaft and a gear wheel 2 fourth transfers.
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Fig. 4.94. Installation on a primary shaft of the plug of a gear wheel of the fifth transfer (1) and the left bearing (2) primary shaft
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Using a hammer and tool DW 09925—98221, establish on a shaft the plug of a gear wheel of the fifth transfer 1 ( fig. 4.94) and the left bearing 2 primary shaft.
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Fig. 4.95. Installation on a primary shaft of the right bearing (1)
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Using a hammer and tool DW 09925—9822, establish on a shaft the right bearing 1 ( fig. 4.95).
Establish the gear mechanism.
Secondary shaft of a transmission
Dismantling
Remove the gear mechanism.
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Fig. 4.96. Use of adaptation DW 09921—57810 for removal of the left bearing (1) secondary shaft and gear wheels of the fifth transfer (2)
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Remove the right bearing of a secondary shaft. Arrange a gear wheel of the fifth transfer on adaptation DW 09921—57810 and выпрессуйте the left bearing 1 ( fig. 4.96) a secondary shaft and a gear wheel of the fifth transfer 2.
Remove the plug of the third-fourth transfers of a secondary shaft.
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Fig. 4.97. Use of adaptation DW 09921—57810 for removal of a gear wheel by the third (1) and the second (2) transfers
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Arrange a gear wheel of the fifth transfer on adaptation DW 09921—57810 and выпрессуйте gear wheels of the third 1 ( fig. 4.97) and the second 2 transfers.
Remove the bearing of a gear wheel of the second transfer of a secondary shaft.
Remove a cogwheel of a gear wheel of the second transfer.
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Fig. 4.98. Removal of a lock ring of the synchronizer of transfers by the first-second
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Remove a lock ring of the synchronizer of the first-second of transfers ( fig. 4.98).
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Fig. 4.99. Use of adaptation DW 09921—57810 for removal of a nave of the synchronizer in gathering (1) and gear wheels of the first transfer / a gear ring of the synchronizer of the first transfer (2)
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Arrange a gear wheel of the fifth transfer on adaptation DW 09921—57810 and выпрессуйте a synchronizer nave in gathering 1 ( fig. 4.99) and a gear wheel of the first transfer / a gear ring of the synchronizer of the first transfer 2.
Remove a gear ring of the synchronizer of the first transfer from a gear wheel of the first transfer.
Disassemble a nave of the first-second of transfers in a following order:
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Fig. 4.100. Removal of a nave (1) the first-second transfers, муфты the synchronizer and a cracker (2) and springs of the synchronizer (3)
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- Remove муфту the synchronizer and a cracker 2;
- Remove springs of the synchronizer 3.
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Fig. 4.101. Removal of the bearing of the first transfer of a secondary shaft
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Remove the bearing of the first transfer of a secondary shaft ( fig. 4.101).
Check up муфту for inadequate work after assemblage of a nave and муфты.
Check up on absence of deterioration a nave and муфту.
Assemblage
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Fig. 4.102. Installation on a secondary shaft of the bearing (1) gear wheels of the first transfer, a gear wheel (2) first transfers and a cogwheel of the synchronizer (3) first transfers
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Put a layer трансмиссионного oils and establish on a secondary shaft the bearing 1 ( fig. 4.102) gear wheels of the first transfer, a gear wheel 2 first transfers and a cogwheel of the synchronizer 3 first transfers.
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Fig. 4.103. Width of a flute for a cracker: And = 8,2 mm — the first gear ring of the synchronizer; In = 9,6 mm — the second gear ring of the synchronizer
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Be cautious, as there is a difference in width of a flute for a cracker between the first and the second gear rings of the synchronizer ( fig. 4.103). The width of a flute for a cracker of the first gear ring of the synchronizer is equal 8,2 mm, and for the second gear ring of the synchronizer — 9,6 mm.
Collect a nave of the synchronizer of the first-second transfer in a following order:
- Establish synchronizer springs in a nave;
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Fig. 4.104. Installation of a nave of the synchronizer of the first-second transfer: 1 — a nave; 2 — муфта; And and In — выступание a spring and a synchronizer cracker
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- Establish a synchronizer cracker. In case of assemblage муфты the synchronizer and a nave, observance of condition А=В ( fig. 4.104) is necessary ;
- Establish a nave 1 in муфту 2.
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Fig. 4.105. Use of tools DW09940-53111 and КМ466—А for installation of a nave of the synchronizer of transfers by the first-second to gathering (1) on a secondary shaft
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Using tools DW 09940 53111 and КМ466—А, establish a nave of the synchronizer of the first-second of transfers in gathering 1 ( fig. 4.105) on a secondary shaft. Arrange a synchronizer cracker in a flute of a gear ring of the synchronizer.
Establish the second cogwheel, having combined the second cogwheel with a cracker.
Establish a lock ring of the synchronizer first-second gear rings ( fig. 4.98 see ).
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Fig. 4.106. Installation on a secondary shaft of the bearing (1) and gear wheels (2) second transfers
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Establish the bearing 1 ( fig. 4.106) and a gear wheel 2 second transfers.
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Fig. 4.107. Use of a hammer and tool DW09913-80112 for installation of the plug of gear wheels of the fourth-fifth transfers (1) and gear wheels of the third transfer (2)
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Using a hammer and tool DW 09913—80112, establish on a secondary shaft the plug of gear wheels of the fourth-fifth transfers 1 ( fig. 4.107) and a gear wheel of the third transfer 2.
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Fig. 4.108. Use of a hammer and tool DW09925-98221 for installation on a secondary shaft of a gear wheel of the fourth transfer (1)
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Using a hammer and tool DW 09925—98221, establish on a secondary shaft a gear wheel of the fourth transfer 1 ( fig. 4.108).
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Fig. 4.109. Use of a hammer and tool DW09925-98221 for installation of the left bearing (1) on a secondary shaft
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Using a hammer and tool DW 09913—80112, establish the left bearing 1 ( fig. 4.109) on a secondary shaft.
Establish the right bearing on a secondary shaft.
Establish the gear mechanism.
Gear change plugs
Dismantling
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Fig. 4.110. Gear change plugs: 1 — a gear change shaft in gathering; 2 — a bolt of blocking of switching; 3 — the gear change lever; 4 — the lever of a choice of transfers in gathering; 5 — пыльник a gear change shaft; 6 — the mechanism of management of a gear change; 7 — a directing bolt of switching; 8 — a directing plate of the mechanism of management of a gear change; 9 — a lining of the mechanism of management of a gear change; 10 — a plug of switching of the first-second of transfers; 11 — a shaft of switching of the first-second of transfers; 12 — a ball/spring of a shaft of switching of the first-second of transfers; 13 — a cam of switching of the first-second of transfers; 14 — a cam of switching of the third-fourth transfers; 15 — a ball/spring of a shaft of switching of the third-fourth transfers; 16 — a shaft of switching of the third-fourth transfers; 17 — a plug of switching of the third-fourth transfers; 18 — the lever of switching of a reverse gear; 19 — a ball fifth/back transfers; 20 — a ball/spring of a shaft of switching by a heel / back transfers; 21 — directing a ball/spring of a shaft of switching of a reverse gear; 22 — a shaft of switching fifth/back transfers; 23 — a cam of switching by a heel / back transfers; 24 — a directing ball of a plug of switching of the fifth transfer; 25 — a plug of switching of the fifth transfer; 26 — the lever of switching of a reverse gear
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Remove the gear mechanism.
Remove each shaft of switching in gathering from the gear mechanism.
Disassemble a shaft of switching of the first-second of transfers in a following order:
- Fix a shaft of switching of the first-second of transfers in gathering in a vice with soft sponges;
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Fig. 4.111. Use of a hammer and a chisel for removal of a finger of a plug of switching of transfers by the first-second
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- Hammer and chisel beat out a finger ( fig. 4.111) plugs of switching of the first-second of transfers;
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Fig. 4.112. An arrangement of a finger (1) plugs of switching of the first-second of transfers (2) and a finger (3) cams of switching of a gear wheel of the first-second of transfers (4)
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- Remove a plug 2 ( fig. 4.112) switchings of a gear wheel of transfers by the first-second;
- A hammer and a chisel beat out a finger 3 cams of switching of a gear wheel of the first-second of transfers;
- Remove a cam of 4 switchings of a gear wheel of the first-second of transfers.
Disassemble a shaft of switching of the third-fourth transfers in gathering in a following order:
- Fix a shaft of switching of the third-fourth transfers in gathering in a vice with soft sponges;
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Fig. 4.113. An arrangement of a finger (1) plugs of switching of the third-fourth transfers (2) and a finger (3) cams of switching of a gear wheel of the third-fourth transfers (4)
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- A hammer and a chisel beat out a finger 1 ( fig. 4.113) plugs of switching of the third-fourth transfers;
- Remove a plug of switching of the third-fourth transfers 2;
- A hammer and a chisel beat out a finger 3 ( fig. 4.113 see ) cam of switching of the third-fourth transfers;
- Remove a plug of switching of the third-fourth transfers 4.
Disassemble a shaft of switching fifth-back transfers to gathering in a following order:
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Fig. 4.114. Removal of a shaft of switching (1) and a ball (2) gear wheels fifth-back transfers and a directing ball and a spring (3) switchings of a reverse gear
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- Press and remove a shaft of switching without a cam 1 ( fig. 4.114);
- Remove a ball of 2 gear wheels fifth-back transfers both directing ball and a spring of 3 switchings of a reverse gear;
- Fix a switching shaft in a vice with soft sponges;
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Fig. 4.115. An arrangement of a finger (1) cams of switching of a reverse gear (2) and a finger (4) cams of switching of the fifth transfer (3)
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- A hammer and a chisel beat out a finger 1 ( fig. 4.115) a cam of switching of a reverse gear;
- Remove a cam of 2 switchings of a reverse gear;
- A hammer and a chisel beat out a finger 4 cams of switching of the fifth transfer;
- Remove a cam of 3 switchings of the fifth transfer.
Check up on absence of a bend, deformation or damage of a shaft of switching and, if necessary, replace a shaft.
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Fig. 4.116. Measurement of a thickness of the end of a plug of switching
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Measure a thickness of the end of a plug of switching ( fig. 4.116). Nominal and maximum permissible sizes of a thickness of the end of a plug of switching are resulted in tab. 4.9. If width below maximum permissible size, replace a plug.
Table 4.9 of the Thickness of the end of a plug of switching
Switching plug
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Thickness of the end of a plug of switching, mm
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The nominal
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Maximum permissible
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The first-second transfer
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8,7
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8,1
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The third-fourth transfer
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7,8
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7,2
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The fifth transfer
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7,8
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7,2
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Assemblage
Assemblage of plugs of a gear change spend to sequences, return to removal. At assemblage establish new fingers of fastening of plugs and cams.
Differential
Dismantling
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Fig. 4.117. Details of differential and картера transmissions: 1 — a conducted gear wheel of a speedometer; 2 — a stopper for check of level of oil; 3 — the left lining; 4 — a cover картера; 5 — the switch of a lantern of a backing; 6 — right картер transmissions; 7 — a plate; 8 — left картер transmissions; 9 — a stopper oil plum; 10 — a plate with a flute for oil; 11 — a plate lateral; 12 — a lateral cover; 13 — a differential cogwheel; 14 — the left epiploon of differential; 15 — the left bearing of differential; 16 — картер differential; 17 — a gear wheel of a drive of a speedometer; 18 — the left bearing of differential; 19 — the right epiploon of differential; 20 — a finger of a shaft of a gear wheel of differential; 21 — an adjusting lining of the satellite; 22 — the satellite; 23 — a shaft of a gear wheel of differential; 24 — a differential gear wheel; 25 — a washer of a gear wheel of differential
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Details of differential and картера transmissions are shown on fig. 4.117.
Remove differential in gathering.
Remove a differential cogwheel in a following order:
- Fix differential in gathering in a vice with soft sponges;
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Fig. 4.118. An arrangement of bolts (1) fastenings of a cogwheel of differential (2)
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- Remove a cogwheel 2.
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Fig. 4.119. Use of a hammer and a chisel for выбивания a finger of a gear wheel of differential
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Hammer and chisel beat out a finger of a gear wheel of differential ( fig. 4.119).
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Fig. 4.120. Extraction of a shaft (1) from a differential box
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Take a shaft 1 ( fig. 4.120) from a differential box.
Remove gear wheels and satellites in a following order:
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Fig. 4.121. An arrangement of a gear wheel and a washer (1), satellites (2) and adjusting linings (3) satellites
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- Rotating the satellite, remove gear wheels and washers 1 ( fig. 4.121);
- Remove satellites 2;
- Remove adjusting linings 3 from satellites.
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Fig. 4.122. Use of stripper DW 220—020А—01 and the holder of the bearing of differential DW220—020А—02 for removal of the right bearing of differential and a gear wheel of a drive of a speedometer (1)
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Using stripper DW220—020А—01 and the holder of the bearing of differential DW220—020А—02, remove the right bearing of differential and a gear wheel of a drive of a speedometer 1 ( fig. 4.122).
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Fig. 4.123. Use of stripper DW 220—020А—01 and the holder of the bearing of differential DW 220—020А—03 for removal of the left bearing of differential (1)
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Using stripper DW220—020А—01 and the holder of the bearing of differential DW220—020А—03, remove the left bearing of differential 1 ( fig. 4.123).
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Fig. 4.124. Measurement люфта a lateral support of differential on an axis of the satellite (1)
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Measure люфт a lateral support of differential on an axis of the satellite 1 ( fig. 4.124). Rating value люфта 0,05 mm, maximum permissible value — 0,33 mm. If люфт exceeds maximum permissible value, replace the satellite.
Check up on absence of deterioration or задиров an adjusting lining of a support.
Assemblage
Put a layer трансмиссионного oils on internal details: the bearing, a washer, an adjusting lining etc.
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Fig. 4.125. Use of the tool 09913—76010 and a hammer for installation of the left bearing (1) differentials
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Using the tool 09913—76010 and a hammer, establish the left bearing 1 ( fig. 4.125) differential.
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Fig. 4.126. Use of the tool 09913—76010 and a hammer for installation of a gear wheel of a drive of a speedometer (1) and the right bearing of differential (2)
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Using the tool 09913—76010 and a hammer, establish a gear wheel of a drive of a speedometer 1 ( fig. 4.126) and the right bearing of differential 2.
Establish satellites and gear wheels in a following order:
- Enter an adjusting lining of a support into satellites;
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Fig. 4.127. Installation in a box of differential of satellites (1) and gear wheels and washers (2)
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- Establish gear wheels and washers 2.
Establish a finger and a gear wheel shaft in a following order:
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Fig. 4.128. Installation of a shaft (1) in an aperture of a gear wheel and a place an arrangement of a finger (2)
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- Rotating, establish a shaft 1 ( fig. 4.128) in a gear wheel aperture;
- Chisel and hammer запрессуйте a new finger 2.
Fix a differential box in a vice with soft sponges.
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Fig. 4.129. An arrangement of bolts of fastening of a cogwheel (1) differentials
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Establish a cogwheel 1 ( fig. 4.129) and fix bolts, having tightened their moment 80—100 Нм.
Establish differential in gathering.
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