Four-speed gearbox housings
1 - clutch housing; 2 - gearbox housing; 3 - oil filler plug; 4 – the switch of lanterns of a backing; 5, 7, 8 - gasket; 6 - back cover; 9 – magnet; 10 - glands; 11 - speedometer drive gear; 12 - speedometer drive gear guide; 13 – O-ring; 14 - pin
Gears and shafts of a four-speed gearbox
1 - reverse gear; 2 – a spring lock ring of a primary shaft; 3 - retaining ring of the bearing, 4 - larger primary shaft rolling bearing; 5 - input shaft; 6 - smaller primary shaft rolling bearing; 7 – a spring lock ring of a secondary shaft; 8 – a lock ring of the bearing; 9 – the bearing of a secondary shaft; 10 - gear wheel of the 4th gear; 11 - synchronizer ring; 12 - synchronizer spring; 13 - retaining ring; 14 - synchronizer hub 3rd and 4th gear; 15 – a sliding ring of the synchronizer of the 3rd and 4th transfer; 16 - gear wheel of the 3rd gear; 17 - retaining ring; 18 - persistent half rings; 19 - gear wheel of the 2nd gear; 20 - retaining ring; 21 - synchronizer hub 1st and 2nd gear; 22 - sliding ring of the synchronizer of the 1st and 2nd gears; 23 - gear wheel of the 1st gear; 24 - secondary shaft; 25 – output shaft bearing; 26 - oil deflector; 27 - snap ring; 28 - satellite; 29 - the axis of the satellites; 30 - side gear; 31 - holder of satellites; 32 - roller tapered differential bearing; 33 - speedometer drive gear; 34 – O-ring; 35 - locking pin; 36 - speedometer drive guide; 37 - speedometer drive gear; 38 - bolt; 39 - differential box; 40 - driven gear of the main gear; 41 - special spring washers; 42 - differential sealing ring
Internal shift mechanism
1 - the axis of the forks; 2 - fork 1st and 2nd gear; 3 - fork 3rd and 4th gear; 4 - ring; 5 - bushing; 6 - spring; 7 - gearshift rod; 8 - blocking disk; 9 - retainer; 10 - spring; 11 - fixing finger; 12 - bushings; 13 - gear shift shaft; 14 - backstage; 15 - sealing ring; 16 - case; 17 - bracket; 18 - axis; 19 - switching levers; 20 - retaining ring; 21 - reverse gear lever; 22 - axis; 23 - retaining ring; 24 - bolt; 25 - pin
1. Thoroughly clean the spline of the gearbox input shaft protruding into the clutch housing and lubricate with a uniform thin layer of molybdenum grease.
2. Install a new gasket on the clutch housing. A small amount of lubricant can be used to secure the gasket.
3. Install the gearbox by inserting the input shaft into the hub of the clutch disc.
4. Insert lower gearbox mounting bolts and tighten to 35–45 Nm.
5. Attach the rear gearbox bracket to the body and tighten the bolt.
6. Attach the front gearbox bracket with 4 bolts and screw new self-locking nuts onto the mounting bolts by hand.
7. Insert the locking pin, spring and screw the gear selector shaft retainer after coating the threads with locking agent SM 4G-4544-AB.
8. Remove the plugs from the gearbox and insert the drive shafts into place, rotating the drive shaft until its splines are fully engaged with the differential side gear, and then press on the wheel until the shaft is fixed.
9. Screw the left transverse link to the body, insert the ball joint into the steering knuckle and tighten to the required torque. Install the right transverse arm in the same way.
Attention! Never turn the Torx bolt when installing the control arms.
10. Install a washer between the gearbox housing and the stabilizer, install the stabilizer and tighten the bolt to 55 Nm.
11. Using a pin with a diameter of 3.5 mm, fix the gear lever by inserting it into the hole at the bottom of the gear selector box. Install, adjust if necessary and tighten the shift rod with the clamping bolt. To set the same gaps, put the axle of the gear lever in the fourth gear position and rotate it clockwise until it stops. In this position, tighten the clamping bolt and remove the pin.
12. Install the shift rod return spring.
13. Install starter and connect wires.
14. Connect the connector to the reversing light switch.
15. Install and screw the clutch housing cover.
16. Lower the car.
17. Remove engine lift (beam).
18. Insert upper gearbox mounting bolts and tighten to 35–45 Nm.
19. Connect the end of the clutch cable to the lever.
20. Insert the speedometer drive cable into the gearbox and tighten with the union nut.
21. Unscrew the oil filler plug and fill the gearbox with SAE 80 engine oil up to the lower edge of the oil filler hole, while the vehicle must be in a horizontal position.
22. Put the heater hose on the thermostat and secure with a clamp.
23. Insert the transmission ventilation pipe into the hole in the side member.
24. Connect ground wire to battery.
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