Gears and shafts of a five-speed manual gearbox
1 - input shaft; 2 - secondary shaft; 3 - gear wheel of constant engagement of the intermediate shaft; 4 - the axis of the block of gears of the intermediate shaft; 5 – an axis of an intermediate gear wheel of a reverse gear; 6 - synchronizer of 3rd-4th gears; 7 - synchronizer of 1st-2nd gears; 8 - synchronizer of the 5th gear; 9 - ball bearing; 10 – a nut of fastening of a gear wheel of 5th transfer on an intermediate shaft; 11 - speedometer drive gear.
The black circles show the gear numbers of the individual gears (AR - reverse gear).
Gearshift mechanism of a five-speed gearbox
1 - control shaft; 2 - selector; 3 - spring lock ring; 4 - forks 3rd-4th gears; 5 – 1st–2nd gear forks; 6 – 5th gear forks; 7 – reverse gear engagement lever; 8 - spring lock pin; 9 - spring
Dismantling the output shaft
1 - sealing ring; 2 - gear wheel of the 1st gear; 3 – a ring of the synchronizer of 1st transfer; 4 - synchronizer of 1st-2nd gears
1. Remove the retaining ring from the 3rd-4th gear synchronizer hub and remove the synchronizer ring and 3rd gear.
2. Remove the circlip and the two 2nd gear dowels.
3. Remove the 2nd gear from the output shaft.
4. Remove the speedometer drive gear from the output shaft.
5. Remove the synchronizer and 5th gear from the output shaft.
6. Remove the bearing circlip from the output shaft and remove the output shaft from the middle of the transmission case.
7. Remove the o-ring, 1st gear and 1st gear synchronizer ring from the output shaft (see fig. Dismantling the output shaft).
8. Remove the output shaft bearing from the middle section of the gearbox housing.
Output shaft assembly
1. Lubricate the surfaces of the interacting parts with gearbox oil before assembling.
2. In the middle part of the gearbox housing, install the output shaft bearing and fix the retaining ring of this bearing.
3. Install the spring rings on the synchronizer hubs.
4. Install the 1st gear synchronizer ring and 1st gear on the output shaft.
5. Install the sealing ring on the secondary shaft with the working edges in the direction away from the bearing (see fig. Dismantling the output shaft).
6. Install the bearing, output shaft and retaining ring in the middle of the gearbox housing.
7. Install the bearing, output shaft and retaining ring in the middle of the gearbox housing.
8. Install the 5th gear, O-ring and 5th synchronizer on the output shaft.
9. Install the speedometer drive gear on the output shaft. Observe distance A = 123±0.5 mm.
10. Install the 1st-2nd gear synchronizer on the output shaft. Groove (for forks) on the sliding sleeve of this synchronizer must be directed forward.
Install the synchronizer ring, 2nd gear and two set half rings and circlip (the figure shows the installation of the 3rd-4th gear synchronizer retaining ring).
Install the 3rd gear, 3rd-4th gear synchronizer and circlip onto the output shaft.
If the synchronizer was disassembled, then when assembling it, make sure that the groove on the sliding sleeve is directed forward.
Disassembly and assembly of the block gears of the intermediate shaft
Dismantling the block of gears of the intermediate shaft does not present any particular difficulties. Care must be taken not to lose the bearing needles and spacers (anterior and posterior) needle bearings. When assembling, carefully install the two spacers and cover the bearing needles with grease so that they do not fall out during the installation of the gear assembly shaft.
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