5.2.3. Features of repair of the transmissionRemoval and installation of a plate of fastening of bearings
||1 – screw;
2 – plate;
3 – back internal ring of the bearing of a main shaft;
4 – case;
I – VI – the sequence of tightening of screws at assembly
Extraction from a case of the main transfer of primary and secondary shaft connected together
||1 – a main shaft assembled with gear wheels;
2 – the leading gear wheel of the main transfer (a secondary shaft) assembled with gear wheels;
3 – forward ring of the bearing;
4 – persistent washer of the 4th transfer;
5 – forward ring of the bearing;
6 – adjusting washer;
7 – case of the main transfer;
8 – an intermediate gear wheel of a backing (a gear wreath it is turned down to a case wall);
9 – backing axis;
10 – fork of inclusion of a backing;
11 – wooden support
Installation on shaft of the plugs and rings adjoining gear wheels of the 5th transfer
||1 – shaft of the leading gear wheel of the main transfer;
2 – back internal ring of the back bearing of the leading gear wheel;
3 – main shaft;
4 – plug of a gear wheel of the 5th transfer;
5 – persistent ring of a gear wheel of the 5th transfer;
6 – washer
Press fitting of a gear wheel of the 4th transfer on a secondary shaft
||1 – press mandrel;
2 – gear wheel of the 4th transfer;
3 – spline;
4 – shaft;
5 – lock ring;
6 – spring washer;
7 – gear wheel of the 3rd transfer;
8 – gear wheel of the 2nd transfer;
9 – synchronizer 1-y-2-y of transfers;
10 – gear wheel of the 1st transfer;
11 – the conducted backing gear wheel;
12 – the forward bearing of the leading gear wheel of the main transfer (it is shown without external ring);
13 – press support;
14, 15 – end faces of a gear wheel and a ring between which by difference wear of cones is determined;
16 – the indicator for measurement of difference between end faces of cones of a ring and a gear wheel
Check by the probe of an axial free wheeling of a gear wheel of the 4th transfer on primary to a shaft, check of inclusion of the 3rd transfer
||1 – a mandrel by means of which the axial subpress of details of poses is carried out. 2 and 3;
2 – internal ring of the forward bearing;
3 – persistent washer of the 4th transfer;
4 – gear wheel of the 4th transfer;
5 – nave;
6 – probe;
7 – the synchronizer coupling (for check of a free wheeling and inclusion the coupling needs to be moved against the stop to a gear wheel cone end face);
8 – gear wheel of the 3rd transfer;
9 – main shaft
Check by the indicator of an axial free wheeling of the synchronizer 1-y-2-y of transfers
||1 – shaft;
2 – indicator;
3 – gear wheel of the 2nd transfer;
4 – the synchronizer coupling (for check of a free wheeling the coupling together with fingers, a spring and rings should be moved with a hand before contact with cones of opposite gear wheels);
5 – gear wheel of the 1st transfer
Inhaling of a nut of the leading gear wheel when determining the assembly size C
||1 – dynamometer key;
2 – a special key for latching of a gear wheel
Inhaling a dynamometer key of a bolt of fastening of a main shaft with application of the second key which is put on the conducted gear wheel of the 5th transfer (by the included 5th transfer)
||1 – a key with the cores entering smooth openings of the conducted gear wheel of the 5th transfer;
2 – synchronizer course limiter;
3 – the dynamometer key which is put on a bolt of fastening of a main shaft;
4 – synchronizer coupling
The case of the main transfer and case of the transmission for obtaining coaxiality and perpendicularity of axes of the main openings are processed in common and make a set, to razukomplektovyvat them it is not allowed.
The cases which are included in the package are marked on the bottom by the general digital tag.
To make tightening of bolts and nuts of fastening of crankcase details gradually (cross-wise).
Sealing laying of cases is recommended to be replaced new; in order to avoid an oil leak on sockets it is recommended to cover them with a thin layer of Litol-24 lubricant.
Between a case of the main transfer and a case of a box предач to apply only laying of factory production in number of 1 piece since non-compliance with this condition can lead to change of the assembly amount of installation of the leading gear wheel main transfers.
On cases of the transmission, a reducer of the main transfer and a cover there should not be cracks, chips; on the surfaces of boring for bearings and rods – excessive iznos, deep рисок and damages. On the surfaces of their interfaces should not be забоин, the joints leading to loss of tightness and to emergence of not coaxiality of shaft. To eliminate insignificant damages of end faces of privalochny surfaces with grinding in on a plate. If details are strongly damaged and worn-out – to replace them new.
Deformation of rods, forks, the switch of transfers is not allowed. To check a condition of grooves of rods, pads of forks and ledges of the switch. Rods and the switch have to slide freely in openings of cases and covers. To check a condition of locks, a pusher of springs and balls of clamps. To replace the details having traces of jamming or the increased wear new.
Plugs of the directing clamps of rods should not act in an opening of rods and have to be fixed from drop-out.
To check epiploons and a sealing rubber ring in a cover. Wear of working edges of these details is allowed on width no more than 1 mm. Even at insignificant damages epiploons and a ring need to be replaced new.
The axis of the mechanism of blocking has to keep densely on the basis, and the lever after its turn in each of extreme provisions – comes back to starting average position under the influence of springs. The lever in a starting position, at district rocking by his hand, should not have a free wheeling.
Locks of rods become stronger in nests of a case of the main transfer from drop-out by a plastering Litol-24 lubricant.
The press fitting of bearings needs to be made smoothly under a press, with a mandrel emphasis in a napressovyvayemy ring and in a shaft or the case in a pressing zone, in order to avoid damage of rings.
Use of the hammer for a napressovka of bearings is not allowed. Bearings with removable and demountable rings to razukomplektovyvat and interchange the position of their rings at assembly it is not allowed.
All bearings have to be in good shape. On the surfaces of their bodies of swing, on racetracks of rings, on separators of damage are not allowed. To replace the damaged bearings new.
The average bearing of a main shaft after installation in a case of the main transfer has to be fixed by the screw which cone has to enter a ring flute on a cylindrical surface of an external ring. The screw has to be законтрен a kerneniye.
To make an inhaling of screws of fastening of a plate to a case in the sequence specified rice. Removal and installation of a plate of fastening of bearings. To zakontrit screws a kerneniye.
Shaft of the transmission are taken and established in a case of the main transfer at the same time (see rice. Extraction from a case of the main transfer of primary and secondary shaft connected together).
At installation of shaft to watch that the edge of an epiploon of a sealant of a main shaft was not turned in. The epiploon of a main shaft is established in a coupling case on paint or the condensing mastic.
To check existence of adjusting pins in a case of the main transfer (on two from a case of coupling and a case of the transmission). If necessary to press them so that they acted on 5 mm over the socket plane.
To check existence of a magnet in a lodgment of a case of the main transfer, if necessary to establish a magnet.
In case of detection of traces of dribble of oil from under a clamp of a fork of switching off of coupling to establish it on paint or the condensing mastic (previously to wash out and degrease an adjusting opening under a clamp).
Since June, 1996 the clamp is not established and the opening for it in a wall of a case of coupling is absent.
Dismantling and assembly of shaft of the transmission is recommended to be carried out with use of the special tool developed at the AZLK plant.
Clamps of forks of rods drag on the moment of 32-40 N · m (3,2–4,0 kgfs · l) also tie round around rods a soft wire.
It is necessary to remove needle bearings of gear wheels from a shaft only their axial movement along a shaft over a neck of a shaft of the increased diameter, without allowing excessive deformation of a separator.
Before installation of a neck of shaft under needle bearings of gear wheels to oil liquid.
Persistent ring 5 (see rice. Installation) with the washer which is put on it 6 at installation on a main shaft 3 it is necessary to focus the small diameter of a cone towards the bearing on shaft of the plugs and rings adjoining gear wheels of the 5th transfer.
To check a condition of teeths of gear wheels of a main shaft and the leading gear wheel of the main transfer and to be convinced that teeths have no chips, забоин and the increased wear. To check a condition of necks under bearings and an epiploon. Vents under naves of synchronizers and a gear wheel, and also a flute under lock rings should not have traces of zadir and wear. Have to be in an axial opening of the leading gear wheel of the forward bridge and keep densely a maslonapravlyayushchy plate and a washer. To clear radial openings in a zone of necks under gear wheels of the 1st and 2nd transfers and an inclined opening in a neck zone under an epiploon of a main shaft. In the presence of damages it is necessary to replace shaft.
To check a condition of lock rings and spring washers. Deformation and iznosa of lock rings and spring washers are not allowed. To replace the deformed and worn-out details new.
It is not recommended to Razukomplektovyvat pair gear wheels of the transmission as at the plant they are selected in sets on noise and contact. In case of need the set is recommended to change replacements.
To check a condition of naves of synchronizers. Vents of naves should not have damages. Special attention should be paid on thickened (and shortened) having chopped off vents at which end faces should not be, and on their side surfaces – a smyatiya and iznos. To replace the damaged and worn-out details new.
To check a condition of synchronizers. End faces of shliyets of couplings should not have chips and smyatiya, and side surfaces – smyatiya and iznos. Couplings have to easily and without jammings to move on vents of naves. Fingers and couplings of synchronizers should not have iznos of the blocking facets. Springs of synchronizers should not be worn-out in zones of contact with fingers and with the coupling. At rings of the synchronizer it is necessary to check a condition of a carving and a cone.
Width of the platform of a carving of a cone has to be no more than 0,3 mm. Otherwise conditions of a rupture of an oil film between cones significantly worsen and failures of the synchronizer appear.
Initial width of the platform of a carving of a cone is equal to 0,1±0,05 mm.
The step of a carving is equal to 0,6 mm.
Degree of wear of a conic surface of gear wheels under the synchronizer and cones of the synchronizer is checked by means of the indicator (see rice. A press fitting of a gear wheel of the 4th transfer on a secondary shaft). Details of poses are similarly pressed. 5, 7, 11, 12 and the nave of the coupling of the synchronizer 1 and 2nd of transfer blocked in the drawing by the synchronizer.
Limit deepening of an end face of the synchronizer concerning a gear wheel end face – 1,5 mm.
Practical check of couple the synchronizer gear wheel consists in the following: the synchronizer is installed on a gear wheel, squeeze them hands and turn one detail concerning another – the synchronizer has to hold a gear wheel from drop-out.
When replacing of freely rotating wheels and synchronizers it is necessary to check their axial gap in the situation which is finally mounted on a shaft:
– the gap for gear wheels has to be not less than 0,1 mm (a maximum permissible gap of worn-out details – 0,7 mm);
– the gap of synchronizers assembled on a shaft has to be: for synchronizers 1-4 transfers – not less than 1,3 mm; for synchronizers of the 5th transfer – not less than 0,8 mm (see rice. A press fitting of a gear wheel of the 4th transfer on a secondary shaft, Check by the probe of an axial free wheeling of a gear wheel of the 4th transfer on primary to a shaft. Check of inclusion of the 3rd transfer (check of an axial free wheeling of a gear wheel of the 3rd and 5th transfers on primary to a shaft, 1-y-2-y transfers on secondary to a shaft and check of inclusion of transfers is similarly made), Check by the indicator of an axial free wheeling of the synchronizer 1-y-2-y of transfers (check of an axial free wheeling of the synchronizer of the 3rd and 4th transfers is similarly made, at the same time the subpress of details of poses has to be made. 2 and 3, shown on rice. A press fitting of a gear wheel of the 4th transfer on a secondary shaft, and also the synchronizer of the 5th transfer)).
The intermediate gear wheel of a backing has to be turned by a gear wreath to a case wall.
Before installation of the switch of transfers to a cover of the transmission it is recommended to dull sharp edges of an end face of a rod of the switch and a groove under a protective cover on a switch rod for an exception of damage of a sealing rubber ring of a rod of the switch.
Rods of forks of the transmission have to be established in neutral situation.
The transmission cover assembled with the switch is established on a transmission case so that the switch of transfers entered gearing with rods of forks.
Moment of an inhaling of clamps of forks of the transmission of 32-40 N · m (3,2–4 kgfs · м).
The moment of an inhaling of a nut of the leading gear wheel of 140-160 N · m (14–16 kgfs · l) (see rice. An inhaling of a nut of the leading gear wheel when determining the assembly size C).
The moment of an inhaling of a bolt of fastening of a main shaft of 25-28 N · m (2,5–2,8 kgfs · l) (see rice. An inhaling a dynamometer key of a bolt of fastening of a main shaft with application of the second key which is put on the conducted gear wheel of the 5th transfer (by the included 5th transfer)).
Axial movement of a main shaft of the transmission – no more than 0,15 mm.
Axial movement of a secondary shaft of the transmission – no more than 0,05 mm.
The bearings and cuffs applied in the transmission and the main transfer are given in subsection 1.6 and in subsection 1.5 respectively.