1. Remove the gearbox from the car (see «Removal and installation of a manual transmission»). Clean it of dirt and wash the outside.
2. Remove the vehicle speed sensor (see «Check and replacement of gauges of a control system of the engine»).
3. Loosen the reverse light switch...
4.... unscrew it by hand and remove the switch.
5. Turn out four bolts of fastening of the case of the mechanism of a gear change and remove the mechanism...
6.... as well as the gasket installed under it.
7. Use a screwdriver to pry off the spring retainer of the leash of the V gear engagement fork...
8....remove the retainer...
9.... and remove the leash.
10. Remove the slave cylinder of the clutch release drive assembly with the clutch release bearing (see «Replacement of the working cylinder of the clutch release drive assembly with the clutch release bearing») and a rubber o-ring installed under the cylinder.
11. Remove an intermediate tube of a hydrodrive of deenergizing of coupling.
12. Turn out eleven bolts of fastening of a back cover of a transmission.
13. Pry off the edge of the cover with a screwdriver in the area of \u200b\u200ba specially designed for this tide, separate the cover from the gasket...
14.... and remove it.
15. Remove the cover gasket.
Note: Replace the gearbox rear cover gasket with a new one each time the joint is disassembled, as a used, crimped gasket may not provide a tight seal when reassembled.
16. Remove a lock ring of the synchronizer of V transfer.
17. Turn out two bolts of fastening of an arm of a fork of inclusion of V transfer...
18.... and remove the bracket assembly with the fork.
19. Remove crackers from the fork.
Note: When assembling, replace worn crackers with new ones.
20. Install a universal puller on the V gear synchronizer clutch...
21.... and press the coupling assembly with the hub off the shaft.
22. Remove the synchronizer blocking ring,..
23.... the driven gear of the 5th gear.
24.... and a needle bearing.
25. Remove the circlip of the 5th gear drive gear.
26. Install a universal puller on the V gear pinion...
27.... and press the gear off the shaft.
28. Remove the locking ring from the secondary shaft...
29.... and remove the two thrust half rings.
30. Remove the five bolts securing the intermediate housing to the gearbox housing...
31.... separate the intermediate crankcase from the crankcase of the box with hammer blows through a wooden spacer supported on a special crankcase tide...
32.... and remove the intermediate housing along with the shafts.
33. Remove the crankcase gasket by separating it with a sharp knife.
Replace the intermediate housing gasket with a new one each time the connection is disassembled, since a used, crimped gasket, when reassembled, may not provide a tight seal.
34. Turn out ten bolts of fastening of the bottom cover of a transmission...
35.... and remove the cover along with the gasket.
36. Separate the gasket from the cover.
Note: Replace the gearbox bottom cover gasket with a new one each time the connection is disassembled, as a used, crimped gasket may not provide a tight seal when reassembled.
37. Mark the position of the differential bearing adjusting nut relative to the gearbox housing.
38. Turn out a bolt of a clamp of an adjusting nut...
39.... remove the latch...
40.... remove the adjusting nut from its place with a mounting spatula, as shown in the photo...
41.... and, counting the number of revolutions, unscrew the nut.
42. Remove the o-ring from the nut.
Replace a severely compressed, hardened or torn ring.
43. Press the axle shaft seal out of the nut.
44. If it is necessary to replace the differential bearings, turn the adjusting nut over, place a pair of wooden blocks and press the outer ring of the differential bearing out of the nut.
45. Turn out five bolts of fastening of a cover of the right differential bearing...
46.... and remove the cover. Remove the sealing ring from it, press the stuffing box out of the cover and, if necessary, the outer ring of the bearing in the same way as they were pressed out of the adjusting nut.
47. Remove the differential assembly from the gearbox housing.
48. Remove the magnet from the crankcase...
49.... and clean it of wear products.
50. Remove the spacer from the reverse idle gear shaft.
The reverse idler gear spacer may remain in the gearbox housing when the gearbox housing and intermediate housing are separated. Remove it from the gearbox housing.
51. Turn out two bolts of fastening of an arm of a dog...
52.... install the fork rods sequentially in the position of II, V and III gears and remove the bracket assembly with the pawl.
53. With a hammer through a chisel with a blunt sting, knock out the plugs of the retainers of the gear shift fork rods...
54.... and remove the clips.
Note: Please note that one of the retainers is different from the other two. After pressing out its plug, remove the spring and rod retainer from the housing of the gearbox housing.
55. Turn out two screws of fastening of a fixing pin...
56.... remove the bracket...
57.... and remove the pin from the bracket.
58. Leaning the free end of the rod on a wooden block, knock out the fastening pin of the fork for engaging the reverse intermediate gear with a beard...
59.... and remove the stem and fork.
60. From the holes of the intermediate crankcase, remove the pin for blocking the simultaneous inclusion of two gears.
61. Knock out the pin for the shift fork of III and IV gears...
62.... remove the stem and remove the fork.
Note: The shift clutches must be in the neutral position when the forks are removed.
63. Raise the leash of the 5th gear fork and remove the 3rd and 4th gears.
64. Remove the rod from the crankcase and remove the leash of the V gear fork.
65. With a puller for internal circlips, compress the spring circlip of the output shaft bearing...
66.... and secure with wire in this position.
67. Knock out the pin for the shift fork of I and II gears...
68.... remove the stem and remove the fork.
69. With a puller for external circlips, open the circlip of the input shaft bearing...
70.... and remove the primary and secondary shafts, removing their shanks from the intermediate crankcase.
71. Remove the reverse idle gear.
72. With a puller, remove the retaining ring of the input shaft bearing from the groove of the intermediate crankcase.
73. Before inspection and troubleshooting, thoroughly rinse and dry the gearbox parts.
74. Inspect the gearbox housing, intermediate housing and rear cover. They should not have chips. There should be no nicks, scratches, dents, etc. on the mating surfaces. Remove minor damage with fine-grained sandpaper. If severely damaged, replace defective parts.
75. Check the bearing seats. These surfaces must not show signs of wear or damage. If there is damage, replace the crankcases.
76. Check up a condition of rods of inclusion of transfers. If they are bent, or if the stems are nicked, burred, or notched, replace the stems.
77. Check the condition of the shift forks. If they are bent or the tabs are worn, replace these parts.
78. If during operation oil leakage through the seals is detected and if their working edges are worn, the seals must be replaced.
79. Check the condition of the bearings. If shells are found on the treadmills and rolling elements, traces of indentation of the rolling elements on the treadmills or if the cages are damaged, the bearings must be replaced.
80. Replace the gaskets of the intermediate housing, the rear cover of the gearbox and the gearshift mechanism.
81. Clean the magnet of wear particles. If the magnet is cracked or magnetically weak, replace the magnet.
Assemble the gearbox in the reverse order of disassembly, taking into account the following.
1. Before assembly, liberally lubricate all friction parts with gear oil.
2. Assemble all threaded connections using an anaerobic threadlocker.
3. Clean the mating surfaces from dirt and from the remnants of old gaskets or sealant.
4. Before installing the secondary shaft in the intermediate crankcase, squeeze the retaining ring with round-nose pliers and fix it with a wire in a compressed state. Remove the wire after installing the shaft in the crankcase, making sure that the ring entered the grooves in the crankcase without distortion.
5. When installing the differential, if its bearings have not been changed, tighten the adjusting nut of its bearings by the same number of turns as when unscrewing, until the marks made during disassembly are aligned.
6. If the bearings of the differential were changed, after installing it, adjust the preload of the bearings according to the moment of resistance to turning the bearings by screwing or unscrewing the adjusting nut. For new bearings, the modulus of resistance must be 2 Nm (0.2 kgf·m) when the main gear driven gear rotates at a speed of 1 rev / s. If the bearings have not been changed, then the moment of resistance should be 1 Nm (0.1 kgf·m).
7. Lubricate the gasket with grease before installing the transmission bottom cover.