1. Press the rear bearing off the secondary shaft...
2. …and take it off.
3. Remove the spring retaining ring by squeezing the tabs…
4. …support washer…
5. … thrust needle bearing…
6. …driven gear of 1st gear…
7. … needle bearing of the driven gear of the 1st gear…
8. …internal blocking ring…
9. …intermediate ring…
10. …and the outer locking ring of the 1st gear synchronizer.
11. Having loosened the puller…
12. …remove the retaining ring…
13. …and a thrust washer.
14. Press the synchronizer of the 1st and 2nd gears together with the driven gear of the 2nd gear from the shaft splines, applying force to the end of the gear..
15. …and remove the synchronizer from the shaft.
16. Remove the outer locking ring, intermediate ring…
17. …internal locking ring of the 2nd gear synchronizer…
18. …and the driven gear of the 2nd gear.
19. Remove the needle bearing of the 2nd gear driven gear.
20. Remove the retaining ring…
21. …and two thrust half rings.
22. Remove the driven gear of the 3rd gear from the shaft…
23. … needle bearing of the driven gear of the 3rd gear…
24. …and the locking ring of the synchronizer of the third gear.
25. Having loosened the retaining ring of the synchronizer hub of the III and IV gears with a puller…
26….remove the retaining ring from the shaft…
27. …and a thrust washer.
28. Press the synchronizer of the III and IV gears off the shaft splines, applying force to the end of the driven gear of the IV gear.
29. Remove the synchronizer of III and IV gears from the shaft…
30. …synchronizer locking ring…
31. …driven gear of the 4th gear…
32. …and a split needle bearing of the driven gear of the 4th gear.
33. Remove the retaining ring from the shaft…
34. …two half rings…
35. …and the secondary shaft rear roller bearing.
36. Inspect the secondary shaft and its parts:
- there should be no signs of fatigue damage on the journals for needle bearings, and no nicks or crushing on the splines for installing synchronizer clutches;
- there should be no signs of wear or scoring on the end surfaces of the thrust half rings and locking rings;
- there should be no nicks or signs of wear on the synchronizer hubs;
- there should be no dents or chipping on the ends of the splines of the synchronizer clutches and blocking rings;
- when installing the synchronizer locking ring on the cone of the corresponding gear, the gap between the ends of the ring and the gear ring must be at least 1 mm. Otherwise, replace the locking ring.
37. Assemble the secondary shaft in the reverse order of disassembly, taking into account the following:
- before pressing onto the shaft, heat the synchronizer hubs in an oil bath to a temperature of 100°C;
- when pressing on the synchronizer hubs, make sure that the crackers fit into the grooves of the locking rings;
- after assembling the secondary shaft, check the rotation of all gears: they should rotate freely.
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