Note: Parts installed in the gearbox must be lubricated with gearbox oil.
When assembling a 4-speed gearbox
- place a roller bearing on the secondary shaft with the small diameter of the separator towards the drive gear. Insert thrust half rings and a lock washer into the shaft groove. Install a single-row needle bearing on the shaft and place the fourth gear gear on the bearing;
- install the synchronizer locking ring on the 4th gear;
- heat the hub assembly with the sliding sleeve of the III-IV gear synchronizer to a temperature of 100°C, monitoring the heating temperature with a thermochromic pencil. Press the hub assembly with the sliding sleeve onto the shaft. Lock the hub of the synchronizer sleeve with a new locking ring, making sure that the crackers enter the grooves of the synchronizer locking ring. Install the thrust washer;
- install a double-row split needle bearing on the secondary shaft and put the third gear on it. Place the thrust half rings in the groove of the shaft and secure them with a retaining ring;
- install the needle bearing on the shaft and put the 2nd gear on the bearing.
- heat the hub assembly with the 1st-2nd gear synchronizer clutch to a temperature of 100°C and press it onto the shaft with the straight-toothed gear towards the 1st gear. Lock the synchronizer clutch hub with a new retaining ring;
- install a locking ring on the synchronizer of the 1st and 2nd gears, put a needle bearing on the secondary shaft and install the 1st gear gear,
- install thrust needle bearing;
- install a retaining ring on the secondary shaft to secure it in the rear cover. Heat the washer to 100°C and press it onto the shaft with a larger diameter to the thrust needle bearing;
- install the ball bearing on the secondary shaft with the closed end facing outward and place a new retaining ring on the bearing;
- place a new retaining ring on the rear end of the primary shaft to ensure its fixation in the rear cover of the gearbox;
- press the rear primary shaft ball bearing on, with the closed side of the bearing facing outwards. Install the washer and new snap ring;
- press the primary shaft into the gear block with the small diameter towards the bearing.
When assembling a 5-speed gearbox
- install the primary shaft gear block retaining ring into the intermediate case annular groove;
- install the primary and secondary shafts;
- install the rod and fork for switching the 5th gear into the intermediate housing, and then the rod and fork for switching the 3rd-4th gears;
- install a retaining bracket on the intermediate housing, screw in new bolts with heads that have capsules with a locking compound, and tighten them;
- install the 5th gear shift fork bracket with the stopper on the intermediate housing so that one of the locking protrusions of the stopper is located opposite the cutout of the 3rd-4th gear shift rod, install and tighten new mounting bolts with heads that have capsules with a locking compound.
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