Contents: Transmission ⬇ Differential ⬇
Transmission
1. Remove the box from the car and clean it from the outside from dirt using kerosene and a stiff brush or using a solvent.
2. Unscrew the bolts and remove the gearshift mechanism cover from the gearbox housing (see photo).
Photo 8.2. Removing the gearshift mechanism cover.
3. Loosen the bolts securing the locking plate and remove the speedometer driven gear.
4. Unscrew and remove the reverse light switch and let the oil drain (see photo).
Photo 8.4. Removing the reverse light switch.
5. Using a screwdriver as a lever, engage 2nd gear by moving the fork closest to the end cap accordingly (see figure 6.16).
6. Unscrew and remove the end cover bolts and nuts.
7. Remove the main crankcase from the end cover and gear blocks (see photo).
Photo 8.7. Removing the main gearbox housing.
8. Pry off and remove the gear lock plugs from the end cover. Remove the springs and plungers of the retainers (see photos).
Photo 8.8A. Removing the retainer plug.
Photo 8.8B. Removing the spring and plunger of the lock.
9. Drive out the cylindrical pins that secure the gear shift forks to the rods.
10. Move the synchronizer sleeve back to the neutral position and then pull the 3/4 gear and reverse gear forks out of the end cap together with their rods.
11. Remove the retaining rings securing the gear blocks of the driven and driving shafts of the gearbox. Remove the magnet to collect metal particles (see photos).
Photo 8.11A. Gearbox driven shaft retaining ring.
Photo 8.11B. Magnet for collecting metal particles.
12. Remove the gear blocks and the 1/2 gear fork together with its rod at the same time (see photo).
Photo 8.12. Removing gear blocks from the end cover.
13. Remove the piston rod locking plungers from the end cap.
14. Remove the reverse intermediate gear shaft from the end cover. To do this, clamp the axle in a vice with soft jaws and, using a brass punch, carefully remove the cover from it. Be careful not to lose the locking ball (see photo).
Photo 8.14. Reverse intermediate gear shaft with locking ball.
Differential
15. Unscrew the bolts and remove the pressed steel cover from the gearbox housing.
16. Mark the position of the bearing adjusting ring relative to the gearbox housing and unscrew the ring retaining plate bolts (see photos).
Photo 8.16A. Mark the position of the differential bearing adjusting ring.
Photo 8.16B. Bearing adjusting ring alignment marks (shown by arrow).
[Information taken from the website OPELBOOK.ru]
Photo 8.16C. Remove the bolts securing the adjusting ring retaining plate.
Figure 6.16. Engaging 2nd gear: Move the fork in the direction shown by the arrow.
17. Unscrew the adjusting ring (a long steel plate can be used as a key) (see photo).
Photo 8.17. Unscrew the bearing adjusting ring.
Figure 6.17. Remove the end cover from the reverse intermediate gear shaft.
18. Remove the differential with the driven gear of the main transmission (see photo).
Photo 8.18. Removing the differential with the driven gear of the final drive.
Figure 6.18. Sectional view of the F10.4 manual transmission
19. Depending on whether the gearbox is being disassembled due to leaking seals or worn bearings, the following should be done.
Figure 6.19. F10.4 gearbox disassembled: 1. Driven shaft roller bearing (stands in the crankcase); 2. Retaining ring; 3. Main gear pinion; 4. Expansion washer; 5. Gear 4; 6. Cone ring; 7. Synchronizer clutch 3/4 gears; 8. Retaining ring; 9. Synchronizer spring; 10. Sliding key; 11. Synchronizer hub 37 3/4 gears; 12. Synchronizer spring; 13. Cone ring; 14. Gear 3; 15. Gear 2; 16. Cone ring; 17. Synchronizer clutch 1/2 gear with reverse gear; 18. Synchronizer spring; 19. 1/2 gear synchronizer hub; 20. Synchronizer spring; 21. Retaining ring; 22. Cone ring; 23. 1st gear pinion; 24. Expansion washer; 25. Driven shaft retaining ring; 26. Back ring; 27. Retaining ring; 28. Cylindrical pin; 29. Fork 3/4 gears; 30. Rod; 31. Fork 1/2 gears 35; 32. Cylindrical pin; 33. Rod; 34. Needle bearing (in the gearbox housing); 35. Cork; 36. Carter; 37. Gasket; 38. Cork; 39. Drive shaft; 40. Drive shaft gear block; 41. Retaining ring of the drive shaft gear block; 42. Bearing; 43. Thrust washer; 44. Retaining ring; 45. Retainer plug; 46. Lock spring; 47. Lock plunger; 48. Long locking plunger; 49. Short locking plunger; 50. Lock plunger; 51. Lock spring; 52. Retainer plug; 53. End cap; 54. Drive shaft screw; 55. Retaining ring; 56. Screw cap; 57. Retainer plug; 58. Lock spring; 59. Lock plunger; 60. Reverse rod; 61. Reverse intermediate gear shaft; 62. Reverse intermediate gear; 63. Thrust washer; 64. Reverse fork; 65. Cylindrical pin; A. Needle bearing on early models; B. Bearing installed on the latest models instead of the spacer washer (24).
20. Replace the seals and bearings in the adjusting ring and gearbox housing, removing the old parts and installing new ones using a metal tube (see photos).
Photo 8.20A. Installing the bearing adjusting ring seal.
Photo 8.20B. Installing the differential seal.
Figure 6.20. Parts of the differential and gear shift mechanism on the F10.4 type gearbox: 1. Gear shift knob; 2. Rubber cover; 3. Gear shift lever; 4. Gear shift lever housing; 5. Cover; 6. Traction; 7. Connecting pin; 8. Connecting pin; 9. Traction; 10. Cap; 11. Intermediate gear shift rod lever; 12. Bushing; 13. Protective cover; 14. Bushing; 15. Casing; 16. Coupling; 17. Tie bolt; 18. Gear shift rod; 19. Switch finger; 20. Cylindrical pin; 21. Gear shift housing; 22. Ventilation plug; 23. Switch finger; 24. Spring; 25. Guide pin spring retainer; 26. Retaining ring; 27. Seal; 28. O-ring with circular cross-section; 29. Bearing adjusting ring; 30. Bearing track; 31. Speedometer driven gear retaining plate; 32. Speedometer driven gear guide; 33. Speedometer driven gear; 34. Seal; 35. Gearbox housing; 36. Bearing track; 37. Tapered roller bearing; 38. Speedometer drive gear; 39. Driven gear of the main transmission; 40. Driven gear bolt; 41. Spring disc; 42. Half-axle gear wheel; 43. Spring disc; 44. Satellite; 45. Satellite; 46. Spring disc; 47. Half-axle gear wheel; 48. Spring disc; 49. Differential box; 50. Tapered roller bearing; 51. Axle of satellites; 52. Retaining ring; 53. Retaining ring; 54. Gasket; 55. Pressed steel lid.
21. Using a suitable puller, remove the tapered roller bearings from the differential.
Figure 6.21. Removing the differential bearing
22. Unscrew the driven gear bolts and drive it out of the holder using a brass punch. If the final drive pinion or driven pinion requires replacement, they should always be replaced in pairs.
Figure 6.22. Removing the bolts of the driven gear of the main transmission
23. Break and remove the speedometer drive gear (a new gear will be required during assembly) (see figure 6.23).
Figure 6.23. Splitting the speedometer drive gear
24. Remove the retaining rings from the satellite axle (see figure 6.24).
Figure 6.24. Removing the retaining rings from the satellite axle
25. Using a punch, drive the pinion shaft out of the differential box.
26. Unscrew the satellites and axle gears and remove them from the differential box. Remove the spring discs.
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