Installation of the secondary shaft

When removing both tapered bearings from the output shaft, they become unusable. Therefore, on one side of the shaft, the cover with the bearing should be replaced, on the other, the outer race of the bearing in the lower crankcase. Then adjust the end play again. On 020 gearboxes (4R) the method of installing the needle bearing in the housing has been changed. Limiter 1 (see fig. 340) needle bearing was replaced with a special bolt, and a threaded hole appeared in the gearbox housing. If old parts are installed, then lubricate the bearings and put the shaft into the box crankcase (attached to the engine). Install the bearing cap correctly, as misalignment will interfere with the installation of the reverse gear. If the bearings are new, then they should be heated in an oil bath to 100°C and put on the secondary shaft from the respective sides. On fig. 347 shows how to install bearings. The inner race of the lower bearing must be well secured.



Check the condition of the synchronizer blocking ring and install the synchronizer in the manner described here.

Put spring washer 12 on the shaft (see fig. 340) ledge towards the bearing cap. Fit the 10th gear with a well lubricated needle bearing.


Heat the hub of the synchronizer of I/II gears with ring 9 to 120°C and install it on the shaft using a piece of pipe.

Slide the inner race of the needle bearing onto the shaft until it stops against the gear.

Put the 2nd gear on the needle bearing.

Heat the 3rd gear gear and install it on the shaft so that its ledge is directed towards the 2nd gear gear. Insert the circlip into the groove.

Measure the clearance between the 3rd gear gear and the circlip (pic. 348). The gap should be as small as possible and be in the range of 0-0.20 mm. Retaining rings are available in various thicknesses ranging from 2.5 to 3.0 mm.



Install 4th gear 3 (see fig. 340) with the ledge pointing upwards, and install a new retaining ring 2. As mentioned earlier, the limiter 1 may be missing.

Screw the bolt into the threaded hole of the reverse gear shaft. Insert the shaft into the hole in the crankcase and position it so that the head of the bolt points to a point equidistant from both holes for the crankcase mounting bolts (dimensions «X» both sides must be the same - see fig. 349). In this position, press the shaft all the way into the bearing cover.