Dismantling and assembly of a secondary shaft

Disassembly

Engage 2nd gear and press the second inner race of the double row tapered roller bearing with the 1st gear gear.

Press the 1st and 2nd gear synchronizer with the 2nd gear gear.

Remove the 3rd gear retaining ring.

Compress the 3rd gear gear.

Remove the 4th gear retaining ring.

Compress the 4th gear.

Press on the tapered roller bearing.

Assembly

Install tapered roller bearing.

Using a press, press the fourth gear gear to the stop with a wide shoulder towards the main gear drive gear, preheating it on the heating plate to a temperature of 120°C.

Install the 4th gear retaining ring of the thickest of those supplied as spare parts (see subsection «Design and specifications»).

Using a press, press the gear of the 3rd gear to the stop with a wide shoulder towards the gear of the 4th gear, preheating it, like the gear of the 4th gear, to a temperature of 120°C.

Calculate the thickness of the retaining ring of the 3rd gear gear. To do this, use a set of feelers to measure the gap between the end face of the gear and the shaft belt. Install a 1.50 mm thick retaining ring if the measured clearance is less than 1.60 mm and a 1.60 mm thick retaining ring if it is equal to or greater than 1.60 mm.

Check the axial clearance between the ends of the blocking rings and the end of the gear rims of the synchronizers of the gears of I and II gears, which must be at least 0.5 mm. If the clearance is less, replace the blocking rings.

Install the needle bearing and 2nd gear sliding gear on the shaft.


Assemble the sliding clutch with the hub of the synchronizer of 1st and 2nd gears, directing the groove of the hub towards the gear of the 1st gear.

Install the crackers and put on the springs, positioning their connectors through 120°C and inserting the bent ends of the springs into the grooves of the crackers.

Using a press, press the 1st and 2nd gear synchronizer onto the shaft, pointing the hub groove towards the 1st gear gear.

Press on 1st gear needle bearing inner race, 1st gear, second inner race of double row tapered roller bearing.