9.2. Mechanical transmission

General information
The transmission will transform the torque transferred from the engine in size and the direction. It is necessary for ensuring optimum speed, high passability of the car and profitability of the engine, and also for the movement of the car a backing. The transmission separates the engine and transmission during a stop and the parking of the car and at its movement on inertia with the working engine.
All models with mechanical transmission are equipped 5-or the 4-staged transmission united in one knot with differential and the main transfer. The torque from the engine is transmitted through the transmission and the main transfer on differential which in turn distributes it between power shafts. All forward transfers join by means of synchronizers, and the lever of gear shifting turns on the internal mechanism of switching by means of a transfer switching rod.
Procedures of removal and repair of the transmission are described taking into account that bearings of the transmission do not demand replacements and the pressed elements are established in starting positions. Installation of new bearings or shaft means that thickness of laying of preliminary loading has to be determined, however at the same time special tools and methods which are inaccessible to the amateur mechanic are used.
Therefore if the transmission is damaged or worn-out as a result of usual operation, then installation of the new or repair block can be the best exit.

Specifications

Moments of an inhaling, N · m
Forward nuts and bolts of fastening of a back cross-piece..... 44–55
Back bolts of fastening of a back cross-piece..... 95–118
Lower bolt of spherical hinged connection..... 44–55
Bolts of fastening of a case of the transmission..... 37–55
Bolts of fastening of the gate..... 12–16
Shaft gear wheel lock-nut..... 130–210
The directing bolt..... 9–14
Bolt of fastening of a back case..... 9–11
Bolt of blocking of an intermediate shaft..... 21–31
Bolts of fastening of the transmission to the engine..... 91–119
Bolts of fastening of an arm of the transmission to the engine..... 55
Bolts of fastening of an arm of the transmission to the transmission..... 38–54
Bolts of fastening of an arm of the transmission to a body..... 44–55

Transmission support
Check
Watch transmission support at the moment when the assistant lifts and presses down on the transmission. If the rubber element of a support separates from the steel basis or the case of the transmission moves up, but does not fall, thereby indicating achievement by a support of the lower limit, replace a support.
Replacement
Disconnect a wire from the negative plug of the rechargeable battery.
Support by a jack through wooden whetstone the transmission.
Turn out bolts of fastening of a support of the power unit to the engine or the transmission.
Turn off nuts of fastening of a support to a body and remove a support.
Correctly arrange a new support and screw fastening bolts to the engine or the transmission. Tighten bolts the required moments.
Screw nuts of fastening of support to a body and tighten them the required moments.
Remove a jack and connect a wire to the negative plug of the rechargeable battery.

 Gear shifting lever
Removal

Fig. 9.12. Gear shifting lever elements: 1 – gear shifting lever handle;
2 – cover; 3 – switching lever details; 4 – spring; 5 – top spherical saddle; 6 – gear shifting lever; 7 – plug; 8 – lower spherical saddle; 9 – holder; 10 – plate; 11 – cover; 12 – nut and washer; 13 – plug; 14 – bolts and nuts; 15 – draft of switching; 16 – draft of lengthening and knot of a suspension bracket; 17 – nuts of fastening of knot of a suspension bracket


In interior of the car remove the handle from the gear shifting lever, a cover of the lever of switching and lobbies and back racks (fig. 9.12).
Lift a forward part of the car and reliably fix on a support.
Turn out lock nuts and bolts and lower draft of switching from the car.

Fig. 9.13. Use of the screw-driver for release of a collar of a spring of the lever of gear shifting


The screw-driver release a collar of a spring of the lever of gear shifting and remove from the car the lever assembled (fig. 9.13).
Turn off nuts of fastening of draft of lengthening and bolts, remove a lengthening core, a suspension bracket and laying.
Installation
Installation is carried out to the sequences, the return to removal, taking into account the following.
Apply lithium lubricant on the moving and rubbing gear shifting lever details.

Removal and installation of the transmission
Removal
Disconnect a wire from the negative plug of the rechargeable battery.
Disconnect from the transmission a speedometer drive cable, the socket from the switch of light of a backing and if the model is equipped, the switch of the 5th transfer.
Turn out bolts of fastening of a suspension bracket of a cable of coupling and disconnect a coupling cable from the coupling switching off lever.
Turn out a bolt of fastening of a wire of "weight" and a bracket of a plait of wires.
Remove a starter.
There are two main ways of support of weight of the engine during operations on removal of a cross-piece and the transmission. It is possible to use special fastening for support which leans on support of a suspension bracket or the winch for raising of the engine. If fastening for support is used, establish it first of all. If the winch is used to raising of the engine, then for increase in working space previously remove a cowl.

Fig. 9.14. An arrangement of the top bolts (1) of fastening of the transmission to the engine


Turn out four top bolts of fastening of the transmission to the engine (fig. 9.14).
Lift a forward part of the car, reliably fix on supports and merge oil from the transmission.
Remove forward wheels, panels of mudguards and disconnect drafts of stabilizers of cross stability. Remove a protective plate of an oil pan if it is established.
Unscrew the lower spherical hinge and connecting bolts of fastening of a rotary fist, then separate the lower levers of a forward suspension bracket from rotary fists.
Separate the left power shaft from the transmission.
Remove an intermediate power shaft. Insert a wooden stopper or a similar cap for keeping on the place of semi-axial gear wheels of differential.
Separate an adjusting lath of switching from draft of switching and separate draft of lengthening from the transmission.
Turn off the lower bolts of fastening of the transmission to the engine.

Fig. 9.15. Removal of a cross-piece and lower left lever of a forward suspension bracket


Turn off a bolt, remove a cross-piece and lower the block of the left lever of a forward suspension bracket (fig. 9.15).
Supporting by a jack the transmission, fix the power unit on a jack.

Fig. 9.16. Support of the engine and use of the industrial elevator for removal of the transmission


Turn out two remained bolts, separate the transmission from the engine and lower it from a motor compartment of the car (fig. 9.16) down. Do not allow lag of the transmission on primary to a shaft at separation of the transmission from the engine. Fix the transmission on a case of its falling from a jack.
Installation
Cover with a thin layer of Moly lubricant of a vent of a main shaft of the transmission.
Lift the transmission, attach to the engine and fix by bolts, having tightened them the required moment.
Connect lengthening thirst for the transmission and thirst of switching for a switching regulator lath.
Establish knot of the lower lever and a cross-piece.
Screw the lower bolts of fastening of the transmission.
Establish an intermediate power shaft.
Establish the left power shaft.
Connect the lower spherical hinges and screw nuts and bolts, having tightened them the required moment.
Connect drafts of the stabilizer of cross stability.
Establish mudguards and forward wheels. Establish a plate of protection of the oil pallet.
Establish a starter.
Remove the jack supporting the transmission, and lower the car.
Screw four top bolts of fastening of the transmission to the engine. Tighten bolts the required moment.
Establish brackets of a plait of wires and a bolt of fastening of a wire of "weight", then connect a coupling cable.
Fill a transmission case with oil.
Connect a cable of the drive of a speedometer and sockets to the switch of light of a backing and the switch of the 5th transfer.
Connect a wire to the negative plug of the rechargeable battery.

Dismantling of the transmission

Fig. 9.17. Basic elements of the transmission: 1 – main transfer and differential; 2 – knot of the cranked lever; 3 – steel ball; 4 – spring;
5 – magnet; 6 – lock bolt; 7 – spring pin; 8 – ring consolidation; 9 – shaft of the cranked lever; 10 – intermediate gear wheel of a backing;
11 – shaft of an intermediate gear wheel of a backing; 12 – gate; 13 – knot of a main shaft; 14 – fork of switching and knot of draft of gear shifting; 15 – drafts of gear shifting (5th transfer and transfer of a backing) and bracket; 16 – gear wheel of the 5th transfer; 17 – lock-nut (5th transfer); 18 – gear wheel plug (5th transfer); 19 – gear wheel of the 5th transfer; 20 – lock bolt; 21 – ring of the synchronizer of the 5th transfer; 22 – nave of the synchronizer of the 5th transfer; 23 – limiter plate (5th transfer); 24 – lock-nut (5th transfer); 25 – spring pin (5th transfer); 26 – switching fork (5th transfer);
27 – back case (5th transfer); 28 – the directing bolt; 29 – a lock bolt with a ball and a spring; 30 – transmission case; 31 – knot of a secondary shaft


Turn off bolts and remove a back case (the 5th transfer) (fig. 9.17).
Using the hammer and a chisel, unbend fillets on each of lock-nuts (the 5th transfer).
Accurately block gear wheels from a provorachivaniye, having inserted the screw-driver or the similar tool between teeths of gear wheels; turn off lock-nuts.
Remove an adjusting pin of a fork of switching of the 5th transfer and a fork of switching.
Remove a plate of the limiter of the 5th transfer, a nave, a synchronizer ring, the plug of a gear wheel and a gear wheel.
Turn out a lock bolt from a transmission case.
Turn out the directing bolt from a case. Turn out a lock bolt and remove a ball and a spring.
Turn out the backing light switch from a transmission case.
Mark the provision of clips of an electrical wiring for simplification of the subsequent assembly and turn out bolts of connection of cases of the transmission.
Accurately separate transmission case halves from a coupling case.

Fig. 9.18. Cases of the transmission and elements of the mechanism of gear shifting: 1 – epiploon of a power shaft; 2 – bolt and washer; 3 – сапун; 4 – casing of a sapun; 5 – consolidation; 6, 8, 30, 31 – external rings of bearings; 7, 13 – funnels; 9 – backing lever shaft; 10 – spring pin; 11 – external ring of the bearing; 12 – diaphragm spring; 14 – drain stopper and washer; 15 – lever of transfer of a backing; 16 – adjusting laying; 17 – bolt; 18 – switching lever; 19 – tube; 20 – the directing plates; 21 – bolts; 22 – lever of the choice of the 5th transfer; 23 – spring pin; 24 – spring; 25 – return gate (5th transfer); 26 – channel of supply of oil; 27 – backing light switch; 28 – epiploon; 29 – adjusting laying; 32 – switching rod; 33 – cover; 34 – epiploon; 35 – speedometer drive gear wheel knot; 36 – the conducted gear wheel; 37 – spring pin; 38 – ring consolidation; 39 – gear wheel casing; 40 – bolt


Remove the channel of supply of oil to the 5th transfer (fig. 9.18).
Take a magnet from a transmission case.
Remove an intermediate shaft and a gear wheel of a backing.
Turn out a lock bolt of the 5th transfer and a lock plate.

Fig. 9.19. Removal of the coulisse of switching of the 4th transfer and lever of transfer of a backing assembled


On models with the 4-staged transmission remove the coulisse of switching and the lever of transfer of a backing assembled, at the same time the switch has to be in the neutral family way (fig. 9.19).
Remove a gear wheel of the 5th transfer and a rod of transfer of a backing.
Remove the coulisse of switching of the 5th transfer and transfer of a backing.
Beat out an adjusting pin of the cranked lever and remove a pin of the 5th transfer.
Moving draft of gear shifting (the 5th transfer), remove knot of the cranked lever.
Having convinced that the face surface of the lock plug is aflush with the face surface of the adjusting lever, turn a switching rod counterclockwise as far as it is possible.
Lift a switching rod from a nest, at the same time, perhaps, it will be required to lift a blocking ball up.
Beat out an adjusting pin from a switching rod.
Include the 4th transfer by movement of the top fork of switching up.
Accurately extend draft of gear shifting from a transmission case. If draft is released from a case, the steel ball will fall from a backing lever shaft.
Lifting, take a secondary shaft with gear wheels and knot of forks of switching from a transmission case.
Remove knot of a main shaft.
Remove differential knot.
Remove the switch of neutral situation or the switch of the 5th transfer.
Remove epiploons of a main shaft and a ring of the bearing.
Remove a funnel from a transmission case.
Turn off a bolt and remove the directing plate of the switch and the lever.
Beat out an adjusting pin of the lever of switching, having convinced that the lever of gear shifting is on average situation.
Remove a switching shaft cover from a case of the transmission and take a shaft.
Remove a spring pin of the coulisse of transfer of a backing and the selector.
Accurately beat out bearing rings.
Remove consolidation of a rod of switching from a transmission case.
Remove consolidation of the conducting axis from a transmission case, beating out it percussion by the hammer and a drift.
Remove a differential bearing ring.
Remove the deflector of a sapun.
Remove a spring of the adjusting lever.
Secondary shaft
Take out a secondary shaft from a transmission case.
Clamp a shaft in a vice through two wooden whetstones for protection it from damage. The probe check an axial side play of gear wheels.

Fig. 9.20. Details of primary and secondary shaft: 1 – internal ring of the bearing; 2 – main shaft; 3 – gear wheel of the 3rd transfer; 4 – ring of the synchronizer of the 4th transfer; 5 – synchronizer 3rd and 4th of transfers; 6 – lock ring; 7 – clamp cracker; 8 – synchronizer nave; 9 – the sliding synchronizer coupling; 10 – lock ring; 11 – synchronizer ring; 12 – gear wheel of the 4th transfer; 13 – internal ring of the bearing; 14 – persistent ring; 15 – internal ring of the bearing; 16 – secondary shaft; 17 – gear wheel of the 1st transfer; 18 – synchronizer ring; 19 – lock ring; 20 – synchronizer ring; 21 – gear wheel of the 2nd transfer; 22 – gear wheel of the 3rd transfer; 23 – lock ring; 24 – gear wheel of the 4th transfer; 25 – external ring of the bearing; 26 – synchronizer; 27 – lock ring; 28 – clamp cracker; 29 – synchronizer nave; 30 – the sliding synchronizer coupling; 31 – spring pin; 32 – control lever; 33 – fork of switching of the 1st and 2-й transfers; 34 – draft of management; 35 – lock plug; 36 – spring pin; 37 – control lever; 38 – fork of switching of the 3rd and 4th transfers; 39 – synchronizer; 40 – lock ring; 41 – clamp cracker; 42 – synchronizer nave; 43 – the sliding synchronizer coupling


Stripper for removal of bearings remove a gear wheel of the 4th transfer (fig. 9.20) from a shaft.
Remove a synchronizer ring
Remove lock rings of a nave of the synchronizer of the 3rd and 4th transfers.
Accurately remove a nave of the synchronizer of the 3rd and 4th transfers from a shaft.
Remove a ring of the synchronizer of the 3rd transfer.
Remove knot of the 3rd transfer.
Remove a lock ring of persistent washers, then persistent washers.
Remove a gear wheel of the 2nd transfer.
Remove a synchronizer ring
Remove a lock ring of the 1st transfer.
Special tools are necessary for a vypressovka of a gear wheel of the 1st transfer and the synchronizer 1 and 2nd of transfers. The expert has to carry out this operation.
Stripper remove the bearing.
Examine gear wheels on existence of wear and damages of cones of synchronizers, plugs of a nave, teeths and working surfaces.
Check a secondary shaft for existence of wear and damages of surfaces of sliding, shliyets and teeths, and also for possible blocking of channels for lubricant.
Check synchronizer rings, having established them into place and rotating for check of smoothness of sliding. Measure by the probe a gap and compare it to specifications.
Examine a nave of the synchronizer and the switch of transfers on existence of flutes, spots of development and wear.
Sort a nave of the synchronizer and examine vents and surfaces on wear existence, examine springs to be convinced that they are not bent and did not weaken.
Collect a nave with the lifted clamp crackers directed to an external part of a nave. At installation of a spring be convinced that it is on the center of deepening of crackers.
The probe check a gap between a nave of the synchronizer and the switch of transfers.
Replace any worn-out or damaged elements new.
Install the bearing on a shaft.
Turn a shaft and establish naves of the synchronizer 1 and 2nd of transfers with a flute on the fork of switching directed down.
Establish persistent rings of a hub 1 and 2nd of transfers.
Establish a synchronizer ring in a nave, leveling grooves with clamps in a nave.
Establish a gear wheel of the 2nd transfer.
Establish a synchronizer ring in a nave, leveling flutes with clamps in a nave.
Establish a lock ring of persistent washers.
Establish a gear wheel and a ring of the synchronizer of the 3rd transfer.
Install the synchronizer 3rd and 4th of transfers by a flute down and leveling grooves with clamps in a nave. At installation the press can be required.
Establish a lock ring of gear wheels of the 3rd and 4th transfers.
Establish a ring of the synchronizer of the 4th transfer together with a gear wheel of the 4th transfer.
For a press fitting of bearings deliver it to a shaft in a workshop.
Main shaft
Remove a main shaft and fix in a vice through two wooden whetstones for protection it from damage.
Stripper remove bearings from a main shaft.
Examine a shaft and gear wheels on existence of wear and damage of shliyets, surfaces of sliding and teeths.
Examine bearings on existence of wear, a side play and traces of pointed corrosion of basic rollers.
Replace all worn-out elements new.
Bearings on a shaft also establish to Napressuyta a main shaft into place.
Differential
Take out differential from a case of the transmission and fix in a vice through two wooden whetstones for protection against damage.
Turn out bolts and remove the conducted gear wheel of the main transfer. The conducted gear wheel of the main transfer can be fixed by rivets, then it cannot be removed.

Fig. 9.21. Differential: 1 – internal rings of the bearing; 2 – speedometer drive gear wheel; 3 – spring pin; 4 – axis of satellites; 5 – the conducted gear wheel of the main transfer with a differential box; 6, 8 – persistent washers; 7 – semi-axial gear wheel; 9 – satellites


Beat out a spring pin of a shaft of a gear wheel, having brought him out of the opposite side of a box of differential (fig. 9.21).
Take out an axis of satellites, satellites and persistent washers.
Using the tool for a vypressovka, remove an internal ring of the bearing from a differential box.
Remove the remained bearings.
Remove a speedometer drive gear wheel.
Examine gear wheels, the sliding surfaces and surfaces of a contact on existence of wear, cracks and corrosion.
Check the block of satellites and the leading gear wheel. Perform this work with the power shafts inserted into a differential box. With axes which are supported on V-blocks measure a gap of both gear wheels, manually moving them on full distance of a free wheeling. If the gap exceeds admissible, get a persistent washer of the corresponding thickness and establish it between a box of differential and satellites.
Before assembly completely wash out each detail in solvent.
In the course of assembly apply pure gearbox oil on all surfaces of sliding and replace new all spring pins which were removed.
Establish a speedometer drive gear wheel.
Install bearings by means of special tools and a hydraulic press or deliver differential in the workshop having the necessary equipment where to you will perform this work.
Establish the leading gear wheel and side drives with application of the corresponding persistent washers.
Establish an axis of satellites, having convinced that the opening of a spring pin is combined with an opening in the transmission.
Establish by the hammer and a core a spring pin, working from a speedometer drive gear wheel.
Establish the conducted gear wheel of the main transfer and fix by bolts.
Install a differential box in a transmission case.

Assembly of the transmission
Screw a drain stopper in a transmission case.
Establish an external ring of the bearing of a secondary shaft, having correctly arranged it with laying.
Slightly knock with the hammer and a drift on ring perimeter before its landing into place.
Establish a ring of the bearing of differential and laying, observing compliance of numbers on laying and numbers on the removed elements.
Establish a spring and laying of a main shaft (the lifted part).
Establish a shaft of the lever of the reverse gear and a spring.
Establish a maslootrazhatel.
Establish an epiploon of draft of gear shifting.
Insert draft of gear shifting and install the switch of transfers, having convinced that the spring pin is in the relevant provision.
Carry out a gear shifting rod tip through the right opening in the return coulisse and omit assembly into place so that it was possible to insert draft of gear shifting.
Establish a spring of the coulisse of a backing and insert draft of gear shifting through a spring on the end of the coulisse.
Install the switching lever on the end of draft of gear shifting.
Attach the selector to draft of gear shifting by a spring pin.
Fix by three bolts the directing selector plate. Bolts differ, the bolt without washer is established in the top right corner. The spring of the coulisse of a backing has to be established around back laying of a bolt.
Screw a lock bolt and a washer on the switching lever.
Establish a funnel for gear wheel lubricant together with a ring of the bearing of a secondary shaft.
Establish consolidation of a main shaft by the open end up.
Install the bearing of a main shaft in a case and knock on it before landing to the place.
Place a magnet in a groove in a transmission case.
Establish differential in a transmission case.
Grease an internal ledge of an epiploon of differential with pure gearbox oil and establish an epiploon in a case.
Establish a spring on a shaft of the lever of transfer of a backing.
Establish assembly of a fork of switching in assembly of a secondary shaft. Be careful at installation and be convinced that gear wheels are properly connected to differential and a main shaft. Assembly of a fork of switching has to be inserted on the corresponding camber in a transmission case.
Accurately pull assembly of a fork of switching a little up and in the direction outside from camber, using an inclination of assembly of a secondary shaft. Insert the lever as far as it will move, and turn on 90 ° from neutral situation. Insert a ball into the end of a shaft of the lever of transfer of a backing and turn the lever in neutral situation. Accurately insert the lever into camber in a transmission case.
Install a spring pin on the lever from a fork of switching and knock on it a little.
Establish assembly of the cranked lever which connects the switching lever to the lever from a switching fork.
Establish new ring consolidation on a shaft of the cranked lever. Oil the cranked lever pure gearbox and establish it. Fix the lever by an adjusting spring pin.
Establish the coulisse of a backing into place. Establish a gear wheel of the 5th transfer and a rod of transfer of a backing into place, at the same time the hollow on a rod has to be directed outside. The opening in draft of gear shifting has to be combined with the coulisse.
Establish an intermediate gear wheel of a backing and a shaft. Correctly arrange a gear wheel, insert a shaft with the shaft opening combined on a transmission case edge.
On models with the 5-staged transmission use a sealant the RTV type for installation of the channel for lubricant on a transmission case.
Establish a transmission case on a differential box, accurately placing it so that primary and secondary shaft entered inflows. Perhaps, it will be required to combine a magnet with a groove in the top half of a case.
Screw bolts of fastening of a case of the transmission and cross-wise tighten them the required moment.
Screw a lock bolt of primary draft of gear shifting and a sealing washer. Perhaps, it will be required to lift a secondary shaft properly to combine a lock bolt. Reliably tighten a bolt (the 5-staged transmission).
Screw a lock bolt of fastening of an intermediate shaft of the reverse gear (the 5-staged transmission).
Establish a main shaft and by hand screw a lock-nut (the 5-staged transmission).
Grease the plug of a main shaft with pure transmission liquid and pull the plug over the place (the 5-staged transmission).
Grease and establish a gear wheel of the 5th transfer.
Establish a ring of the synchronizer of the 5th transfer.
Install the synchronizer and a fork of switching, having combined clamps with grooves in a synchronizer ring the cylindrical pin holding a fork (the 5-staged transmission).
Establish a restrictive plate of the synchronizer (the 5-staged transmission).
By hand screw a lock-nut of a secondary shaft (the 5-staged transmission).
Tighten both lock-nuts, hammer with a center punch and the hammer fillets of nuts into flutes of shaft for their protection from an otvorachivaniye (the 5-staged transmission).
Apply sealant on a privalochny surface of a case of the 5th transfer, establish it and fix by bolts, having tightened them the required moment.
Establish epiploons of power shafts.
Install the backing light switch.
Slightly oil ring consolidation by pure gearbox and establish it on speedometer drive gear wheel knot. Establish speedometer drive gear wheel knot.
Install the transmission.

Replacement of epiploons of the transmission
The epiploon of a main shaft can be replaced only after removal of the transmission. Epiploons of power shafts can be replaced at the installed transmission. You make replacement as follows.
Disconnect a power shaft from the transmission.
The blunted screw-driver or the similar tool accurately take outside an old epiploon.
Oil a new epiploon. Establish an epiploon, working edges of an epiploon have to be directed in a transmission case. For installation of an epiploon use a tubular mandrel of the corresponding diameter.
Establish a power shaft.