Gearbox disassembly
Clean the gearbox, drain the oil from the gearbox crankcase and place it on a stand for disassembly.
Loosen the mounting bolts and remove the rear cover of the gearbox, remove the adjusting ring of the rear output shaft bearing and the sealing gasket.
Move carefully the 3rd and 4th shift fork shaft in the direction of 3rd gear until the lock is released. Remove the lock, then set the fork stem to the neutral position.
Warning. Pull the 3rd and 4th shift fork rod only to the required amount so that the synchronizer crackers do not fall out. If they fall out, the fork stem will not be able to be set to the neutral position without removing the nut from the end of the output shaft.
Engage reverse and 1st gear to block the input and output shafts, and unscrew the nut from the end of the output shaft.
Install the mounting cross to the clutch housing.
Screw the bolt all the way into the input shaft shank.
Remove the circlip and thrust washer from the input shaft.
Press the input shaft ball bearing out of the clutch housing.
Remove the gearbox housing together with the shafts and knock out the dowel pins.
Clamp the gearbox housing with shafts in a soft metal vice.
Knock out the spring cotter pin from the shift fork of III and IV gears, while holding the fork rod with a hammer so as not to damage the hole for the fork rod in the wall.
Pull out the 3rd and 4th shift fork shaft until the 3rd and 4th shift fork can be removed. Then move the fork rod to the neutral position.
Remove input shaft from gearbox housing.
Knock out the axle and remove the reverse idler gear.
Knock out the spring pin from the leash of the shift fork rod of the 1st and 2nd gears using a punch and remove the leash from the fork rod.
Press the output shaft out of the gearbox housing.
Warning. When pressing out the secondary shaft, make sure that the fork of 1st and 2nd gears is not blocked. If it is stuck, lightly tap the fork to release it.
Loosen the differential output shaft mounting bolts, holding the shaft with a mandrel.
Loosen the differential cover bolts.
Remove the differential cover using two mounting blades.
Remove differential.
Details of the four-speed gearbox:
1 - input shaft;
2 - secondary shaft;
3 - bearings;
4 - needle bearings of gears;
5 — an axis of an intermediate gear wheel of a backing;
6 - intermediate reverse gear;
7 - retaining ring;
8 - blocking synchronizer ring;
9 - synchronizers;
10 - synchronizer springs;
11 — a nut of a secondary shaft;
12 - driven gear of the main gear;
13 - differential box;
14 - side gears;
15 - satellites;
16 - persistent clip;
17 - differential bearing adjusting ring;
16 - drive gear speedometer drive;
19 - differential output shaft;
ZX - reverse.
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