- Install a splitter under the 2nd gear which rotates freely on the shaft and remove it.
- Remove retaining ring.
- Remove the 1st and 2nd gear synchronizer sleeve and hub.
- The selection of new gears or a new secondary shaft should be carried out taking into account the technical characteristics of the gearbox being repaired.
- Tapered roller bearings are replaced in pairs.
List of assembly unit parts «output shaft» Gearbox type 0A4 with technological notes to the drawing VC4.101:
1. Hexagon nut: 25 Nm and tighten by turning 90°:
- 4 pcs., for fastening the cup of the bearing of the intermediate support.
2. Clutch housing.
3. Adjusting washer of the secondary shaft.
4. Small tapered roller bearing outer race.
5. Small tapered roller bearing race inner race.
6. Secondary shaft.
7. Inner race with large tapered roller bearing race.
8. O-ring:
- 4 pcs., installed on the bolts of the bearing cup of the intermediate support.
9. Bearing cup with large tapered roller bearing outer ring and bolts:
- The outer ring can only be replaced in combination with a large tapered roller bearing and bearing cup.
10. Thrust washer:
- is installed with a ledge to the tapered roller bearing.
11. 1st gear freely rotating on the shaft.
12. 1st gear needle bearing.
13. 1st gear synchronizer inner ring:
- check wear;
- Check the lugs for signs of heavy wear.
14. 1st gear synchronizer intermediate ring:
- check wear;
- replace in the presence of furrows and traces of intensive wear.
15. 1st gear synchronizer blocking ring:
- check wear.
16. Coupling and hub of the synchronizer of 1st and 2nd gears:
- after removing the retaining ring;
- is removed together with the cup of the bearing of the intermediate support.
17. Retaining ring.
18. 2nd gear synchronizer blocking ring:
- check wear;
- install so that the synchronizer clutch crackers enter the grooves of the ring.
19. Intermediate ring synchronizer 2nd gear:
- set to blocking (external) synchronizer ring;
- replace in the presence of furrows and traces of intensive wear.
20. Synchronizer inner ring 2nd gear:
- check wear;
- Check the lugs for signs of heavy wear.
21. 2nd gear freely rotating on the shaft.
22. 2nd gear needle bearing.
23. Thrust washer.
24. Bushing for 3rd gear needle bearing;
- removed together with the 2nd gear freely rotating on the shaft.
25. 3rd gear needle bearing.
26. 3rd gear freely rotating on the shaft.
27. 3rd gear synchronizer blocking ring:
- check wear.
28. Clutch and hub synchronizer 3rd and 4th gear:
- is removed together with the 2nd and 3rd gears freely rotating on the shaft.
29. Needle bearing bushing:
- removed together with the clutch and synchronizer hub of 3rd and 4th gears.
30. 4th gear needle bearing.
31. 4th gear synchronizer blocking ring:
- check wear.
32. 4th gear freely rotating on the shaft.
33. Thrust washer.
34. Needle bearing of the secondary shaft.
35. Transmission housing.
36. Sleeve under the needle bearing of the secondary shaft.
37. Gear 5th gear.
38. Belleville spring.
39. Screw M10: 80 Nm:
- must be replaced.
Pressing out the outer race of a small tapered roller bearing:
Pressing in the outer race of a small tapered roller bearing:
Removing the small tapered roller bearing inner race:
Install the grip behind the bearing race and tighten the grip as much as possible. After that, turn the bearing and tighten the grip again.
Pressing on the inner race with small tapered roller bearing race:
Removing the 3rd and 4th gear synchronizer hub and clutch, the 2nd, 3rd and 4th gears freely rotating on the shaft and the sleeve for the needle bearing of the secondary shaft:
Install the separating puller in such a way that when removing the necessary parts, do not also remove the 1st and 2nd gear synchronizer clutch.
Removing the clutch and synchronizer hub together with the bearing cup of the intermediate support:
First you need to remove the retaining ring (arrow).
Removing the inner race of a large tapered roller bearing:
Before installing the puller, screw a M10x20 hexagon head screw into the hole at the end of the output shaft.
Pressing on the inner race with the race of a large tapered roller bearing:
Before pressing on, install a thrust washer on the shaft with a ledge to the inner ring.
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