Figure 6.15. Main shaft components (Section 6): 1 - Spring clamp; 2 - 3/4 speed synchronizer; 3 - Synchronizer ring; 4 - 3rd gear pinion; 5 - Needle bearing; 6 - Main shaft; 7 - Thrust washer; 8 - Needle bearing; 9 - 2nd gear pinion; 10 - Synchronizer ring; 11 - 1/2 speed synchronizer; 12 - Bushing; 13 - Needle bearing; 14 - Synchronizer ring; 15 - 1st gear pinion; 16 - Thrust washer.
1. From the front end of the main shaft, remove the spring clip from the groove in the shaft, and then remove the 3/4 synchronizer and 3rd gear. They can be simply removed from the shaft without any problems.
2. Remove the 3rd gear needle bearing from the main shaft.
3. From the rear end of the main shaft, remove the 1st gear thrust washer, 1st gear, 1/2 gear synchronizer and 2nd gear. Do this either by supporting the rear face of the 2nd gear and pulling the components off the shaft, or by using a suitable puller and placing it behind the gears. Be careful not to damage the gear teeth.
4. Remove the needle bearings for the 1st and 2nd gears, as well as the 2nd gear thrust washer.
5. With the main shaft completely disassembled, check for chipped or worn gears, loose or rattling bearings, and faulty synchronizers as described below.
6. The need for partial or complete replacement of synchronizers is usually known in advance due to the presence of noise when shifting gears.
7. Press the synchronizer ring onto the gear cone and turn it. It should fit snugly on the cone, and the gap between the ring and the teeth should not exceed 2.5 mm. If the gap is larger, replace the ring.
Figure 6.14. Synchronizer ring test diagram (Section 6). a = 2.5 mm
8. Check the remaining components for wear in the hub and cotter pins, as well as the condition of the teeth.
9. When assembling synchronizers, pay attention to the following points:
- The 1st gear synchronizer ring has no notches on its outer edge, while the 2nd gear ring has three notches;
- When aligning the synchronizer hub with the sleeve, try several positions until you find one that provides minimal wobble or "loose play." Also note that the 1/2-gear synchronizer has its sleeve groove located next to the second gear pinion when installed on the mainshaft;
- The sliding keys should be positioned at an angle of 120° to each other, and the circular springs should be installed so that they rotate in opposite directions, with their curved ends aligned with the keys.
Photo 6.9a. 1/2-speed synchronizer.
Photo 6.9.b. 3/4 speed synchronizer.
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10. Continue assembly by installing the second gear thrust washer onto the rear end of the shaft. Make sure the non-grooved surface of the washer faces the 2nd gear side (see photo 6.10).
Photo 6.10. Installing the 2nd gear thrust washer on the main shaft.
11. Lubricate and install the 2nd gear needle bearing (see photo 6.11).
Photo 6.11. Installing the 2nd gear needle bearing onto the main shaft.
12. Install the 2nd gear (see photo 6.12).
Photo 6.12. Installing the 2nd gear on the main shaft.
13. Install the 2nd gear synchronizer ring (see photo 6.13).
Photo 6.13. Installing the 2nd speed synchronizer ring on the main shaft.
14. Install the 1/2 speed synchronizer, ensuring that the groove on the sleeve faces the 2nd gear gear (see photo 6.14).
Figure 6.20. Components of the 1/2 speed synchronizer (Section 6): 1 - Locking key; 2 - Hub; 3 - Sleeve.
Photo 6.14. Installing the 1/2 speed synchronizer on the main shaft.
15. Install the 1st gear needle bearing together with its inner race, lubricating them thoroughly with oil (see photo 6.15).
Photo 6.15. Installing the 1st gear needle roller bearing onto the main shaft.
16. Install the 1st gear synchronizer ring (see photo 6.16).
Figure 6.16. 1st gear synchronizer ring (Section 6).
Figure 6.17. 2nd gear synchronizer ring. Mark the notch (marked with an arrow) (Section 6).
Photo 6.16. Installing the 1st speed synchronizer ring on the main shaft.
17. Install the 1st gear pinion and its thrust washer (see photos 6.17a and b).
Photo 6.17a. Installing the 1st gear pinion on the main shaft.
Photo 6.17b. Installing the 1st gear thrust washer.
18. Install a needle roller bearing on the front end of the main shaft (well lubricated) 3rd gear (see photo 6.18).
Photo 6.18. Installing the 3rd gear needle bearing on the main shaft.
19. Install the 3rd gear (see photo 6.19).
Photo 6.19. Installing the 3rd gear pinion on the main shaft.
20. Install the 3rd speed synchronizer ring (see photo 6.20).
Photo 6.20. Installing the 3rd gear synchronizer ring.
21. Install the 3/4 speed synchronizer so that its wider shoulder on the hub faces the 3rd gear gear (see photo 6.21).
Photo 6.21. Installing the 3/4 speed synchronizer.
22. Install the new spring clip (having the greatest possible thickness) into the shaft groove (see photo 6.22).
Photo 6.22. Installing the 3/4 speed synchronizer spring clip.
Figure 6.21. 3/4 Speed Synchronizer Components (Section 6): 1 - Locking key; 2 - Hub; 3 - Sleeve.
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