Removing
Details of installation of an intermediate crankcase
37 - Helical gear 5th gear; 38 - Helical speedometer drive gear; 38a, 51 - Thrust washer; 42, 50 - Sealing gasket; 43, 43d, 45 - Bearing outer ring; 43a - Ball bearing; 43b, 54, 57 - Retaining rings; 43c - Roller sleeve; 44 - Gaskets; 46 - Reverse shaft; 47, 80 - Bolt; 48 - Helical reverse gear; 49 - Intermediate crankcase; 52, 53 - Synchronizer ring; 55 - Needle bearing; 56 - Synchronizer clutch; 62 - Cover; 70 - Bearing pin; 71 - Spring; 72 - Bushing; 73 - Spring gasket; 74 - Nut; 75, 79 - Switch lever; 76 - Internal shift lever; 77 - O-ring; 78 - Cover; A - Gearbox with helical roller bearings (1 to 6141000); B - Gearbox with ball bearings (from 6141001)
1. Remove the gearbox (see Section Removal and installation of a transmission).
2. Remove the gearbox rear cover (see Section Removal and installation of a back cover of a transmission).
3. Remove the speedometer gear (38) and thrust washer (38a).
4. Remove retaining ring (57), synchronizer clutch (56), synchronizer ring (38), synchronizer ring (52), needle bearing (55) and thrust washer (51).
5. Disconnect the helical gear (37) fifth gear.
6. Remove the bolt (47) reverse gear shaft mounting (46).
7. On gearboxes with helical roller bearings, remove the intermediate housing (49).
8. On gearboxes with ball bearings, disconnect the intermediate housing (48).
Disassembly
1. Remove the shift lever (79) for 5th gear and reverse gear, cover (78) and sealing ring (77). Replace o-ring (77).
2. Remove the bearing pin (70), spring (71), sleeve (72),spring gasket (73) and lever (75).
3. Press the reverse gear shaft out of the intermediate crankcase (46), reverse helical gear (48).
4. On gearboxes with helical roller bearings, use a drift to press out the outer races of the bearings (43) And (45).
5. Remove roller sleeve (43c), and press out the bearing outer ring (43d) (on gearboxes with ball bearings).
6. Remove bearing outer race (43b) and press out the ball bearing (43a).
7. Measure the distance «a» between the contact surface and the groove of the bearing race of the output shaft of the gearbox on the old and new intermediate crankcases using a vernier caliper (approx. 300 mm long). If the result of the measurement carried out on the new intermediate case does not correspond to the result of the measurement carried out on the old one, it is necessary to install additional gaskets - gaskets are available in thicknesses of 0.1, 0.3 and 0.5 mm.
8. Using the setting tool, press in the bearing outer race.
9. On gearboxes with helical roller bearings, check the preload of the input and countershaft tapered roller bearings.
Installation
Installation is carried out in the reverse order of removal.