Measuring gearbox dimensions
Dimensions checked:
- Distance "A" between the mating surface of the gearbox housing and the drive shaft, the end of the 5th gear engagement clutch (nominal value is 141.8 mm.
- Distance "B" - between the end surface of the 4th/5th gear synchronizer and the mating surface of the intermediate housing (the nominal value is 140.4 mm).
- Distance "C" - between the mating surface of the intermediate housing and the inner bearing race.
- Distance "A" is adjusted by shims (43a) of the drive shaft.
1. Press the drive shaft (2) together with the ball bearing (43) into the gearbox housing and install the front valve with gaskets.
2. Using a caliper, measure the distance from the mating surface of the gearbox housing to the end face of the coupling. The nominal value is 141.8 mm. Determining the thickness of the gasket:
Nominal value (141.8 mm) - Measured distance (141.4 mm) = Spacer thickness (0.4 mm).
Gaskets are available in thicknesses of 0.2, 0.3 and 0.9 mm.
3. Carefully install the input shaft with the ball bearing into the gearbox housing. 4. Press the spacers (arrow) onto the ball bearing and press the input shaft into the gearbox housing using a drift. Check the nominal distance.
5. Distance "B" with gaskets (36) in the front friction ring (35) of the 2nd gear helical gear (33).
6. Press the ball bearing (70) into the intermediate housing and tighten the bolts (69) of the retaining ring (73) to 30 Nm.
7. Using a press, seat the intermediate crankcase onto the driven shaft.
8. Using a caliper, measure the distance from the 4th/5th gear synchronizer to the mating surface of the intermediate case. The nominal value is 140.4 mm. Determining the thickness of the gaskets:
Nominal value (140.4 mm) - Measured distance (140.1 mm) = Gasket thickness (0.3 mm).
Gaskets are available in thicknesses of 0.2, 0.3, 0.5 and 1.4 mm.
9. Remove the intermediate plate from the driven shaft and adjust the clearance with shims. 10. Distance "C" is adjusted with shims (66) on the ball bearing in the intermediate plate.
11. Secure the driven shaft with the intermediate plate in a vice and, using a caliper, measure the distance from the rear surface of the intermediate housing to the inner race of the bearing. Determining the thickness of the gasket:
Measured distance (25.9 mm) - Nominal value (24.3 mm) = Gasket thickness (1.6 mm).
Gaskets with thickness of 0.1, 0.3, 0.5 and 1.4 mm.
12. Adjust the distance with shims by installing them between the ball bearing and the friction ring.
13. Remove the intermediate housing and press out the driven shaft ball bearing.