Cars with engines 111.948 and 601.970
Disassembly
1. Disassemble the gearbox.
2. Unscrew bolt 2 (see figure 6.34).
Figure 6.34. Driven shaft (cars with engines 111.948 and 601.970):
1. Driven shaft (assembled),
2. Bolt,
3. Ball bearing,
4. Gaskets,
5. 5th gear pinion,
6. 4th gear pinion,
7. 3rd gear pinion,
8. Needle bearing,
9. Bearing bushing,
10. 2nd gear pinion,
11. Rubbing ring,
12. Cone ring,
13. Synchronization ring,
14. Clutch synchronizer for 1st and 2nd gear engagement,
15. Roller bearing,
16. 1st gear pinion,
17. Driven shaft.
3. Press out ball bearing 3 and gears 5 of 5th and 6th and 4th gears. Do not mix gaskets 4 with those of the drive shaft.
4. Engage the 1st gear pinion on the synchronizer clutch 14 for engaging 1st and 2nd gears, insert the removable plate between the pinion 10 and the sleeve.
5. Insert the pressure sleeve, press out the fixed gear 7 of the 3rd gear and gear 10 of the 2nd gear and remove the needle bearing 8.
6. Set synchronizer clutch 14 to neutral position.
7. Press out bearing bushing 9, synchronizer sleeve 14 for engaging 1st and 2nd gears and remove gear 16 of 1st gear.
8. Disassemble the 14 synchronizer coupling for engaging 1st and 2nd gears. To do this, remove the sliding sleeve 2 from the synchronizer housing. Loosen balls 5 and locking pins 4 for a while (see figure 6.35). Remove springs 3.
Figure 6.35. Disassembling and assembling the synchronizer clutch
1st and 2nd gear (cars with engines 111.948 and 601.970):
1. Synchronizer housing,
2. Sliding sleeve,
3. Spring,
4. Locking finger,
5. Ball.
9. Remove roller bearing 15.
10. Check the wear of the rings 13 of the synchronizer for engaging 1st and 2nd gears (see figure 6.36). Connect gear 4, friction ring 3, cone ring 2 and synchronization ring 1. Using feeler gauge 5, check the distance between synchronization ring 1 and gear 4. It should be 0.8 mm. If the distance is greater than the permissible value, replace friction ring 3 and, if necessary, rings 2 and 1.
Figure 6.36. Checking wear between synchronizer rings and clutch housing (cars with engines 111.948 and 601.970):
1. Synchronization ring,
2. Cone ring,
3. Friction ring,
4. Gear,
5. Probe.
11. Check the driven shaft 17 and the fixing holes of gears 5, 6 and 7 for wear.
Assembly
12. Lubricate all bearings with oil before installation.
13. Install roller bearing 15, 1st gear pinion 16, roller bearing 15, friction ring 11, cone ring 12 and synchronization ring 13.
14. Install synchronizer sleeve 14 on the synchronizer housing with the grooves facing up and press it in. The guides on the synchronization ring 13 must be engaged with the synchronizer housing.
15. Assemble the 1st and 2nd gear synchronizer coupling 14. Press the sliding sleeve 2 onto the synchronizer housing and make sure that the groove (arrow) matches the 1st gear pinion. The teeth with the notch (arrow) must be installed in the center of the notch of the synchronizer housing 1 (see figure 6.35). Insert springs 3 and locking pins 4 into the recess in synchronizer housing 1. The chamfer of locking pin 4 should be facing outward. The notches (arrow) on the extended part of the locking pin 4 must be visible. Raise the locking pins 4 so that the balls 5 can be inserted into the holes. Press balls 5 into the holes, set locking pins 4 downwards and after a while insert them into sliding sleeve 2. Insert the 2nd gear synchronization ring, press it in and set sliding sleeve 2 to the neutral position.
16. Install synchronization ring 13, conical ring 12, friction ring 11. The guides of friction ring 11 must be engaged with synchronization ring 13.
17. Press in bearing sleeve 9 until it stops.
18. Install needle bearing 8 and 2nd gear gear 10. The guides of the conical ring 12 must engage with the grooves of the gear 10.
19. Press in gear 7 of the 3rd gear with the grooves facing up until it stops.
20. Press in gear 6 of the 4th gear with the grooves facing up until they stop.
21. Install gaskets 4.
22. Press in ball bearing 3 with groove facing up.
23. Screw in bolt 2.
24. Assemble the gearbox.
Cars with engine 611.980
Disassembly
25. Disassemble the gearbox.
26. Press out fixed gears 2 and 3, 5th and 4th gears (see figure 6.37).
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Figure 6.37. Driven shaft (cars with engine 611.980):
1. Driven shaft (assembled),
2. 5th gear pinion,
3. 4th gear pinion,
4. 3rd gear pinion,
5. Needle bearing,
6. Bearing bushing,
7. 2nd gear pinion,
8. Rubbing ring,
9. Cone ring,
10. Synchronization ring,
11. Clutch synchronizer for 1st and 2nd gear engagement,
12. Roller bearing,
13. 1st gear pinion,
14. Driven shaft.
27. Engage first gear.
28. Press out fixed gears 4 and 7 of 3rd and 2nd gears.
29. Disconnect needle bearing 5 and bearing sleeve 6.
30. Press out the 11th and 2nd gear synchronizer clutch.
31. Disassemble the synchronizer clutch P. Check the wear of the synchronizer rings (see figure 6.36).
32. Remove roller bearing 12.
33. Check driven shaft 14 and gear fixing holes 2, 3 and 4 for wear.
34. Lubricate all bearings with oil before installation.
35. Install roller bearing 12, gear 13, friction ring 8, synchronization ring 10.
36. Install coupling 11 on the synchronizer housing with the grooves facing up and press it in.
37. Assemble the clutch 11 for engaging 1st and 2nd gears (see figure 6.35).
38. Install synchronization ring 10, cone ring 9, friction ring 8.
39. Press in bearing sleeve 6 until it stops.
40. Install needle bearing 5 and gear 7.
41. Press the gear with 4 slots facing up until it stops.
42. Press the gear with 3 grooves facing up until it stops.
43. Press the gear with 2 grooves facing up until it stops.
44. Assemble the gearbox.