Contents: Shift mechanism housing ⇩ Fifth gear housing ⇩ Fifth gear gears of the secondary…⇩ Main body of the checkpoint ⇩ Primary, secondary and reverse gear…⇩ Disassembling the secondary shaft ⇩ Front gearbox cover ⇩ Gearbox spacer ⇩ Fifth gear housing ⇩ Shift mechanism housing ⇩
Shift mechanism housing
1. Disconnect the gearbox from the transfer case.
2. Unscrew the screws and remove the top cover of the mechanism.
3. Remove the transfer case shift mechanism housing.
4. Remove the gearbox shift housing.
Fifth gear housing
1. Remove the oil seal cover retaining ring.
2. Using a special tool, remove the cover.
3. Unscrew the bolts and remove the housing.
4. Secure the center spacer with two 8x35mm bolts.
5. Remove the rod leash from the rod.
Fifth gear gears of the secondary and intermediate shafts
1. Remove the secondary shaft seal ring.
2. Remove the oil pump drive shaft.
3. Disconnect the mounting clips from the fork.
4. Remove the fifth gear sleeve.
5. Remove the fork bracket.
6. Install the holder.
7. Install the fixture for fixing the intermediate shaft fifth gear.
8. Unscrew the lock nut.
9. Remove the fifth gear synchronizer retaining ring.
10. Install the puller and adapter as shown.
Caution: Make sure the adapter and puller are installed correctly.
11. Remove the fifth gear synchronizer assembly.
12. Remove the intermediate shaft using special tools.
Main body of the checkpoint
1. Install the reverse gear shaft lock "A" onto the gearbox spacer.
2. Screw the threaded pins "B" into the housing.
3. Turn the body over and place it on stand "E", aligning the recesses in the stand with the pins.
4. Disconnect the shift fork shaft bushing lock.
5. Unscrew the bolts and remove the front cover and gasket.
6. Remove the adjusting washers.
7. Unscrew the bolts and separate the housing.
8. Secure the spacer to the stand with a bolt and nut.
Primary, secondary and reverse gear shafts
1. Remove the retainer and reverse gear shaft.
2. Remove the thrust washer, reverse gear and bushing.
3. Remove the reverse gear lever locking pin.
4. Remove the lever and shoe.
5. Remove the input shaft and the fourth gear synchronizer ring.
6. Remove the intermediate shaft as shown in the figure
7. Unscrew the plug and remove the outer spring and ball.
8. Align the fifth gear shaft pin with the groove in the spacer.
9. Remove the secondary shaft, pinion gears and forks as shown.
10. Remove the gear fork.
11. Remove the inner ball and spring from the hole in the spacer.
12. Using special tools, remove the intermediate shaft bearings.
Disassembling the secondary shaft
1. Remove the first gear retaining ring.
2. Remove the roller bearing, washer, needle bearing, first gear sleeve, cone ring and synchronizer rings.
3. Remove the retaining ring to remove the first and second gear synchronizer.
4. Use a puller to remove the first gear from the shaft.
5. Remove the synchronizer rings.
6. Using a puller, lift the bearing, 3/4 gear synchronizer, 2nd and 3rd gear gears.
7. Remove the washer, 3/4 gear synchronizer, 3rd gear locking ring, needle bearings, bushing and 2nd gear.
8. Remove the retaining rings, the second gear cone ring bushing.
Front gearbox cover
1. Remove the oil seal from the cover; do not install the new oil seal yet.
Gearbox spacer
1. Remove the bearing races.
2. Check components for damage and wear.
3. Carefully install the reverse gear shaft and check the gap between the lever and the shoe, which should not be more than 0.2 mm.
Fifth gear housing
1. Check components for damage and wear.
2. Unscrew the pump cover, check, replace components if necessary.
3. Check the feed tube but do not remove it.
4. Remove the drain pipe, clean the filter, change it if necessary.
5. Replace the oil seal.
6. Replace the ferroasbestos bushing.
Caution: The bushing contains asbestos, do not attempt to clean it.
7. Install the new bushing with the holes facing inwards/away from the oil seal.
Caution: If the bushing is installed incorrectly, oil may leak through the seal.
8. If the housing is changed, replace the Allen screws and install them with Loctite.
9. Install the new oil seal, lips inward, using a drift.
10. Assemble the pump gears and install the cover.
11. Check the guide, replace if necessary.
Shift mechanism housing
1. Remove the return plunger and washers.
2. Unscrew the spring fixing bolts.
Caution: Be careful to avoid injury.
3. Remove the two springs.
4. Unscrew the mounting bolts to access the bottom of the lever.
5. Check the guide pins and grooves for damage.
6. Turn the case over and check the lock mounting bolts.
7. Remove the oil seal and replace it with a new one, with the lips facing inward.
8. Check the springs and replace if necessary.
9. Lubricate the lever ball with lithium-based grease, replace the plastic bushing.
10. Install the lever.
11. Install the limit plate
Note: Apply Loctite to the threads of the two short bolts and install them into the front pair of holes. Tighten the bolts to prevent the plate from shifting while installing the springs.
12. Place the springs with their long ends over the lever.
13. Check the operation of the return plunger.
Note: Apply a load of 45-55 kg to the plunger, it should work without jamming, the plunger is non-separable and can be replaced as an assembly.
14. Check the operation of the reverse light switch.
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