798646e1

9.1.2. Dismantling

During dismantle try to remember the adjusting provision of all removed components. It has to simplify the subsequent assembly.

Carburetor models of 4.2 l

 PERFORMANCE ORDER

  1. Remove transmission from the car. Clear the external surfaces of assembly, watching that solvent did not get to the release bearing of coupling.
  2. Give fixing bolts and remove from transmission a coupling dome, the lever of switching off and the release bearing assembled.
  3. Give fixing bolts and remove from a transmission case the top cover with laying (see an accompanying illustration).
1 — the synchronizer coupling
2 — - a gear wheel of the 1st transfer
3 — - a gear wheel of the 3rd transfer
4 — - the synchronizer coupling
5 — - a coupling dome
6 — - a lengthening casing
7 — - a gear wheel of the reverse gear
8 — - the synchronizer coupling
9 — - a gear wheel of the 2nd transfer
  1. Give fixing screws and by means of the hammer with soft brisk remove from a transmission case a lengthening casing (see an accompanying illustration). Take an epiploon from a casing and you will throw out it.
1 — the remote plug
2 — the bearing
3 — the holder
4 — the conducted shaft
5 — a lock ring
6 — a switching fork
7 — a synchronizer cone
8 — a gear wheel of the fifth transfer of an intermediate shaft
  1. Remove a lock ring, the holder and With-shaped rings from the end of the conducted shaft.
  2. Measure by the probe of lezviyny type a gap behind a gear wheel of the fifth transfer of an intermediate shaft. If the size of an axial side play goes beyond admissible limits (see size tables and adjustments at the end of the Management), attentively check components of the fifth transfer (after dismantling of the transmission) for existence of signs of wear.

Components of an intermediate shaft are shown on an accompanying illustration.
1 — - the holder
2 — - a dish-shaped spring
3 — - a gear ring
4 — - an intermediate shaft
5 — - an internal holder
6 — - an internal holder
7 — - a lock ring
8 — - a ball
9 — - a persistent washer
10 — - the coupling
11 — - the blocking synchronizer ring
12 — - a washer
13 — - an external holder
14 — - the bearing
15 — - a gear wheel of the 5th transfer
16 — - a synchronizer cone
17 — - a lock ring

  1. Remove a lock ring and a washer from an intermediate shaft.
  2. Remove a lock plate of an intermediate shaft of the reverse gear.
  3. Include at the same time two transfers to avoidance of a provorachivaniye of an intermediate shaft and establish a two-gripping stripper, having got his legs for a gear wheel of the fifth transfer. Remove a synchronizer cone, a gear wheel of the fifth transfer, assembly of the synchronizer, a fork of switching and a rod assembled. Take the roller bearing from the coupling of a gear wheel of the fifth transfer.

In order to avoid damage of teeth of a gear wheel of the fifth transfer use a stripper with broad captures.

  1. Give bolts and remove from transmission the holder of the bearing.
  2. By means of a stripper remove the back bearing of the conducted shaft, a gear wheel of the fifth transfer and the remote plug from the conducted shaft. In case of need delay the conducted shaft a hand for simplification of installation of a stripper back.
  3. Establish a separator of bearings behind the coupling of the roller bearing of a gear wheel of the fifth transfer, strongly tighten bolts. By means of a stripper remove the bearing coupling from an intermediate shaft (see an accompanying illustration) and take a persistent washer, remembering adjusting position of the last.
1 — a separator of bearings
2 — the coupling
3 — a stripper
  1. Establish a lock plate of an intermediate shaft of the reverse gear and a fixing bolt.
  2. By means of a stripper remove the bearing of the conducted shaft.
    to be strongly fixed behind a lock ring of an external holder of the bearing. At removal of the bearing use the wooden block as an emphasis.
  3. Give fixing bolts and remove from transmission a forward cover with laying. Remove an epiploon from a cover and you will throw out it together with laying.
  4. Slightly knock on a back end face of an intermediate shaft with the hammer with soft brisk and rotary progress take an external holder of the forward bearing of an intermediate shaft from a transmission case.
  5. Slightly knock with the hammer with soft brisk on a forward end face of an intermediate shaft, remove an external holder of the back bearing and lower an intermediate shaft on a transmission case bottom.

Extraction of an external holder of the back bearing of an intermediate shaft perhaps requires a stripper.

  1. Turn a main shaft so that one of лысок gear wheels of its synchronizer turned to an opening of the top cover Take a main shaft with the bearing from a transmission case.
  2. Remove the directing bearing and the blocking synchronizer ring from the forward end of the conducted shaft.
  3. Take assembly of the conducted shaft and an intermediate shaft from a transmission case through an opening of the top cover.

Appearance of assembly of the conducted shaft
1 — - a gear wheel of the 3rd transfer
2 — - a gear wheel of the 2nd transfer
3 — - a gear wheel of the reverse gear
4 — - the conducted shaft
5 — - couplings of synchronizers
6 — - a gear wheel of the 1st transfer
7 — - the synchronizer coupling

  1. Give a fixing bolt and remove a lock plate of an intermediate shaft of the reverse gear. Remember the adjusting direction intermediate gear wheels of the reverse gear and take a shaft, a gear wheel, persistent washers and roller bearings from a transmission case.
  2. Remove a lock ring and a remote ring of fastening of the bearing on primary to a shaft (see an accompanying illustration), by means of the press equipped with basic plates remove the bearing.
1 — a remote ring
2 — a lock ring
3 — the bearing
4 — a main shaft
5 — the blocking synchronizer ring
6 — the directing bearing
  1. Measure by the probe of lezviyny type the size of axial side plays of gear wheels of the first, second and back transfers on conducted to a shaft. Write down results of measurements.
  2. For measurement of an axial side play of a gear wheel of the third transfer clamp on it a separator of bearings and strongly fix on a separator the dial measuring instrument so that its plunger rested against a shaft end face (see an accompanying illustration). Move a gear wheel back and forth and write down instrument reading. If the axial side play of a gear wheel goes beyond admissible limits (see size tables and adjustments at the end of the Management), sort the conducted shaft on components and carefully check the corresponding gear wheel and components accompanying it Replace defective parts.
1 — the dial measuring instrument
2 — a separator of bearings
  1. Sort the conducted shaft on components (see an accompanying illustration):
1 — - a lock ring
2 — - the blocking synchronizer ring
3 — - the bearing
4 — - a gear wheel of the 2nd transfer
5 — - the bearing
6 — - the blocking rings
7 — - the bearing
8 — - assembly of the synchronizer
9 — - a gear wheel of the 3rd transfer
 10 — - the coupling
11 — - a lock ring
12 — - assembly of the synchronizer
13 — - a gear wheel of the 1st transfer
14 — - the bearing
15 — - the blocking ring
16 — - the conducted shaft
17 — - a gear wheel of the reverse gear
18 — - assembly of the synchronizer
    1. Remove a lock ring from the forward end of the conducted shaft.
    2. Establish a separator of bearings behind a gear wheel of the third transfer and remove it by means of a press with basic plates, then remove assembly of the synchronizer 3/4 of transfers and the roller bearing from a shaft. Remember the adjusting direction of a nave of the synchronizer.
    3. Establish a separator behind a gear wheel of the second transfer and by means of a press remove a gear wheel, the roller bearing and the coupling of the bearing from a shaft.
    4. Remove a lock ring of fastening on a shaft of a nave of the synchronizer 1/2 of transfers.
    5. Establish the conducted shaft in a press with basic plates, having propped up the last a gear wheel of the first transfer and remove assembly of the synchronizer 1/2 of transfer, a gear wheel of the first transfer and the roller bearing from a shaft.
    6. Turn the conducted shaft and an oboprita on basic plates a gear wheel of the reverse gear. Remembering the adjusting provision of components, remove a gear wheel of the reverse gear, assembly of the synchronizer and the roller bearing from a shaft.
  1. Investigate on components assembly of an intermediate shaft (see an illustration):
    1. By means of a press with basic plates remove internal holders of forward and back bearings from an intermediate shaft.
    2. Remove from the forward end of a shaft a lock ring, the holder, a dish-shaped spring, a gear ring and a ball.
  1. In case of need sort on components the top cover (see an accompanying illustration):
1 — a cap
2 — a spring
3 — a plunger
4 — a casing
5 — a stopper
6 — a ball
7 — a rod of the choice of transfers
8 — a pin
9 — a plate
10 — bolts
11 — the choice rod lever
12 — a choice rod arm
    1. Give fixing bolts and disconnect a casing of the selector of transfers from the top cover. Components of a casing of the selector are shown on an accompanying illustration.
    2. Turn out a restrictive stopper from the top part of a casing of the selector, take a spring and a ball. Turn out the remained caps and take springs and plungers, remembering the adjusting provision of each of components.
    3. By means of a drift take a pin of fastening of an arm of the selector on a rod of the choice of transfers.
    4. Turn a selector casing, give fixing bolts and remove the directing plate. Remember adjusting provisions of bolts.
    5. Drift beat out a pin of fastening of the lever on a rod of the choice of transfers, at the same time taking a spherical cap from a casing. Beat out a rod of the choice of transfers from a selector casing forward. Pick up an arm of the selector and a forward cap.
    6. Turn out a cap and take the fixing spring, a guide and a ball from the top cover.
    7. Remove the sensor switch of fires of a backing.
    8. By means of the hammer and the screw-driver remove and you will throw out traffic jams of a rod of the choice of transfers.
    9. Remove fixing pins of a fork of turning on of the reverse gear and lever of the choice of the reverse gear. Take a rod of the choice of the reverse gear, then remove a fork and the lever, remembering their adjusting situation. The top cover with the removed casing of the selector is shown on an accompanying illustration.
1 — control assembly of the reverse gear
2 — the shock lever
3 — a shock clamp
4 — the lever of the choice of the reverse gear
5 — a fork of turning on of the reverse gear
6 — rods of the choice of transfers
7 — a fork of switching of 3/4 transfers
    1. Take a fixing pin of the shock lever, take a choice rod, then, remembering the adjusting provision of components, take the shock lever, a shock clamp and forks of switching from the top cover. Internal components of the top cover are shown on an accompanying illustration.
1 — a shock clamp
2 — - the shock lever
3 — - a pin
4 — - a cap
5 — - a guide
6 — - a spring
7 — - a ball
8 — - control assembly of the reverse gear
9 — - a stopper
10 — - traffic jams
11 — - a rod
12 — - a fork of switching of 3/4 transfers
13 — - a fork of switching of 1/2 transfers
14 — - a cover
15 — - the sensor switch of fires of a backing
16 — - a fork of turning on of the reverse gear
17 — - a rod
18 — - the lever of turning on of the reverse gear
19 — - pins
    1. Take a fixing pin and remove control assembly of the reverse gear.
  1. In case of need sort a casing of management of the lever of gear shifting:
    1. Remove collars and shift a rubber protective cover up the lever.
    2. Remove a big lock ring and take from a casing the gear shifting lever with a spring.
    3. Remove a lock ring, take the switching lever from a nest and remove from it a rubber saddle (see an accompanying illustration).
1 — laying
2 — a casing
3 — a spring
4 — a lock ring
5 — a nest
6 — a saddle
7 — the plug
8 — a washer
9 — a protective cover
10 — the gear shifting lever
11 — the handle

Models of 4.2 l of EFI

Dismantling of the transmission is made in the same order, as on carburetor models of 4.2 l taking into account the listed below changes. Components of the conducted shaft are presented on an accompanying illustration - on inserts the blocking rings of synchronizers of models of late years of release are shown.
1 — the blocking synchronizer rings (model of late years of release)
2 — assembly of the synchronizer
3 — a lock ring
4 — the blocking synchronizer rings (model of early years of release)
5 — a gear wheel of the 3rd transfer
6 — the bearing
7 — the bearing coupling
8 — a gear wheel of the 2nd transfer
9 — the blocking synchronizer ring
10 — a gear wheel of the 1st transfer
11 — the conducted shaft
12 — a gear wheel of the reverse gear

 PERFORMANCE ORDER

  1. At implementation of points b) and e) procedures of dismantling of the conducted shaft it is necessary to remember adjusting provisions of assemblies of the blocking rings of the synchronizer 2/3 of transfers.
  1. For check of serviceability of assemblies of the blocking rings of synchronizers of the 2nd and 3rd transfers measure gaps between an external ring and a cone (see an accompanying illustration), - its size should not exceed 0.2 mm and between an internal ring and a cone (see an accompanying illustration), - the difference of heights should not exceed 0.2 mm.
  1. At assembly of components of the conducted shaft establish rings of synchronizers of the 2nd and 3rd transfers according to the instruction made in the course of dismantle.

On release models since October, 1994 the remote plug of the forward bearing of a main shaft and a washer of a cone of the synchronizer of an intermediate shaft are removed.

Models of 3.0 l

 PERFORMANCE ORDER

  1. Remove assembly of transmission from the car and clear it outside, watching that solvent did not get to the release bearing of coupling.
  2. Take the lever of switching off of coupling and the release bearing from a case (dome) of coupling.
  3. Turn out a cap and take a control spring and a ball from the coupling of a clamp located on a coupling dome wall (components of the drive of gear shifting are shown on an accompanying illustration).
1 — a switching rod
2 — a washer
3 — a lock ring
4 — a ball
5 — a bolt
6 — a cap
7 — the clamp coupling
8 — a sealing ring
9 — a spring
10 — a clamp
11 — a cylindrical pin
12 — a rod of switching of the back / 5th transfer
13 — a plunger
14 — a fork of switching of 3/4 transfers
15 — the shock lever
16 — a fork of switching of 1/2 transfers
17 — a fork of turning on of the reverse gear
18 — a selector arm
19 — a fork of inclusion of the 5th transfer
20 — a nut
21 — the coupling

Give a fixing bolt and remove the clamp coupling. Remove a sealing ring and you will throw out it.

If not to take out a control spring and a ball earlier, then at removal of the coupling they can drop out in transmission.

  1. If did not remove earlier, take a spring and a ball from an opening in the surface of interface of a casing of lengthening to a casing of management of the lever of gear shifting.
  2. By means of a drift beat out a cylindrical pin of fastening of an arm of the selector on a switching rod.
  3. Give fixing bolts and by means of the hammer with soft brisk remove a casing of lengthening and an arm of the selector from transmission. Take an epiploon from a lengthening casing, you will throw out it.
  4. Give fixing bolts and remove the top cover with laying for what pass the lever throughout an opening under installation of the lever of switching off in a coupling dome. Take an epiploon from a cover and you will throw out it.
  5. Remove lock rings from an external holder of the bearing of a main shaft and from a switching rod. Remove a washer from a rod.
  6. Having propped up a back part of the conducted shaft, separate a coupling dome from the bearing plate by means of the hammer with soft brisk. Remove the persistent bearing and an adjusting washer from the forward end of an intermediate shaft.
  7. Clamp the bearing plate in a vice with soft sponges and give a bolt of fastening of a rod of switching of transfers by the back/fifth to a fork of turning on of the reverse gear. Take a rod from the bearing plate.
  8. Drift beat out a cylindrical pin of fastening of the shock lever and a clamp on a switching rod. Take a switching rod from the bearing plate and remove the shock lever and a clamp, and also forks of switching 1/2, 3/4 and back transfers, remembering the adjusting provision of components.
  9. By means of a drift take a cylindrical pin of fastening of a fork of the fifth transfer on a switching rod. Take a rod and remove a fork.
  10. Measure by the probe of lezviyny type an axial side play of gear wheels of the first, second, third and back transfers on conducted to a shaft. Also measure an axial side play of a gear wheel of the fifth transfer on intermediate to a shaft. If the axial side play any of gear wheels goes beyond admissible limits (see size tables and adjustments at the end of the Management), attentively check the corresponding components for existence of signs of wear, replace defective parts.
  11. Take the connecting coupling of the reverse gear from a nave, having remembered the adjusting direction of its landing. Remove a lock ring from the end of the conducted shaft, then by means of the hammer remove With-shaped lock half rings (see an illustration).
1 — the bearing plate
2 — a lock ring
3 — the conducted gear wheel of the 5th transfer
4 — the coupling
5 — bearings
6 — a nave
7 — the holder
8 — the conducted gear wheel of the reverse gear
9 — the synchronizer coupling
10 — the remote plug
11 — With-shaped lock half rings
12 — a lengthening casing
13 — the leading gear wheel of the 5th transfer
14 — the sliding key
15 — the blocking ring
16 — the leading gear wheel of the reverse gear
17 — a cone of the synchronizer of the reverse gear
18 — the blocking synchronizer ring
19 — a washer
20 — an intermediate shaft of the reverse gear
21 — a pin
22 — a persistent washer
23 — an intermediate gear wheel of the reverse gear
  1. Remove a lock ring and a washer from the back end of an intermediate shaft, then by means of a stripper remove the bearing and a gear wheel of the reverse gear.
  2. Remove a gear wheel, bearings and persistent washers from an intermediate shaft of the reverse gear, remembering adjusting position of the last.
  3. Establish a stripper by captures behind a gear wheel of the reverse gear and remove the bearing, the remote plug, a nave of the reverse gear, a gear wheel of the reverse gear and roller bearings from the conducted shaft. Try to remember the adjusting provision of components.
  4. Remove the coupling of the synchronizer of the fifth transfer with the blocking rings and the sliding keys of the fifth and back transfers. Try to remember adjusting provisions of the coupling and the sliding keys.
  5. By means of a stripper remove the coupling of the roller bearing of a gear wheel of the reverse gear from the conducted shaft.
  6. Establish a stripper by captures behind a gear wheel of the fifth transfer and remove at the same time a cone of the reverse gear, a gear wheel of the fifth transfer and an intermediate shaft of the reverse gear.
  7. Establish the bearing plate in a press, having propped up it basic plates and serially squeeze out the conducted and intermediate shaft of a plate. Remember the provision of a gear wheel of the fifth transfer of the conducted shaft. After removal of an intermediate shaft take a main shaft and remove with conducted a shaft roller bearings and the remote plug.
  8. Give bolts and remove from the bearing plate the holder of the bearing.
  9. Remove a washer, a ball, a gear wheel of the first transfer and the roller bearing from the conducted shaft.
  10. Establish the conducted shaft in a press, having propped up basic plates a gear wheel of the second transfer and remove the coupling of the roller bearing of a gear wheel of the first transfer, assembly of the synchronizer 1/2 of transfers and a gear wheel of the second transfer with the roller bearing.
  11. Remove a lock ring from the forward end of the conducted shaft, then establish a shaft in a press, having propped up basic plates a gear wheel of the third transfer. Remove assembly of the synchronizer 3/4 of transfers, a gear wheel of the third transfer and the roller bearing.
  12. Establish an intermediate shaft in a press and remove the back persistent bearing, having remembered the adjusting direction of its landing. Remove a lock ring from the forward end of an intermediate shaft, then remove the plug, a conic spring, a gear ring and a ball.
  13. Remove a lock ring and a washer from a main shaft. Establish a main shaft in a press, having propped up basic plates the bearing and remove the last.
  14. By means of a suitable mandrel remove bearings from the bearing plate, a casing of lengthening and a case of coupling.

Components of assembly of the lever of gear shifting
1 — a spring
2 — bolts
3 — the lower saddle
4 — a lock ring
5 — washers
6 — the gear shifting lever
7 — the top saddle
8 — a collar
9 — a protective cover