Subaru Forester
+ Cars Subaru Forester
+ The maintenance instruction
+ Routine maintenance
+ The engine
+ Systems of cooling, heating
+ The power supply system and release
+ Engine electric equipment
+ Control systems of the engine
- Gear change box
- 5-step manual box of a gear change (РКПП)
The general information
Removal and installation of a box of a gear change
Preparation for performance of repair work on restoration РКПП
Dismantling and assemblage of a distributing box, service of components
Major repairs РКПП of all-wheel drive models
Service of a drive of a gear change
Service of the lever of switching of a distributing box
+ 4-step automatic transmission (АТ)
+ Coupling, трансмиссионная a line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
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Major repairs РКПП of all-wheel drive models
Dismantling
Division полукартеров
Design of the mechanism of a gear change
Design 5-step РКПП
Design 5-step РКПП with a reducer
All boxes
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1. Remove выжимной the bearing and a plug of deenergizing of coupling.
2. Turn out bolts of fastening of the bearing of a secondary shaft. |
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Only boxes with a reducer
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1. Turn out bolts of fastening of the holder of a leading gear wheel of a reducer.
2. By means of approaching a small beard beat out a spring pin of fastening of the lever of switching of a divider. |
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At выбивании a pin watch, that it has not rested against a wall картера РКПП. |
All boxes
Remove a persistent flange of a primary shaft.
Only boxes with a reducer
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1. Turn out заглушку and take a spring and a ball of a clamp of a gear change of a reducer.
2. Turn out the gauge-switch of activation of lowering transfer of a reducer. |
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All boxes
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1. Wind with an adhesive tape шлицы power shafts.
2. Having given 17 coupling болтовых steam, divide картер РКПП into two half, - on boxes with a reducer try not to damage an epiploon of an axis of the switch of a divider in right полукартере!
3. Take from left полукартера assemblage of a secondary shaft, - in case of need take advantage for extraction of a shaft by the hammer handle. |
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Only boxes with a reducer
Slightly raise assemblage of a primary shaft with a leading gear wheel of a divider and remove a plug of a gear change of a reducer together with an axis and a washer, - try not to drop in картер two crackers of a plug!
All boxes
Take assemblage of a primary shaft.
Only boxes with a reducer
Extraction of a primary shaft in gathering with a leading gear wheel of a reducer (only РКПП with a reducer)
Take a primary shaft in gathering with a leading gear wheel of a reducer, then remove a gear wheel from a shaft, - track, that the needle bearing remained in a gear wheel. Try not to admit соскакивания blocking rings of the synchronizer of a reducer.
All boxes
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1. Take differential.
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Do not mix external holders of the right and left bearings of differential! |
2. Beat out a spring pin and remove a plug of inclusion of 5th transfer.
3. Turn out заглушки, remove springs and balls of clamps.
4. Beat out a spring pin and take a rod of a plug of switching of 3/4 transfers.
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At extraction of one rod keep the others in neutral position. Spring pins should be beaten out inside картера and so that not to admit damage of the last. |
5. Remove a lock ring and remove a tip from a rod of inclusion of transfer of a backing. Take from a rod a spring and a clamp ball, remove blocking плунжер. Take a rod.
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At tip removal watch, that the ball has not fallen out of it. |
6. Take коромысло inclusions of transfer of a backing.
7. On the models equipped with a turbo-supercharging, remove the gauge of speed of movement VSS 2. |
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Dismantling right полукартера
Only boxes with a reducer
Dismantling of a divider of transfers РКПП with a reducer
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| 1. Put forward greatest possible forward an axis of the block of gear wheels of a reducer and remove a lock ring. |
| 2. Remove a persistent washer from the back end of an axis of the block of gear wheels and take from an axis a pin. |
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| 3. Liberate an axis from the block of gear wheels, - try not to damage a sealing ring of an axis and not to drop a pin from the forward end of an axis. |
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Do not drop in a crater planted on an axis the block of gear wheels, the persistent washers, two needle bearings and распорную the plug! |
All boxes
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1. Remove a blooming ring and a conducted gear wheel of a drive of a speedometer. Remove from a power shaft of a speedometer a washer.
2. Remove the holder of the bearing of differential. |
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Assemblage
Assemblage right полукартера
Only boxes with a reducer
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Track, that the end face of an axis of the block of gear wheels equipped with a cut acted from a wall картера РКПП! |
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1. Plant on an axis of the block of gear wheels of a divider a sealing ring, fill a pin.
2. Fill in right полукартер an axis of the block of the gear wheels, two persistent washers, two needle bearings, the block of gear wheels of a divider. Establish pins and a spring lock ring. |
| 3. Achieve the position of a cut shown on an illustration in an end face of an axis of the block of gear wheels. |
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4. Plant on an axis a spring lock ring in internal diameter of 19 mm and measure backlash size between the given ring and a persistent washer of the block. If the result of measurement falls outside the limits a demanded range (0.05 0.35 mm), make selection of a new lock ring. Lock rings of two standard sizes are issued: № 031319000, thickness of 1.50 mm and № 805019010, thickness of 1.72 mm.
5. Plant a washer on a shaft of a drive of a speedometer, then запрессуйте by means of the special tool a new epiploon (if the old has been removed).
6. Establish a conducted gear wheel of a drive of a speedometer and a blooming lock ring. |
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Assemblage left полукартера
All boxes
Details of assemblage left полукартера
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It is necessary to fill an axis of an intermediate gear wheel from the back party картера. On the models equipped with a turbo-supercharging, the additional washer is established and ahead of an intermediate gear wheel. |
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1. Establish a spring, a ball and blocking плунжер (5.56х19.6) in a tip of a rod of a plug of inclusion of transfer of a backing. Pass a rod in an aperture of a tip and fix by means of a blooming lock ring, - try not to admit loss of a ball from a rod aperture.
2. Establish a ball ( 7.1438) and a spring in a nest left полукартера opposite to a rod of inclusion of transfer of a backing. Screw and tighten заглушку, - do not forget to replace a sealing washer.
3. Move a rod of inclusion of transfer of a backing in position "Backing" and adjust position of an intermediate gear wheel by selection of a side scene of inclusion of a reverse gear for backlash size between a gear wheel and a wall картера. |
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Side scenes of three standard sizes are issued:
Side scene of inclusion of a reverse gear
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№ details |
Marks |
The note |
| 32820AA000 |
0 |
The increased backlash |
| 32820AA010 |
-
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The standard size |
| 32820AA020 |
2 |
The reduced backlash |
After side scene selection include neutral transfer and adjust backlash size between an intermediate gear wheel and an opposite wall картера by washer selection:
Washer
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№ details |
Thickness, mm |
| 803020151 |
0.4 |
| 803020152 |
1.1 |
| 803020153 |
1.5 |
| 803020154 |
1.9 |
| 803020155 |
2.3 |
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1. Fill a rod in a plug of switching of 1/2 transfers, having passed it in an aperture in a back wall картера РКПП. Achieve combination of fixing apertures and by means of a pin (6х22) fix a plug on a rod. The remark: Other rods are translated in neutral position. Make sure that blocking плунжер the rod of switching of 3/4 transfers is displaced in the aperture aside.
2. Preliminary having greased консистентной with greasing, fill blocking плунжер in an aperture of a rod of a plug of switching of 3/4 transfers. Fill a rod in a plug, having passed it in an aperture in a back wall картера. Achieve combination of fixing apertures and fix a plug a pin (6х22).
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Rod of a plug of inclusion of a reverse gear establish in neutral position. Track, that blocking плунжер has been displaced towards a rod of inclusion of transfer of a backing. |
3. Plant a plug of inclusion of 5th transfer on the back end of a rod of inclusion of transfer of a backing and fasten details a pin.
4. Establish balls ( 7.1438) and clamp springs in nests расточек under rods of switching of 3/4 and 1/2 of transfers and turn заглушки, - do not forget to replace sealing washers. |
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Boxes without a reducer
Establish a washer and a shaft of a drive of a speedometer, then запрессуйте a new epiploon. Establish a conducted gear wheel of a drive of a speedometer and a lock ring. If gauge VSS 2 has been removed, establish it on a place (only models with a turbo-supercharging).
Joint полукартеров
Only boxes with a reducer
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Pick up adjusting linings of the holder of the bearing of a leading gear wheel of a divider: connect assemblage of a primary shaft to a leading gear wheel. The necessary quantity of linings can be calculated under the formula: D = And - (In +), where: And: total length картера (353 mm); In: Length of a leading gear wheel of a divider with the bearing; With: Length assemblage of a primary shaft. |
On the basis of results of the spent calculation define demanded quantity of linings:
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The size D, mm |
Quantity of linings |
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52.46 53.23
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—
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51.96 52.45
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1
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51.34 51.95
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2
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Thickness of a lining:
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0.45 0.55 mm
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All boxes
Identifikatsionaaja marks of leading and conducted gear wheels of the main transfer
Preparation for adjustment of position of a leading gear wheel of the main transfer
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1. Check up leading and conducted gear wheels of the main transfer on marks presence. The top number at an end face of a leading gear wheel should correspond to the marks put on forming surface of the conducted gear wheel, is more gentle - serves for selection of an adjusting lining at debugging of gearing of gear wheels. If the bottom marks are absent, hence the lining is not required.
2. Lay assemblage of a secondary shaft in right полукартер РКПП without linings and tighten bolts of fastening of the back bearing.
3. Check up and adjust position калибровочной scales, - at scale hit in one plane with a plate the index should be on a mark 0.5.
4. Having achieved demanded result, tighten two bolts.
5. Establish calibre, having filled its finger in an aperture картера transmissions.
6. Advance калибровочную a scale along a plate and, at combination with an end face of a leading gear wheel, consider the scale indication.
7. The thickness of a package of adjusting linings is defined by summation of the value which have been beaten out at an end face of a leading gear wheel, - the bottom label, - and indications of a measuring scale of calibre.
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If the bottom label has a sign “+”, value of the amendment is necessary for adding to calibre indications, if “-” to take away. |
8. Pick up from one to three linings (see the table) so that the general thickness of a package made the value received as a result of calculations. |
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Adjusting linings
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№ details |
Thickness, mm |
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32295AA031
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0.150
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32295AA031
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0.175
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32295AA051
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0.200
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32295AA061
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0.225
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32295AA071
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0.250
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32295AA081
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0.275
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32295AA091
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0.300
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32295AA101
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0.500
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Establish assemblage of forward differential in left полукартер transmissions.
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In order to avoid damage of working edges of an epiploon at assemblage wrap up шлицы power shafts an adhesive tape. |
Boxes without a reducer
Landing of an epiploon of a primary shaft to a forward wall полукартера
Establish the needle bearing and an epiploon on a forward pin of a primary shaft, then fill shaft assemblage in left полукартер РКПП.
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Шлицы a shaft also wrap up an adhesive tape protective layer. An epiploon establish so that its back part rested against an edge And nests in left полукартере. Do not forget to grease sealing sponges of an epiploon. Track, that the fixing pin has been established in an aperture in an external holder of the needle bearing. |
Only boxes with a reducer
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At installation of a ring of the synchronizer achieve combination of cuts with crackers. At installation of a leading gear wheel of a divider do not forget to establish the linings picked up in advance. |
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1. Make assemblage of a primary shaft with the needle bearing, the synchronizer of a divider of transfers, lubricant knot and a leading gear wheel of a divider.
2. Establish a plug of a gear change of a divider with two crackers on муфту the synchronizer.
3. Slightly raise assemblage of a primary shaft and develop it on 90 concerning a transmission. Keeping a shaft in such position, fill a plug axis in an aperture left полукартера. Establish on an axis of a plug of a washer. |
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Try not to admit соскальзывания a leading gear wheel of a divider from assemblage of a primary shaft. Track, that the lubricant knot has been established in a flute left полукартера, and a fixing pin - in an aperture of the needle bearing. Nylon tips of a plug grease трансмиссионным with oil. Develop a cutting lock ring of the bearing on a back pin of a primary shaft the lock to assemblage of a secondary shaft. |
All boxes
Adjustment of position of components of 1/2 transfers
Adjustment of position of components of 3/4 transfers
Adjustment of position of components of 1/2 transfers
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1. Establish assemblage of a secondary shaft with the package of adjusting linings picked up in advance in картер transmissions. Make sure that the fixing pin has got to an aperture of an external holder of the bearing.
2. Pick up plugs of switching 1/2, 3/4 and 5th transfers (tables) so that муфты synchronizers see and a conducted gear wheel of a reverse gear settled down on the centre of synchronizers. |
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Plug of switching of 1/2 transfers |
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№ details |
Marks |
The note |
| 32804AA060 |
1
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Shifts муфту on 0.2 mm to a gear wheel of 1st transfer |
| 32804AA070 |
-
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Does not change position муфты |
| 32804AA080 |
3
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Shifts муфту on 0.2 mm to a gear wheel of 2nd transfer |
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Plug of switching of 3/4 transfers |
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№ details |
Marks |
The note |
| 32810AA060 |
1
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Shifts муфту on 0.2 mm to a gear wheel of 4th transfer |
| 32810AA070 |
-
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Does not change position муфты |
| 32810AA080 |
3
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Shifts муфту on 0.2 mm to a gear wheel of 3rd transfer |
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Plug of switching of 5 transfers |
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№ details |
Marks |
The note |
| 32812AA060 |
1
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Shifts муфту on 0.2 mm to a gear wheel of 5th transfer |
| 32812AA070 |
-
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Does not change position муфты |
| 32812AA080 |
3
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Shifts муфту on 0.2 mm from a gear wheel of 5th transfer |
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Measure sizes of backlashes And and In between tips of rods. If any of backlashes falls outside the limits the resolved range (see the table), replace a corresponding rod or a plug. |
Backlash And between tips of rods of plugs of 1/2 and 3/4 of transfers
0.5 1.5 mm
Backlash In between tips of rods of plugs of 3/4 and 5th transfers
0.6 1.4 mm
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Carefully wipe solvent interfaced surfaces, impose a pillow of hermetic of type Tree-bond 1215 and connect to honey itself полукартеры РКПП. Establish 17 coupling bolts and in strictly certain order tighten their nuts with demanded effort (bolts М8: 23 26 Nanometers; bolts М10: 36 42 Nanometers). |
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Bolts are inserted from below, nuts наворачиваются from above. At a joint полукартеров watch, that adjusting linings of the bearing of a secondary shaft and the holder of a primary shaft have not appeared are jammed. |
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1. Make sure that leading and conducted gear wheels of a drive of a speedometer have entered into gearings and that the lever of switching of direct and lowering transfers of a divider (a box with a reducer) are established properly.
2. Tighten bolts of fastening of the holder of the bearing. |
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Only boxes with a reducer
Tighten bolts of fastening of the holder of the bearing of a leading gear wheel of a divider.
All boxes
Adjust position of a leading gear wheel of the main transfer and a pretightness of bearings of a gear wheel (see further).
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At adjustment of a pretightness of conic roller bearings keeping of a secondary shaft from проворачивания is made by means of the special tool. |
Adjustment of position of gear wheels of the main transfer and pretightness of bearings of gear wheels
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1. Establish a transmission left полукартером downwards and press a cover of the top bearing special cargo.
2. By means of a special key draw the holder of the bearing of differential from below to left полукартеру. Put on the special handle on шлицы a primary shaft. Include 4th or 5th transfer and some times turn a primary shaft. Start to tighten a nut of the holder until will feel easy resistance to handle rotation that is a sign of an input of gear wheels in gearing. For a guarantee of correctness of an input in gearing of leading and conducted gear wheels of the main transfer repeat the described procedure some times.
3. Remove pressing a cover of the bearing cargo and wrap the holder of the bearing in top (right) полукартер boxes without a sealing ring before occurrence of easy resistance to a tightening.
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The backlash size in гипоидном gearing of gear wheels of the main transfer is equal in the given position of the holder to zero. |
4. Establish a lock plate of the holder of the bearing. For the purpose of reception of a demanded backlash turn on the holder of the bottom (left) bearing on 1.5 teeth of a lock plate and on the same size hold on the holder of the top bearing.
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Переворачивание a lock plate leads to displacement on 1/2 teeth. |
5. For creation of a pretightness of roller bearings of differential hold on the top holder on 1 tooth.
6. Temporarily tighten the top and bottom lock plates and mark position of both holders and their plates.
7. Turning a primary shaft slightly обстучите a hammer with soft brisk картер round holders of bearings, - обстукивание with проворачиванием it is necessary to make during some time.
8. By means of a magnetic bed fix on картере РКПП циферблатный a measuring instrument плунжерного type. Плунжер a measuring instrument pass through an aperture for plum of oil and rest it against a surface of a tooth of a conducted gear wheel of the main transfer at right angle. Check up size of a backlash of gearing of gear wheels, - if the result of measurement falls outside the limits an admissible range (0.13 0.18 mm), make corresponding updating by rotation of the holder of the bearing of differential in right полукартере.
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Turn of the holder on 1/2 turns leads to backlash change approximately on 0.04 mm. |
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Gearing of gear wheels of the main transfer is adjusted truly
The backlash of gearing of gear wheels is too great
The backlash of gearing of gear wheels is too small
The thickness of a package of adjusting linings of a leading gear wheel is excessive
The thickness of a package of linings is insufficient
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1. For check of correctness of gearing of gear wheels of the main transfer put a continuous layer of lead minium on forward and back surfaces of three-four teeths of a conducted gear wheel. Rotate a primary shaft forward-back until on both surfaces of teeths the trace of a contact stain accurately will not be printed. By position of a contact stain the conclusion about correctness of gearing of gear wheels can be made. In case of need make corresponding updating. Backlash reduction can be made a way отпускания the holder of the bearing in right полукартере and pullings up on the same size of the left holder. For backlash increase release the bottom (left) holder and tighten on the same size top (right).
2. On a site of a contact stain the conclusion about correctness of selection of a package of adjusting linings of a leading gear wheel of the main transfer also can be made. In case of need make selection of a new package of linings.
3. Having finished check of correctness of position of gear wheels of the main transfer, remove lock plates, then turn out holders of bearings so that flutes under installation of a sealing ring have seemed. Establish in flutes of a sealing ring and again tighten holders in former positions according to the marks put earlier. Establish and tighten with demanded effort (22 27 Nanometers) lock plates. |
| 4. Pick up a back lock plate of fastening of a primary shaft in картере transmissions for what with the help колумбуса define size And выступания an external holder of the ball bearing from a wall картера РКПП and according to result of measurement pick up a lock plate (see the table). |
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Size And выступания the bearing, mm |
№ details (a lock plate) |
Marks |
| 4.00 - 4.13 |
32294AA040 |
1 |
| 3.87 - 3.99 |
32294AA050 |
2 |
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Before measurement slightly обстучите a hammer with soft brisk an end face of a primary shaft for the purpose of it усадки and backlash liquidations between a lock ring of the bearing and a box wall. |
Only boxes without a reducer
Establish a plug of deenergizing of coupling and выжимной the bearing.
Only 10-step boxes
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1. Establish a ball and a spring of a clamp of the switch of transfers of a divider. Screw and tighten заглушку, - do not forget to replace a sealing washer.
2. Establish the lever of a gear change of a divider on an axis of a plug and fix its spring pin (6х22), - track correctness of installation of the lever.
3. Establish the gauge-switch of a choice of lowering transfer of a divider.
4. Establish a plug of deenergizing of coupling and выжимной the bearing. |
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Service of assemblage of a secondary shaft and leading gear wheel of the main transfer
Models with constant (Full Time) a full drive
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At dismantling and assemblages for выпрессовывания and напрессовывания details use only a press complete with approaching оправками and strippers. Use of a hammer or other percussion instrument is categorically inadmissible! |
Design of assemblage of a secondary shaft with a leading gear wheel of the main transfer of models with a constant full drive
Dismantling
Otdavanie nuts of fastening of gear wheels of a secondary shaft
Order of removal of components of interaxal differential
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1. Расчеканьте a nut of fastening of assemblage of gear wheels of a secondary shaft. Using the holder and блокиратор give a nut.
2. Remove details of interaxal differential as their numbering. |
| 3. Press the roller bearing. |
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4. For the purpose of prevention of damage of components wrap up rags the end of a secondary shaft from outside the persistent bearing.
5. Расчеканьте also give a fixing nut (take advantage of the holder and a stopper). |
| 6. Press a conducted gear wheel of 5th transfer. |
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| 7. Remove segment шпонку. |
| 8. Press the roller bearing (42х74х40) and conducted gear wheels of 3rd and 4th transfers. |
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9. Remove assemblage of a conducted gear wheel of 2nd transfer.
10. Press a conducted gear wheel of 1st transfer, the plug of a gear wheel of 2nd transfer and a synchronizer nave.
11. In case of need replace a cogwheel (a conducted gear wheel of a reverse gear) and a synchronizer nave. Without special necessity do not assort the synchronizer, - if it is not possible to avoid dismantling, mark adjusting position of each of components. |
| 12. Remove демпферы conducted gear wheels of 1st and 2nd transfers. |
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Assemblage
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Secondary shaft |
Conducted gear wheel of 1st transfer |
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№ details |
Diameter And, mm |
№ details |
The note |
| 32229AA130 |
49.459 - 49.966 |
32231AA270 |
Models without a turbo-supercharging |
| 32229AA130 |
49.459 - 49.966 |
32231AA290 |
Models with a turbo-supercharging |
| 32229AA120 |
49.967 - 49.975 |
32231AA260 |
Models without a turbo-supercharging |
| 32229AA120 |
49.967 - 49.975 |
32231AA280 |
Models with a turbo-supercharging |
Assemblage of the synchronizer of 1/2 transfers
Landing to a secondary shaft of the block of conducted gear wheels of 3/4 transfers
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It is necessary to dissolve the ends of springs of synchronizers at an angle 120 . |
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| 1. Collect the synchronizer of 1/2 transfers. |
| 2. Make a selection of a conducted gear wheel of 1st transfer (see the table) from a condition of observance of a demanded radial backlash. |
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3. Establish on a secondary shaft a conducted gear wheel 1st transfers blocking rings of the synchronizer of 1/2 transfers and assemblage of the synchronizer. Track correctness of landing of the synchronizer!
4. With the help оправки and the press establish the plug of a conducted gear wheel of 2nd transfer, - a shaft pin preliminary wrap up an adhesive tape protective layer.
5. Establish on shaft assemblage a conducted gear wheel of 2nd transfer and blocking rings of the synchronizer of 1/2 transfers, - do not forget to plant preliminary on a shaft шпонку. By means of a press and оправки plant on a shaft the block of conducted gear wheels of 3/4 transfers.
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Track hit of sliding keys (crackers) of synchronizers in reception flutes of blocking rings |
6. Напрессуйте on a shaft the dual roller bearing (42х74х40).
7. Plant in проточку in a back pin of a secondary shaft segment шпонку, then напрессуйте a conducted gear wheel of 5th transfer.
8. Establish a lock washer (42х53х2). Screw a nut and tighten it with demanded effort (245 10 Nanometers). The tightened nut законтрите in two points кернением.
9. Check up effort of resistance of the roller bearing проворачиванию, - demanded value makes 0.1 1.5 Nanometers. |
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At installation of the roller bearing of a leading gear wheel of the main transfer track correctness of placing of an aperture under a lock pin
Connection to a leading gear wheel of the main transfer of assemblage of a secondary shaft
Order of landing of components on a pin of a secondary shaft
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1. Establish on a leading gear wheel of the main transfer the roller bearing, then with the help оправки напрессуйте a washer (33х50х5).
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Track correctness of an arrangement of an aperture under installation of a lock pin. |
2. Establish the persistent bearing (33х37х23) and the needle bearing (30х37х23). Connect to a leading gear wheel of the main transfer assemblage of a secondary shaft.
3. Plant on a pin of a secondary shaft the components listed on an illustration as their numbering. |
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Adjustment of a pretightness of persistent bearings
Adjustment of a pretightness of persistent bearings
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1. Pick up an adjusting washer №2 so that the size Н at visual check was nulled. Establish a washer (18.3х30х4), then - lock (18х30х2).
2. By means of the holder and блокиратора tighten a fixing nut with demanded effort (118 8 Nanometers).
3. If the effort of resistance проворачиванию does not correspond to rating value, pick up a new adjusting washer №1 (see the table) and repeat check.
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Adjusting washer № 1 |
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№ details |
Thickness, mm |
|
803025051
|
3.925
|
|
803025052
|
3.950
|
|
803025053
|
3.975
|
|
803025054
|
4.000
|
|
803025055
|
4.025
|
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803025056
|
4.050
|
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803025057
|
4.075
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If by selection of an adjusting washer №1 it is not possible to achieve demanded effort проворачиванию, be engaged in selection of an adjusting washer №2 (tables see) and again repeat check.
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The resistance moment |
The size Н |
Washer №2 |
| It is less than demanded |
It is less than demanded |
To pick up a washer большей thickness |
| It is more than demanded |
It is more than demanded |
To pick up a washer of a smaller thickness |
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Adjusting washer № 2 |
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№ details |
Thickness, mm |
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803025059
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3.850
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803025054
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4.000
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803025058
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4.150
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Having achieved demanded result on effort of resistance проворачиванию, законтрите a nut кернением in four points.
Models with a disconnected drive of back wheels
Design of assemblage of a secondary shaft with a leading gear wheel of the main transfer of models with a disconnected drive of back wheels
Dismantling
Otpuskanie nuts of fastening of components of a secondary shaft
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1. Расчеканьте, then by means of the special tool (a wrench and the holder) release a fixing nut.
2. By means of special strippers remove a holder of the needle bearing of a gear wheel of 5th transfer, the needle bearing and a leading gear wheel of intermediate transfer of a drive of back wheels.
3. Remove распорную the plug of a leading gear wheel.
4. By means of a special stripper remove a gear wheel of 5th transfer.
5. Take segment шпонку.
6. By means of a suitable stripper press the ball bearing and the block of conducted gear wheels of 3/4 transfers.
7. Remove a conducted gear wheel of 2nd transfer.
8. By means of a special stripper press a conducted gear wheel of 1st transfer, the sliding plug of a gear wheel of 2nd transfer and synchronizer assemblage. |
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Before removal of the plug of a gear wheel of 2nd transfer do not forget to remove шпонку. |
By means of a special stripper press the sliding plug of a gear wheel of 1st transfer, a persistent washer and the roller bearing (41х71х23).
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The removed roller bearing is subject to replacement without fail! |
Assemblage
Landing of the roller bearing to a shaft of a leading gear wheel of the main transfer
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External diameter the plug, mm |
Conducted gear wheel of 1st transfer |
| 41.983 - 41.996 |
32231AA320 |
| 41.968 - 41.982 |
32231AA330 |
| 41.954 - 41.967 |
32231AA340 |
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1. Make assemblage of the synchronizer of 1/2 transfers.
2. By means of two оправок напрессуйте on a shaft of a leading gear wheel of the main transfer the roller bearing.
3. By means of the same оправок напрессуйте the sliding plug of a gear wheel of 1st transfer.
4. Measure external diameter of the plug and according to result of measurement pick up a conducted gear wheel of 1st transfer (see the table).
5. Establish a gear wheel of 1st transfer, blocking ring and synchronizer assemblage, - track hit of crackers (sliding keys) in reception grooves of a blocking ring.
6. By means of two оправок напрессуйте the sliding plug of a gear wheel of 2nd transfer.
7. Establish blocking ring of the synchronizer, a gear wheel of 2nd transfer and шпонку, then напрессуйте on a shaft the block of conducted gear wheels of 3/4 transfers.
8. Establish the ball bearing (29х74х38).
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The probability is not excluded that the bearing will be put on a shaft freely, without application оправки. |
9. Plant segment шпонку (5х6.5х1.5) in a groove in back pins of a shaft of a leading gear wheel of the main transfer. By means of approaching оправки напрессуйте a conducted gear wheel of 5th transfer.
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Track, that the gear wheel of 5th transfer has appeared developed by the end face equipped with a flute back. |
10. Establish распорную the plug and a leading gear wheel of intermediate transfer of a drive of back wheels. By means of special оправки запрессуйте a holder of the needle bearing of a gear wheel of 5th transfer.
11. Establish the needle bearing and a lock washer.
12. Screw and tighten with demanded effort (112 124 Nanometers) a fixing nut. Законтрите a nut кернением in two points. |
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Service of assemblage of a leading gear wheel of a divider (РКПП with a reducer)
Design of a reducer of transfers and primary shaft РКПП with a reducer
Dismantling
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1. Remove lubricant knot from the holder of the bearing of a shaft of a leading gear wheel of a divider. Also remove adjusting linings of the holder (the quantity of linings can vary from 0 to 2).
2. Wind шлицы a shaft of a leading gear wheel with an adhesive tape protective layer.
3. By means of a stripper take from the holder a lock ring.
4. Having fixed the holder, accurately beat out a gear wheel of a divider blows of a hammer with soft brisk on an end face equipped шлицами shaft pins.
5. Remove a lock ring, a clamp of a leading shaft and a half ring.
6. By means of a press and a stripper dismantle the bearing (25х62х17). |
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Preliminary remove an internal lock ring. |
Assemblage
Installation of half rings, clamp and lock ring
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1. Plant the ball bearing (25х62х17) on a shaft of a leading gear wheel of a divider, - before installation fill the internal lock ring picked up in advance on a thickness in space between the bearing and a reducer gear wheel.
2. Establish on a half ring shaft, a clamp and a lock ring. |
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Half rings steal up on a thickness so that axial люфт the bearing made 0 0.08 mm (see the table). |
Half rings of a shaft of a leading gear wheel of a divider
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№ details |
Thickness, mm |
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35204АА000
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2.43
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35204АА010
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2.51
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35204АА020
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2.59
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1. Having greased консистентной with greasing of a sponge of an epiploon, plant it in the holder of the bearing of a shaft of a leading gear wheel.
2. Wind шлицы a leading shaft with an adhesive tape, manually (with effort) fill a shaft with напрессованным on it the bearing in the holder.
3. Plant in a flute of the holder of the bearing a lock ring. |
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The ring steals up on a thickness (see the table) so that axial люфт the bearing in the holder made 0 0.08 mm. |
Lock ring (external diameter of 62 mm)
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№ details |
Thickness, mm |
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805162011
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1.75
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805162012
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1.83
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805162013
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1.91
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Establish on the holder of the bearing a sealing ring and lubricant knot.
Service of assemblage of a primary shaft (all РКПП)
Design of primary shaft РКПП without a reducer
Dismantling
Only boxes without a reducer
Wind with an adhesive tape шлицы pins of a primary shaft, then remove an epiploon and the needle bearing.
All boxes
Otdavanie nuts of fastening of details of a primary shaft
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1. Расчеканьте also give a nut of fastening of details of a primary shaft.
2. Remove from a shaft a lock plate of crackers (sliding keys), a nave and муфту the synchronizer of 5th transfer, the blocking ring, a leading gear wheel of 5th transfer and the needle bearing.
3. By means of a special stripper remove an internal holder of the needle bearing, a persistent washer of a gear wheel of 5th transfer, the ball bearing (25.5х65х31), a persistent washer of a gear wheel of 4th transfer, a nave and муфту the synchronizer in a pine forest, blocking ring of the synchronizer, the needle bearing of a gear wheel of 4th transfer, the internal holder of the needle bearing conducting a gear wheel of 3rd transfer and a detail of the synchronizer of 3rd transfer. |
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In case of need replace муфту and a nave of the synchronizer with new assemblage. In case of need synchronizer dismantlings mark adjusting position of each of removed components. |
Only boxes with a reducer
Remove a lock ring in internal diameter of 25 mm from the forward end of a primary shaft, then remove the needle bearing (25х33х24) gear wheels of 3rd transfer, the prorate of a conducted gear wheel of lowering transfer of a divider and the needle bearing (27х46х21).
Assemblage
All boxes
Design of the synchronizer of a divider (РКПП with a reducer)
Assemblage of the synchronizer of 5th transfer
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1. Collect synchronizers of 3/4 and 5th transfers, and also the reducer synchronizer (on boxes with a reducer).
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On a face surface of a nave of the synchronizer of 3/4 transfers is available two маркировочных apertures, the synchronizer of 5th transfer - one. Having finished assemblage, dissolve springs of synchronizers with locks under 120 . |
2. Plant a primary shaft a leading gear wheel of 3rd transfers, blocking ring and assemblage of the synchronizer of 3/4 transfers, and also the needle bearing (32х36х25.7).
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Track hit of sliding keys (crackers) in reception flutes of a blocking ring. |
3. By means of approaching оправки plant a shaft a holder of the needle bearing of a leading gear wheel of 4th transfer.
4. Establish blocking ring of the synchronizer, the needle bearing (32х30х25.7), a leading gear wheel of 4th transfer and a persistent washer.
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Track, that the persistent washer has appeared is developed by flutes to a gear wheel. |
5. By means of approaching оправки напрессуйте the ball bearing on a back pin of a primary shaft.
6. By means of the same оправки plant on a shaft a persistent washer of a leading gear wheel of 5th transfer (flutes to a gear wheel), a holder of the needle bearing of a gear wheel of 5th transfer, the needle bearing (32х36х25.7), a leading gear wheel of 5th transfer, the synchronizer of 5th transfer, a lock plate of sliding keys (crackers) of the synchronizer and a washer (22х38х2).
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Track, that the uvula of a lock plate of crackers has entered into an aperture in diameter of 4 mm in a synchronizer nave. |
7. Screw a nut (22х13), tighten it with demanded effort (112 124 Nanometers) and законтрите кернением in two points. |
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Only boxes with a reducer
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1. Plant on the forward end of a primary shaft the needle bearing (27х46х21), a ball ( 3.9538 mm), the prorate of a gear wheel of lowering transfer of a divider (a flute in a lateral surface forward on a shaft), the needle bearing (25х33х24), a conducted gear wheel of lowering transfer of the divider, blocking ring of the synchronizer of a divider and actually synchronizer assemblage.
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At installation of the needle bearing try not to damage a step surface of a shaft! |
2. Plant on a primary shaft the NEW lock ring in internal diameter of 25 mm, - the ring steals up on a thickness (see the table) so that a backlash between it and a synchronizer nave made 0.060 0.1000 mm. |
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Lock ring in internal diameter of 25 mm
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№ details |
Thickness, mm |
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805025058
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2.37
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805025051
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2.42
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805025052
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2.47
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805025053
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2.52
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805025054
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2.57
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805025055
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2.62
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805025056
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2.67
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805025057
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2.72
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Service of assemblage of interaxal differential (model with a constant full drive)
Design of interaxal differential of models with a constant full drive
Dismantling
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1. Having hooked a screw-driver with a flat sting, remove a lock ring in external diameter of 110 mm.
2. Uncover differential.
3. Remove вязкостную муфту.
4. Remove needle bearings.
5. Remove an adjusting washer (45х62хt).
6. Remove an axis of satellites, satellites and persistent washers.
7. Remove a conic conducted gear wheel of differential.
8. Remove a persistent washer.
9. Выпрессуйте from a differential cover the ball bearing.
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The removed ball bearing is subject to replacement without fail! |
10. If be going to make replacement of the needle bearing, remove a washer вязкостной муфты, - the removed washer is subject to replacement without fail!
11. Remove the needle bearing (35х42х12). |
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Assemblage
Measurement of size axial люфта вязкостной муфты interaxal differential
Lock ring in external diameter of 110 mm
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№ details |
Thickness, mm |
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805100061
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2.10
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805100062
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2.21
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805100063
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2.32
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Adjusting washer (45х62хt)
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№ details |
Thickness, mm |
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803045041
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1.60
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803045042
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1.80
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803045043
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2.00
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803045044
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2.20
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803045045
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2.40
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1. Assemblage is made as it should be the return to an order of dismantle of components. At installation of the new needle bearing (35х42х12) запрессовывайте it together with a new washer вязкостной муфты by means of special оправки. Track, that the persistent washer of a conic conducted gear wheel of differential has appeared the developed internal facet to a gear wheel. An adjusting washer establish an internal facet to вязкостной муфте.
2. Having finished assemblage, take advantage probeом лезвийного type for measurement of size of a backlash between a lock ring in external diameter of 110 mm and a differential cover (axial люфт). If the result of measurement falls outside the limits an admissible range (0 0.15 mm), pick up new, corresponding on a thickness, a lock ring (see the table).
3. Having collected differential, fix on it циферблатный a measuring instrument плунжерного type and measure size axial люфта вязкостной муфты. If the result of measurement falls outside the limits an admissible range (0.62 0.86 mm), pick up a new adjusting washer of a corresponding thickness (see the table). |
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Service of assemblage of forward interwheel differential
Dismantling
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1. Remove spring lock rings and take two equipped шлицами a power shaft.
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At assemblage shaft should be established strictly on the former places, - put corresponding marks. |
2. Turn out 12 fixing bolts and remove гипоидную a gear wheel of the main transfer.
3. Beat out a pin of fastening of an axis of satellites in a flange direction гипоидной gear wheels.
4. Beat out an axis of satellites and take satellites, lateral gear wheels and washers.
5. By means of a stripper remove roller bearings. |
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Assemblage
Washers of lateral gear wheels of differential
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№ details |
Thickness, mm |
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803038021
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0.925 0.950
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803038022
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0.975 1.000
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803038023
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1.025 1.050
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1. Establish in a differential box lateral gear wheels with washers and satellites, then fill an axis of satellites.
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Washers are established by internal facets to lateral gear wheels. |
2. Rest плунжер циферблатного a measuring instrument against a tooth of the satellite and measure size of a backlash of gearing of satellites and lateral gear wheels. If the result of measurement falls outside the limits an admissible range (0.13 0.18 mm), pick up new, corresponding on a thickness, washers (see the table).
3. Achieve combination of apertures under a lock pin in an axis of satellites and a differential box. Begin to knock and законтрите a new pin.
4. Establish on a differential box roller bearings (40х80х19.75).
5. Establish conducted гипоидную a gear wheel of the main transfer, screw and tighten with demanded effort (57 67 Nanometers) twelve fixing bolts.
6. Establish two шлицевых a power shaft and fix from by means of lock rings. Measure backlash size between shaft and an axis of satellites, - if the result of measurement falls outside the limits an admissible range (0 0.2 mm), pick up new, a corresponding thickness, spring lock rings (see the table). |
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Spring lock rings
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№ details |
Thickness, mm |
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805028011
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1.05
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805028012
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1.20
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