Disassembly
1. Before removing parts from the input shaft, measure the axial clearance of the 5th gear drive gear (see section «Data for adjustments and control»). If it does not lie within the specified limits, disassemble the shaft and check the contact surfaces of the gear, shaft and synchronizer clutch hub. Then check the clearance between the retaining ring and the groove (see subsection «Assembly»).
2. Remove the circlip and 5th gear thrust washer.
3. Remove the 5th gear synchronizer, pinion gear and needle bearing using the tool.
4. Remove the input shaft front bearing snap ring and spacer ring.
5. Press the input shaft front bearing.
6. Remove the bearing holder.
Examination
Shaft with gears. Check for cracks, visible wear and bent shaft. The gear teeth must be free of chips, cracks and signs of wear.
Synchronizer. Check clutch splines, synchronizer hubs and gears for cracks or wear. Locking rings must not be worn or deformed. Also make sure that there is no wear or deformation of the crackers.
Measure the clearance between the blocking ring and the gear ring:
- Nominal clearance - 1.0-1.35 mm
- Maximum allowable - 0.7 mm
Bearings. Check that the bearings rotate freely, without abnormal noise, cracks, pitting and visible wear.
Assembly
1. Assemble the 5th gear synchronizer. Please note that the ends of the return springs must be hooked on different crackers.
2. Install the bearing holder.
3. Press the front bearing onto the input shaft using tool ST22350000.
4. Put on the distance ring.
5. Select and install the retaining ring that fits into the groove of the shaft with a gap of 0-0.1 mm. Available ring thicknesses are listed in section «Data for adjustments and control».
6. Install the 5th gear needle bearing, gear, synchronizer and thrust washer. Use tool ST37750000 to press on the synchronizer clutch hub.
7. Check gear end play (see subsection «Disassembly»).
8. Select and install the retaining ring that fits into the groove of the shaft with a gap of 0-0.1 mm. Available 5th gear synchronizer stop track thicknesses are listed in section «Data for adjustments and control».