Replacement of synchronizers

The operation to repair the synchronizers can be carried out on the gearbox mounted on the car.

■ Disengage the universal joint on the gear lever.

■ Unscrew the reverse light switch.

■ Unscrew and remove the cover of the internal gearshift.

■ Switch on 2. run.

■ Secure the rear wheels. apply the emergency brake and raise the front of the car.

■ Unscrew the screws on the main gear cover and drain the gear oil

■ Remove the plug on the rear cover of the gearbox housing and pull the main shaft out until it stops,

■ Remove the screws securing the rear cover to remove it from the housing

■ Pull out the cover with the bearings and with the main and drive shafts.

■ Use a suitable tool to knock out three hole plugs with guide pins from the cover.

■ From the fork 3. and 4. gear and reverse gear, knock out the expansion pins Remove the sliders and forks from the rear cover.

■ Remove the two snap rings from the rear cover that hold the main and drive shafts.

■ Pull the main rollers out of the same cover, driving, reverse gear and forks with sliders 1. and 2. running.

■ To dismantle the drive shaft, first remove the ball bearing under the press, a spacer and a toothed wheel 1. and 2. running, and then pull off the gear that drives the main gear, each time removing the securing ring. Remove the spacer and gear 4. running. Remove the synchronizer ring, and then squeeze out the synchronizer hub 3. and 4. gear and cogwheel 3. running.

■ Remove the needle roller bearings of the gears and press out the synchronizer hub.

■ The coiled bushing can only be replaced with the gearbox housing removed.

■ In the case of the final drive gear z 77 teeth, remove the main gear beforehand.

All removed parts should be cleaned and inspected. Worn out elements must be replaced.

Prepare new rings before assembling the gearbox, springs and wedges of synchronizers. All elements, as well as the synchronizer hubs and spacers are the same for both synchronizers. Lubricate moving parts in their seatings with gear oil. To fold the drive shaft, first insert the gear 3. gear and put the synchronizer ring on this wheel. Piastę synchronizatora 3/4 heat to 100JC and push it onto the shaft under the press. Install the locking ring. Slide the synchronizer ring and gear over the shaft 4. running. Heat the distance washer and the toothed wheel driving the main gear to 100 ° C and push it onto the shaft, and then secure with the snap ring. Then slide the gear onto the drive shaft 2. gear and synchronizer ring. Then press the synchronizer hub under the press 1 /2 running, heated to 100 C, and secure with a snap ring. Slide on the synchronizer ring and gear 1. running, heat the distance washer to 100 ° C and push it onto the shaft together with the ball bearing. Secure the whole thing with a snap ring. In order to install the rear cover with bearings, the main and drive shafts must be inserted into it, forks with sliders 1. and 2. gear and the reverse gear. Place the retaining rings on the main and drive shafts. Forks and sliders 2. and 4 and reverse gear with new dowels. Insert separately three dowel pins together with springs into the cover with bearings and knock in the plugs. Engage second gear with the help of the sliding sleeve. Using the right tool, press the coiled sleeve of the drive shaft bearing and the race of the needle bearing of the main shaft into the gearbox housing. Carefully insert the complete rear cover into the gearbox housing and fasten it with screws, tightening them with the appropriate torque. Follow the steps in the reverse order to that described at the beginning. By screwing in the rear cover cap properly, adjust the position of the main shaft and the gearshift mechanism. Fill the box with oil up to the lower edge of the inspection hole.