3.2.2. Removal and installation

Removal.
Install the car on the elevator or a viewing ditch. Lift a cowl of the engine and record it in this situation.
The works on removal which are carried out from within an engine compartment:
– disconnect wires from the rechargeable battery, from the traction relay of a starter;
– disconnect a wire of "weight" from a coupling case;
– disconnect the lower part of a cable of the drive of coupling as it is described in subsection. "Coupling";
– turn off two top bolts of fastening of a case of coupling to the block of the engine and two top nuts of fastening of a starter, fix on the left hairpin of fastening of a final collector of the engine a bracket for raising of the power unit;

Fig. 3.10. Installation of a cross-piece for maintenance of the power unit: 1 – cross-piece 67.7820.9514

– establish on water waste fillets a cross-piece of 67.7820.9514 (fig. 3.10) for maintenance of the engine and hook on it a hook for the bracket established on a hairpin of a final collector. In the absence of a cross-piece you will hang out the power unit a waist.
The works on removal which are carried out from below the car:
– remove a mudguard of the engine and the lower cover of a case of coupling;
– merge oil from the transmission;
– disconnect wires from the backing light switch;

Fig. 3.11. Fastening of the transmission on the car: 1 – engine; 2 – arm of fastening of the power unit; 3 – suspension bracket lever extension arm; 4 – extension; 5 – transmission; 6 – wheel drive shaft; 7 – suspension bracket lever; 8 – stabilizer of cross stability; 9 – back support of the power unit; 10 – collar; 11 – draft of the drive of the lever of gear shifting; 12 – case of the internal hinge

– weaken a collar of 10 (fig. 3.11) and disconnect draft 11 from the hinge of a rod of the choice of transfers;
– turn off a nut of a hairpin of fastening of the transmission to the engine;
– disconnect spherical hinges of levers of a suspension bracket from rotary fists;
– using a stripper 67.7801.9524 or having sharply struck the case 12 of the internal hinge with the hammer through a drift, beat out one hinge from a semi-axial gear wheel, then record a semi-axial gear wheel the technological mandrel or a cap applied when transporting differential (otherwise the unrecorded semi-axial gear wheel can drop out in a transmission case); then beat out the second hinge;
– take shaft of drives of wheels to the parties;

       NOTE
In case of difficulties in separation of the drive of a wheel with a semi-axial gear wheel on the car remove the transmission assembled with the drive of a wheel and on a workbench, using the same stripper, a vypressuyta the hinge from a semi-axial gear wheel.

– turn off on the left side three nuts of hairpins of fastening of the transmission to an arm 2 (see fig. 3.11) suspension brackets of the power unit, and then a nut from a bolt of fastening of the arm. Having removed an arm from transmission hairpins, take out an arm 2 suspension brackets from body longeron eyes;
– turn off bolts of fastening of a back support 9 of a suspension bracket of the power unit;
– turn off the lower nut of fastening of a starter and remove it;
– establish under the transmission a special support with the hydraulic elevator;
– slightly lower the engine, having extended the supporting draft of a cross-piece or having lowered таль, turn off the lower bolt of fastening of a case to the block of the engine and displace from the engine the transmission assembled with a coupling case to separate a shaft of the transmission and the conducted clutch plate;
– remove the transmission.

       PREVENTION
At removal or installation of the transmission not to an opirayta a main shaft of a box on petals of a press spring not to damage them.

You carry out installation of the transmission as it should be, the return to removal, tightening bolts and nuts the moments specified in the appendix 1 taking into account the following:
– before connection of shaft of drives of wheels with semi-axial gear wheels replace lock rings on internal hinges new as at installation of old rings perhaps spontaneous separation of drives of wheels and semi-axial gear wheels at the movement of the car;

Fig. 3.7. Transmission: 1 – coupling switching off bearing; 2 – the directing plug; 3 – main shaft; 4 – roller bearing of a secondary shaft; 5 – secondary shaft; 6 – lock ring; 7 – axis of satellites; 8 – leading gear wheel of the drive of a speedometer; 9 – the cap is transport; 10 – wheel drive epiploon; 11 – roller conic bearing of differential; 12 – half shaft gear wheel; 13 – satellite; 14 – differential box; 15 – coupling case; 16 – the conducted gear wheel of the main transfer; 17 – stopper of a drain opening; 18 – adjusting ring; 19 – the conducted gear wheel of the I transfer of a secondary shaft; 20 – transfer synchronizer I and II assembled; 21 – the conducted gear wheel of the II transfer of a secondary shaft; 22 – lock ring; 23 – persistent half ring; 24 – the conducted gear wheel of the III transfer of a secondary shaft; 25 – transfer synchronizer III and IV assembled; 26 – the conducted gear wheel of the IV transfer of a secondary shaft; 27 – needle bearing of gear wheels of a secondary shaft; 28 – ball bearing of a secondary shaft; 29 – persistent plate; 30 – the conducted gear wheel of the V transfer of a secondary shaft; 31 – transfer synchronizer V assembled; 32 – nut; 33 – persistent washer; 34 – leading gear wheel of the V transfer of a main shaft; 35 – back cover of a case of the transmission; 36 – ball bearing of a main shaft; 37 – transmission case; 38 – roller bearing of a main shaft; 39 – сапун; 40 – epiploon of a main shaft

Fig. 3.3. Centering of the conducted disk: 1 – flywheel; 2 – coupling assembled; 3 – mandrel And. 70081

– before installation of the transmission apply a thin film of SHRUS-4 lubricant on the external surface of the directing plug 2 (see fig. 3.7) coupling switching off bearing couplings. If necessary center the conducted clutch plate a mandrel And. 70081 (see fig. 3.3).
After installation of the transmission adjust a full speed of a pedal of coupling (see subsection. "Coupling") and the drive of control of the gear shifting mechanism in the following order:

Fig. 3.8. Gear shifting drive: 1 – transmission case; 2 – case of the mechanism of the choice of transfers; 3 – mechanism of the choice of transfers; 4 – coupling case; 5 – rod lever; 6 – rod of the choice of transfers; 7 – rod hinge; 8 – draft of the drive of management of the transmission; 9 – protective cover of draft; 10 – gear shifting lever; 11 – spherical finger of the lever; 12 – spherical support of the lever; 13 – collar; X — distance between end faces of a collar and draft

– working from below the car, at the weakened coupling bolt of a collar 13 (see fig. 3.8) drafts 8 establish a rod 6 in neutral situation;
– install the lever 10 in necessary situation by adaptation 67.7800.9513;
– working from below the car choose an axial side play in the direction back, influencing the hinge 7 and an angular side play in the direction against the course of an hour hand, tighten a nut of a coupling collar 13, previously having established it at distance of X =1–3 mm. You make the choice of side plays the easy movement not to cause movements of levers of the mechanism of the choice in the transmission. Then fill in oil in the transmission.
At connection of the drive of gear shifting with the transmission you watch that there was no retwist or deformation a corrugation of a protective cover of the hinge 7.