Subaru Forester
+ Subaru Forester cars
+ Maintenance instruction
+ Routine maintenance
+ Engine
+ Cooling systems, heating
+ Power supply system and release
+ Engine electric equipment
+ Control systems of the engine
- Gear shifting box
- 5-staged manual box of gear shifting (MBGS)
General information
Removal and installation of a box of gear shifting
Preparation for performance of repair work on restoration of RKPP
Dismantling and assembly of the transfer case, service of components
Capital repairs of RKPP of all-wheel drive models
Service of the drive of gear shifting
Service of the lever of switching of the transfer case
+ 4-staged automatic transmission (AT)
+ Coupling, transmission line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
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Capital repairs of RKPP of all-wheel drive models
Dismantling
Division of semi-cases
Gear shifting mechanism design
Design of 5-staged RKPP
Design of 5-staged RKPP with a reducer
All boxes
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1. Remove the release bearing and a fork of switching off 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 the leading gear wheel of a reducer.
2. By means of suitable a small beard beat out a spring pin of fastening of the lever of switching of a divider. |
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At knocking-out of a pin you watch that it did not rest against RKPP case wall. |
All boxes
Remove a persistent flange of a main shaft.
Only boxes with a reducer
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1. Turn out a cap and take a spring and a ball of a clamp of gear shifting of a reducer.
2. Turn out the sensor switch of activation of the lowering transfer of a reducer. |
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All boxes
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1. Wind with an adhesive tape of a vent of power shafts.
2. Having given 17 coupling bolted couples, divide RKPP case into two half, - on boxes with a reducer try not to damage a divider switch axis epiploon in the right semi-case!
3. Take assembly of a secondary shaft from the left semi-case, - in case of need use the hammer handle for extraction of a shaft. |
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Only boxes with a reducer
Slightly raise assembly of a main shaft with the leading gear wheel of a divider and remove a fork of gear shifting of a reducer together with an axis and a washer, - try not to drop two crackers of a fork in a case!
All boxes
Take assembly of a main shaft.
Only boxes with a reducer
Extraction of a main shaft assembled with the leading gear wheel of a reducer (only RKPP with a reducer)
Take a main shaft assembled with the 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 allow soskakivaniye of the blocking reducer synchronizer rings.
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 fork of inclusion of the 5th transfer.
3. Turn out caps, remove springs and balls of clamps.
4. Beat out a spring pin and take a rod of a fork of switching of 3/4 transfers.
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At extraction of one rod hold the others in neutral situation. Spring pins should be beaten out in a case and so that not to allow damage of the last. |
5. Remove a lock ring and remove a tip from a rod of inclusion of transfer of a backing. Take a spring and a ball of a clamp from a rod, remove the blocking plunger. Take a rod.
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At removal of a tip you watch that the ball did not fall out of it. |
6. Take a yoke of inclusion of transfer of a backing.
7. On the models equipped with a turbo-supercharging remove the sensor of speed of the movement VSS 2. |
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Dismantling of the right semi-case
Only boxes with a reducer
Dismantling of a divider of transfers of RKPP with a reducer
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| 1. Put forward it is greatest possible an axis of the block of gear wheels of a reducer forward 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 a pin from an axis. |
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| 3. Release 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 the blocks of gear wheels, persistent washers, two needle bearings and the expansion plug put on an axis! |
All boxes
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1. Remove a blooming ring and the conducted speedometer drive gear wheel. Remove a washer from a power shaft of a speedometer.
2. Remove the holder of the bearing of differential. |
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Assembly
Assembly of the right semi-case
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 RKPP case wall! |
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1. Put a sealing ring on an axis of the block of gear wheels of a divider, fill a pin.
2. Fill an axis of the block of gear wheels, two persistent washers, two needle bearings, the block of gear wheels of a divider in the right semi-case. Establish pins and a spring lock ring. |
| 3. Achieve the provision 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. Put a spring lock ring with an internal diameter of 19 mm on an axis and measure gap size between this ring and a persistent washer of the block. If the result of measurement exceeds the limit of the required range (0.05 ÷ of 0.35 mm), make selection of a new lock ring. Lock rings of two standard sizes are issued: No. 031319000, 1.50 mm thick and No. 805019010, 1.72 mm thick.
5. Put a washer on a speedometer drive shaft, then press a new epiploon by means of the special tool (if old was removed).
6. Establish the conducted gear wheel of the drive of a speedometer and a blooming lock ring. |
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Assembly of the left semi-case
All boxes
Details of assembly of the left semi-case
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The axis of an intermediate gear wheel should be filled from the back party of a case. On the models equipped with a turbo-supercharging, the additional washer is established also ahead of an intermediate gear wheel. |
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1. Establish a spring, a ball and the blocking plunger (5.56х19.6) in a tip of a rod of a fork of inclusion of transfer of a backing. Pass a rod throughout an opening of a tip and record by means of a blooming lock ring, - try not to allow losses of a ball from a rod opening.
2. Establish a ball (Ø 7.1438) and a spring in a nest of the left semi-case opposite to a rod of inclusion of transfer of a backing. Screw and tighten a cap, - do not forget to replace a sealing washer.
3. Move a rod of inclusion of transfer of a backing to situation "Backing" and adjust the provision of an intermediate gear wheel by selection of the coulisse of turning on of the reverse gear for gap size between a gear wheel and a wall of a case. |
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The scenes of three standard sizes are issued:
Coulisse of turning on of the reverse gear
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detail No. |
Marking |
Note |
| 32820AA000 |
0 |
The increased gap |
| 32820AA010 |
- |
Standard size |
| 32820AA020 |
2 |
The reduced gap |
After selection of the coulisse include neutral transfer and adjust gap size between an intermediate gear wheel and an opposite wall of a case by selection of a washer:
Washer
|
detail No. |
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 fork of switching of 1/2 transfers, having passed it throughout an opening in a back wall of a case of RKPP. Achieve combination of fixing openings and by means of a pin (6х22) record a fork on a rod. Remark: Other rods are transferred to neutral situation. Make sure that the blocking plunger is displaced in the opening a rod of switching of 3/4 transfers aside.
2. Previously having greased with jellied lubricant, fill the blocking plunger in an opening of a rod of a fork of switching of 3/4 transfers. Fill a rod in a fork, having passed it throughout an opening in a back wall of a case. Achieve combination of fixing openings and record a fork a pin (6х22).
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Establish a rod of a fork of turning on of the reverse gear in neutral situation. Track that the blocking plunger was displaced towards a rod of inclusion of transfer of a backing. |
3. Put a fork of inclusion of the 5th transfer on the back end of a rod of inclusion of transfer of a backing and fasten details with a pin.
4. Establish balls (Ø 7.1438) and springs of a clamp in nests of boring under rods of switching of 3/4 and 1/2 transfers and wrap caps, - do not forget to replace sealing washers. |
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Boxes without reducer
Establish a washer and a shaft of the drive of a speedometer, then press a new epiploon. Establish the conducted gear wheel of the drive of a speedometer and a lock ring. If the VSS 2 sensor was removed, install it on the place (only to model with a turbo-supercharging).
Joint of semi-cases
Only boxes with a reducer
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Pick up adjusting laying of the holder of the bearing of the leading gear wheel of a divider: connect assembly of a main shaft to the leading gear wheel. The necessary number of laying can be calculated on a formula: D = And - (In + C), where: А: total length of a case (353 mm); В: Length of the leading gear wheel of a divider with the bearing; С: Length assembly of a main shaft. |
On the basis of results of the carried-out calculation define the required number of laying:
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Size D, mm |
Number of laying |
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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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Laying thickness:
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0.45 ÷ 0.55 mm
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All boxes
Identifikatsionay marking of the leader and the main transfer conducted gear wheels
Preparation for adjustment of provision of the leading gear wheel of the main transfer
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1. Check the conducting and conducted gear wheels of the main transfer for marking existence. The top number at an end face of the leading gear wheel has to correspond to the marking applied on the forming surface of the conducted gear wheel, is more gentle - serves for selection of adjusting laying when debugging gearing of gear wheels. If the lower marking is absent, therefore laying is not required.
2. Lay assembly of a secondary shaft in the right semi-case of RKPP without laying and tighten bolts of fastening of the back bearing.
3. Check and adjust the provision of a calibration scale, - at hit of a scale in one plane with a plate the index has to be on a mark 0.5.
4. Having achieved the required result, tighten two bolts.
5. Establish caliber, having filled his finger in a transmission case opening.
6. Advance a calibration scale along a plate and, at combination with an end face of the leading gear wheel, consider the indication of a scale.
7. Thickness of a package of adjusting laying is defined by summation of the value which is beaten out at an end face of the leading gear wheel - the lower tag, - and indications of a measuring scale of caliber.
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If the lower tag has the sign "+", value of the amendment needs to be added to indications of caliber if "-", to take away. |
8. Pick up from one to three laying (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 laying
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detail No. |
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 assembly of forward differential in the left semi-case of the transmission.
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In order to avoid damage of working edges of an epiploon at assembly wrap up vents of power shafts an adhesive tape. |
Boxes without reducer
Landing of an epiploon of a main shaft to a forward wall of a semi-case
Install the needle bearing and an epiploon on a forward pin of a main shaft, then fill assembly of a shaft in the left semi-case of RKPP.
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Also wrap up shaft vents a protective layer of an adhesive tape. Establish an epiploon so that its back part rested against an edge And nests in the left semi-case. Do not forget to grease sealing sponges of an epiploon. Track that the fixing pin was established in an opening 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 the leading gear wheel of a divider do not forget to establish the laying which is picked up in advance. |
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1. Make assembly of a main shaft with the needle bearing, the synchronizer of a divider of transfers, lubricant knot and the leading gear wheel of a divider.
2. Install a fork of gear shifting of a divider with two crackers on the synchronizer coupling.
3. Slightly raise assembly of a main shaft and develop it on 90 ° concerning the transmission. Holding a shaft in such situation, fill a fork axis in an opening of the left semi-case. Establish on a washer fork axis. |
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Try not to allow sliding of the leading gear wheel of a divider from assembly of a main shaft. Track that the lubricant knot was established in a flute of the left semi-case, and the fixing pin - in an opening of the needle bearing. Oil nylon tips of a fork gearbox. Develop a cutting lock ring of the bearing on a back pin of a main shaft the lock to assembly of a secondary shaft. |
All boxes
Adjustment of provision of components 1/2 of transfer
Adjustment of provision of components 3/4 of transfer
Adjustment of provision of components 1/2 of transfer
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1. Establish assembly of a secondary shaft with the package of adjusting laying which is picked up in advance in a transmission case. Make sure that the fixing pin got to an opening of an external holder of the bearing.
2. Pick up forks of switching of the 1/2, 3/4 and 5 transfers (see tables) so that couplings of synchronizers and the conducted gear wheel of the reverse gear settled down on the center of synchronizers. |
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Fork of switching of 1/2 transfers |
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detail No. |
Marking |
Note |
| 32804AA060 |
1
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Shifts the coupling on 0.2 mm to a gear wheel of the 1st transfer |
| 32804AA070 |
-
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Does not change position of the coupling |
| 32804AA080 |
3
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Shifts the coupling on 0.2 mm to a gear wheel of the 2nd transfer |
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Fork of switching of 3/4 transfers |
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detail No. |
Marking |
Note |
| 32810AA060 |
1
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Shifts the coupling on 0.2 mm to a gear wheel of the 4th transfer |
| 32810AA070 |
-
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Does not change position of the coupling |
| 32810AA080 |
3
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Shifts the coupling on 0.2 mm to a gear wheel of the 3rd transfer |
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Fork of switching of the 5th transfer |
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detail No. |
Marking |
Note |
| 32812AA060 |
1
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Shifts the coupling on 0.2 mm to a gear wheel of the 5th transfer |
| 32812AA070 |
-
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Does not change position of the coupling |
| 32812AA080 |
3
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Shifts the coupling on 0.2 mm from a gear wheel of the 5th transfer |
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Measure sizes of gaps And yes In between tips of rods. If any of gaps exceeds the limit of the allowed range (see the table), replace the corresponding rod or a fork. |
Gap And between tips of rods of forks of 1/2 and 3/4 transfers
0.5 ÷ 1.5 mm
Gap In between tips of rods of forks of the 3/4 and 5 transfers
0.6 ÷ 1.4 mm
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Carefully wipe with solvent the interfaced surfaces, impose a sealant pillow like Tree-bond 1215 and connect to honey yourself RKPP semi-cases. Establish 17 coupling bolts and in strictly certain order tighten their nuts with the required effort (M8 bolts: 23 ÷ 26 Nanometers; M10 bolts: 36 ÷ 42 Nanometers). |
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Bolts are inserted from below, nuts well up from above. At a joint of semi-cases you watch that adjusting laying of the bearing of a secondary shaft and the holder of a main shaft were not jammed. |
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1. Make sure that the conducting and conducted gear wheels of the drive of a speedometer entered gearings and that the lever of switching of a straight line and lowering transfers of a divider (a box with a reducer) are installed 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 the leading gear wheel of a divider.
All boxes
Adjust the provision of the 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 a provorachivaniye is made by means of the special tool. |
Adjustment of provision of gear wheels of the main transfer and pretightness of bearings of gear wheels
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1. Install the transmission by the left semi-case down and press a cover of the top bearing special freight.
2. By means of a special key attract the holder of the bearing of differential from below to the left semi-case. Put on the special handle vents of a main shaft. Include the 4th or 5th transfer and several times turn a main shaft. Begin to tighten the holder's nut until you feel the easy resistance to rotation of the handle that is a sign of an entrance of gear wheels to gearing. For a guarantee of correctness of an entrance to gearing of the leader and the main transfer conducted gear wheels repeat the described procedure several times.
3. Uncover the freight pressing the bearing and turn the holder of the bearing in the top (right) semi-case of a box without sealing ring before emergence of easy resistance to tightening.
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Gap size in gipoidny gearing of gear wheels of the main transfer is equal in this position of the holder to zero. |
4. Establish a lock plate of the holder of the bearing. For the purpose of receiving the required gap turn off the holder of the lower (left) bearing on 1.5 teeth of a lock plate and at the same size hold on the holder of the top bearing.
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The turning of a lock plate leads to shift 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 lower lock plates and mark position of both holders and their plates.
7. Turning a main shaft slightly tap the hammer with soft brisk a case around holders of bearings, - the obstukivaniye with a provorachivaniye should be made for some time.
8. By means of a magnetic bed fix the dial measuring instrument of plunger type on RKPP case. Pass a plunger of the measuring instrument through an opening for discharge of oil and rest it against the surface of tooth of the conducted gear wheel of the main transfer at right angle. Check the size of a gap of gearing of gear wheels, - if the result of measurement exceeds the limit of the admissible range (0.13 ÷ of 0.18 mm), make the corresponding adjustment by rotation of the holder of the bearing of differential in the right semi-case.
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The turn of the holder on 1/2 turns leads to change of a gap approximately on 0:04 mm. |
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Gearing of gear wheels of the main transfer is adjusted truly
The gap of gearing of gear wheels is too big
The gap of gearing of gear wheels is too small
Thickness of a package of adjusting laying of the leading gear wheel is excessive
Thickness of a package of laying is insufficient
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1. For check of correctness of gearing of gear wheels of the main transfer apply a continuous layer of lead minium on forward and back surfaces of three-four teeths of the conducted gear wheel. Rotate a main shaft back and forth until on both surfaces of teeths the trace of a contact spot accurately does not imprint. Under the provision of a contact spot the conclusion about correctness of gearing of gear wheels can be made. In case of need make the corresponding adjustment. Reduction of a gap can be made by an otpuskaniye of the holder of the bearing in the right semi-case and pullings up at the same size of the left holder. For increase in a gap release the lower (left) holder and tighten top (right) at the same size.
2. On location of a contact spot the conclusion about correctness of selection of a package of adjusting laying of the leading gear wheel of the main transfer can be also made. In case of need make selection of a new package of laying.
3. Having finished check of correctness of provision 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 seemed. Establish in flutes of a sealing ring and again tighten holders in former provisions according to the marking put earlier. Establish and tighten lock plates with the required effort (22 ÷ 27 Nanometers). |
| 4. Pick up a back lock plate of fastening of a main shaft in a transmission case for what by Columbus determine the size A of a vystupaniye of an external holder of the ball bearing from a wall of a case of RKPP and according to result of measurement pick up a lock plate (see the table). |
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Size A of a vystupaniye of the bearing, mm |
detail No. (lock plate) |
Marking |
| 4.00 - 4.13 |
32294AA040 |
1 |
| 3.87 - 3.99 |
32294AA050 |
2 |
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Before measurement slightly tap the hammer with soft brisk an end face of a main shaft for the purpose of its shrinkage and elimination of a gap between a lock ring of the bearing and a wall of a box. |
Only boxes without reducer
Establish a fork of switching off of coupling and the release bearing.
Only 10-staged 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 a cap, - do not forget to replace a sealing washer.
2. Install the lever of gear shifting of a divider on an axis of a fork and fix it by a spring pin (6х22), - track correctness of installation of the lever.
3. Install the sensor switch of the choice of the lowering transfer of a divider.
4. Establish a fork of switching off of coupling and the release bearing. |
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Service of assembly of a secondary shaft and leading gear wheel of the main transfer
Models with constant (Full Time) the four-wheel drive
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When dismantling and assemblies for a vypressovyvaniye and a napressovyvaniye of details use only a press complete with suitable mandrels and strippers. Use of the hammer or other percussion instrument is categorically inadmissible! |
Design of assembly of a secondary shaft with the leading gear wheel of the main transfer of models with the constant four-wheel drive
Dismantling
Otdavany nuts of fastening of gear wheels of a secondary shaft
Order of removal of components of interaxal differential
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1. Raschekante nut of fastening of assembly of gear wheels of a secondary shaft. Using the holder and the lock 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 the persistent bearing.
5. Also give to Raschekanta a fixing nut (use the holder and a stopper). |
| 6. Press the conducted gear wheel of the 5th transfer. |
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| 7. Remove a segment spline. |
| 8. Press the roller bearing (42х74х40) and the conducted gear wheels of the 3rd and 4th transfers. |
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9. Remove assembly of the conducted gear wheel of the 2nd transfer.
10. Press the conducted gear wheel of the 1st transfer, the plug of a gear wheel of the 2nd transfer and a nave of the synchronizer.
11. In case of need replace a cogwheel (the conducted gear wheel of the reverse gear) and a synchronizer nave. Without special need do not disassemble the synchronizer, - if dismantling does not manage to be avoided, mark the adjusting provision of each of components. |
| 12. Remove dampers of the conducted gear wheels of the 1st and 2nd transfers. |
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Assembly
|
Secondary shaft |
The conducted gear wheel of the 1st transfer |
|
detail No. |
Diameter And, mm |
detail No. |
Note |
| 32229AA130 |
49.459 - 49.966 |
32231AA270 |
Models without turbo-supercharging |
| 32229AA130 |
49.459 - 49.966 |
32231AA290 |
Models with a turbo-supercharging |
| 32229AA120 |
49.967 - 49.975 |
32231AA260 |
Models without turbo-supercharging |
| 32229AA120 |
49.967 - 49.975 |
32231AA280 |
Models with a turbo-supercharging |
Assembly of the synchronizer 1/2 of transfers
Landing to a secondary shaft of the block of the conducted gear wheels of 3/4 transfers
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The ends of springs of synchronizers should be parted at an angle 120 °. |
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| 1. Collect the transfer synchronizer 1/2. |
| 2. Make a selection of the conducted gear wheel of the 1st transfer (see the table) from a condition of observance of the required radial gap. |
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3. Establish the conducted gear wheel of the 1st transfer, the blocking rings of the synchronizer 1/2 of transfers and assembly of the synchronizer on a secondary shaft. Track correctness of landing of the synchronizer!
4. By means of a mandrel and a press install the plug of the conducted gear wheel of the 2nd transfer, - previously wrap up a shaft pin a protective layer of an adhesive tape.
5. Establish the conducted gear wheel of the 2nd transfer and the blocking rings of the synchronizer 1/2 of transfers on assembly of a shaft, - do not forget to put previously on a shaft a spline. By means of a press and a mandrel put the block of the conducted gear wheels of 3/4 transfers on a shaft.
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Track hit of the sliding keys (crackers) of synchronizers in reception flutes of the blocking rings |
6. Napressuyte on a shaft the dual roller bearing (42х74х40).
7. Put in a pro-point in a back pin of a secondary shaft a segment spline, then a napressuyta the conducted gear wheel of the 5th transfer.
8. Establish a lock washer (42х53х2). Screw a nut and tighten it with the required effort (245 ± 10 Nanometers). You zakontrit the tightened nut in two points a kerneniye.
9. Check effort of resistance of the roller bearing to a provorachivaniye, - the required value makes 0.1 ÷ 1.5 Nanometers. |
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At installation of the roller bearing of the leading gear wheel of the main transfer track correctness of placement of an opening under a lock pin
Connection to the leading gear wheel of the main transfer of assembly of a secondary shaft
Order of landing of components to a pin of a secondary shaft
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1. Install on the leading gear wheel of the main transfer the roller bearing, then by means of a mandrel to a napressuyta a washer (33х50х5).
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Track correctness of an arrangement of an opening under installation of a lock pin. |
2. Install the persistent bearing (33х37х23) and the needle bearing (30х37х23). Connect assembly of a secondary shaft to the leading gear wheel of the main transfer.
3. Put 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 No. 2 so that the size N at visual check was nullified. Establish a washer (18.3х30х4), then - lock (18х30х2).
2. By means of the holder and the lock tighten a fixing nut with the required effort (118 ± 8 Nanometers).
3. If the effort of resistance to a provorachivaniye does not correspond to nominal rate, pick up a new adjusting washer No. 1 (see the table) and repeat check.
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Adjusting washer No. 1 |
|
detail No. |
Thickness, mm |
|
803025051
|
3.925
|
|
803025052
|
3.950
|
|
803025053
|
3.975
|
|
803025054
|
4.000
|
|
803025055
|
4.025
|
|
803025056
|
4.050
|
|
803025057
|
4.075
|
If by selection of an adjusting washer No. 1 the provorachivaniye does not manage to achieve the required effort, be engaged in selection of an adjusting washer No. 2 (see tables) and again repeat check.
|
Resistance moment |
Size N |
Washer No. 2 |
| It is less than demanded |
It is less than demanded |
To pick up a washer of bigger thickness |
| It is more than demanded |
It is more than demanded |
To pick up a washer of smaller thickness |
|
Adjusting washer No. 2 |
|
detail No. |
Thickness, mm |
|
803025059
|
3.850
|
|
803025054
|
4.000
|
|
803025058
|
4.150
|
Having achieved the required result on effort of resistance to a provorachivaniye, you zakontrit a nut a kerneniye in four points.
Models with the switched-off drive of back wheels
Design of assembly of a secondary shaft with the leading gear wheel of the main transfer of models with the switched-off drive of back wheels
Dismantling
Otpuskany nuts of fastening of components of a secondary shaft
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1. Raschekante, 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 the 5th transfer, the needle bearing and the leading gear wheel of intermediate transfer of the drive of back wheels.
3. Remove the expansion plug of the leading gear wheel.
4. By means of a special stripper remove a gear wheel of the 5th transfer.
5. Take a segment spline.
6. By means of a suitable stripper press the ball bearing and the block of the conducted gear wheels of 3/4 transfers.
7. Remove the conducted gear wheel of the 2nd transfer.
8. By means of a special stripper press the conducted gear wheel of the 1st transfer, the sliding plug of a gear wheel of the 2nd transfer and assembly of the synchronizer. |
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Before removal of the plug of a gear wheel of the 2nd transfer do not forget to remove a spline. |
By means of a special stripper press the sliding plug of a gear wheel of the 1st transfer, a persistent washer and the roller bearing (41х71х23).
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The removed roller bearing is subject to replacement without fail! |
Assembly
Landing of the roller bearing to a shaft of the leading gear wheel of the main transfer
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Outer diameter plug, mm |
The conducted gear wheel of the 1st transfer |
| 41.983 - 41.996 |
32231AA320 |
| 41.968 - 41.982 |
32231AA330 |
| 41.954 - 41.967 |
32231AA340 |
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1. Make assembly of the synchronizer 1/2 of transfers.
2. By means of two mandrels to a napressuyta on a shaft of the leading gear wheel of the main transfer the roller bearing.
3. By means of the same mandrels to a napressuyta the sliding plug of a gear wheel of the 1st transfer.
4. Measure the outer diameter of the plug and according to result of measurement pick up the conducted gear wheel of the 1st transfer (see the table).
5. Establish a gear wheel of the 1st transfer, the blocking ring and assembly of the synchronizer, - track hit of crackers (the sliding keys) in reception grooves of the blocking ring.
6. By means of two mandrels to a napressuyta the sliding plug of a gear wheel of the 2nd transfer.
7. Establish the blocking synchronizer ring, a gear wheel of the 2nd transfer and a spline, then a napressuyta on a shaft the block of the conducted gear wheels of 3/4 transfers.
8. Install 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 of a mandrel. |
9. Put a segment spline (5х6.5х1.5) in a groove in back pins of a shaft of the leading gear wheel of the main transfer. By means of a suitable mandrel to a napressuyta the conducted gear wheel of the 5th transfer.
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Track that the gear wheel of the 5th transfer was the developed end face equipped with a flute back. |
10. Install the expansion plug and the leading gear wheel of intermediate transfer of the drive of back wheels. By means of a special mandrel press a holder of the needle bearing of a gear wheel of the 5th transfer.
11. Install the needle bearing and a lock washer.
12. Screw and tighten a fixing nut with the required effort (112 ÷ 124 Nanometers). Zakontrite a nut a kerneniye in two points. |
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Service of assembly of the leading gear wheel of a divider (RKPP with a reducer)
Design of a reducer of transfers and main shaft RKPP with a reducer
Dismantling
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1. Remove lubricant knot from the holder of the bearing of a shaft of the leading gear wheel of a divider. Also remove adjusting laying of the holder (the number of laying can vary from 0 to 2).
2. Wind vents of a shaft of the leading gear wheel with a protective layer of an adhesive tape.
3. By means of a stripper take a lock ring from the holder.
4. Having recorded the holder, accurately beat out a divider gear wheel blows of the hammer with soft brisk on an end face of the shaft pin equipped with vents.
5. Remove a lock ring, a clamp of the leading shaft and a half ring.
6. By means of a press and a stripper dismantle the bearing (25х62х17). |
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Previously remove an internal lock ring. |
Assembly
Installation of half rings, clamp and lock ring
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1. Put the ball bearing (25х62х17) on a shaft of the leading gear wheel of a divider, - before installation fill the internal lock ring which is picked up in advance for thickness in space between the bearing and a gear wheel of a reducer.
2. Establish on a half ring shaft, a clamp and a lock ring. |
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Half rings are selected on thickness so that the axial side play of the bearing made 0 ÷ 0.08 mm (see the table). |
Half rings of a shaft of the leading gear wheel of a divider
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detail No. |
Thickness, mm |
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35204AA000
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2.43
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35204AA010
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2.51
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35204AA020
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2.59
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1. Having greased with jellied lubricant of a sponge of an epiploon, put it in the holder of the bearing of a shaft of the leading gear wheel.
2. Wind vents of the leading shaft with an adhesive tape, manually (with effort) fill a shaft with the bearing, napressovanny on it, in the holder.
3. Put a lock ring in a flute of the holder of the bearing. |
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The ring is selected on thickness (see the table) so that the axial side play of the bearing in the holder made 0 ÷ 0.08 mm. |
Lock ring (outer diameter is 62 mm)
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detail No. |
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 a sealing ring and lubricant knot on the holder of the bearing.
Service of assembly of a main shaft (all RKPP)
Design of main shaft RKPP without reducer
Dismantling
Only boxes without reducer
Wind with an adhesive tape of a vent of a pin of a main shaft, then remove an epiploon and the needle bearing.
All boxes
Otdavany nuts of fastening of details of a main shaft
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1. Also give to Raschekanta a nut of fastening of details of a main shaft.
2. Remove from a shaft a lock plate of crackers (the sliding keys), a nave and the coupling of the synchronizer of the 5th transfer, the blocking ring, the leading gear wheel of the 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 the 5th transfer, the ball bearing (25.5х65х31), a persistent washer of a gear wheel of the 4th transfer, a nave and the coupling of the synchronizer in pine forest, the blocking synchronizer ring, the needle bearing of a gear wheel of the 4th transfer, the internal holder of the needle bearing conducting a gear wheel of the 3rd transfer and a detail of the synchronizer of the 3rd transfer. |
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In case of need replace the coupling and a nave of the synchronizer with new assembly. In case of need dismantling of the synchronizer mark the adjusting provision of each of the removed components. |
Only boxes with a reducer
Remove a lock ring with an internal diameter of 25 mm from the forward end of a main shaft, then remove the needle bearing (25х33х24) gear wheels of the 3rd transfer, a pro-rate of the conducted gear wheel of the lowering transfer of a divider and the needle bearing (27х46х21).
Assembly
All boxes
Divider synchronizer design (RKPP with a reducer)
Assembly of the synchronizer of the 5th transfer
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1. Collect synchronizers of the 3/4 and 5 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 3/4 of transfers there are two marking openings, the synchronizer of the 5th transfer - one. Having finished assembly, part springs of synchronizers with locks under 120 °. |
2. Put a main shaft the leading gear wheel of the 3rd of transfers, the blocking ring and assembly of the synchronizer 3/4 of transfers, and also the needle bearing (32х36х25.7).
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Track hit of the sliding keys (crackers) in reception flutes of the blocking ring. |
3. By means of a suitable mandrel put a shaft I will embrace the needle bearing of the leading gear wheel of the 4th transfer.
4. Establish the blocking synchronizer ring, the needle bearing (32х30х25.7), the leading gear wheel of the 4th transfer and a persistent washer.
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Track that the persistent washer was developed by flutes to a gear wheel. |
5. By means of a suitable mandrel to a napressuyta the ball bearing on a back pin of a main shaft.
6. By means of the same mandrel put on a shaft a persistent washer of the leading gear wheel of the 5th transfer (flutes to a gear wheel), a holder of the needle bearing of a gear wheel of the 5th transfer, the needle bearing (32х36х25.7), the leading gear wheel of the 5th transfer, the synchronizer of the 5th transfer, a lock plate of the sliding keys (crackers) of the synchronizer and a washer (22х38х2).
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Track that the uvula of a lock plate of crackers entered an opening with a diameter of 4 mm in a synchronizer nave. |
7. Screw a nut (22х13), tighten it with the required effort (112 ÷ 124 Nanometers) and a zakontrita kerneniy in two points. |
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Only boxes with a reducer
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1. Put on the forward end of a main shaft the needle bearing (27х46х21), a ball (Ø of 3.9538 mm), a pro-rate of a gear wheel of the lowering transfer of a divider (a flute in a side surface forward on a shaft), the needle bearing (25х33х24), the conducted gear wheel of the lowering transfer of a divider, the blocking ring of the synchronizer of a divider and actually assembly of the synchronizer.
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At installation of the needle bearing try not to damage a step surface of a shaft! |
2. Put the NEW lock ring with an internal diameter of 25 mm on a main shaft, - the ring is selected on thickness (see the table) so that the gap between it and a nave of the synchronizer made 0.060 ÷ 0.1000 mm. |
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Lock ring with an internal diameter of 25 mm
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detail No. |
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 assembly of interaxal differential (model with the constant four-wheel drive)
Design of interaxal differential of models with the constant four-wheel drive
Dismantling
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1. Having hooked the screw-driver with a flat sting, remove a lock ring with an outer diameter of 110 mm.
2. Uncover differential.
3. Remove the viscous coupling.
4. Remove needle bearings.
5. Remove an adjusting washer (45x62xt).
6. Remove an axis of satellites, satellites and persistent washers.
7. Remove the conic conducted differential gear wheel.
8. Remove a persistent washer.
9. Vypressuyte from a differential cover the ball bearing.
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The removed ball bearing is subject to replacement without fail! |
10. If you are going to make replacement of the needle bearing, remove a washer of the viscous coupling, - the removed washer is subject to replacement without fail!
11. Remove the needle bearing (35х42х12). |
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Assembly
Measurement of size of an axial side play of the viscous coupling of interaxal differential
Lock ring with an outer diameter of 110 mm
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detail No. |
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 (45x62xt)
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detail No. |
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. Assembly is made as it should be the return to an order of dismantle of components. At installation of the new needle bearing (35х42х12) press it together with a new washer of the viscous coupling by means of a special mandrel. Track that the persistent washer of the conic conducted gear wheel of differential was the developed internal facet to a gear wheel. Establish an adjusting washer by an internal facet to the viscous coupling.
2. Having finished assembly, use the probe of lezviyny type for measurement of size of a gap between a lock ring with an outer diameter of 110 mm and a cover of differential (an axial side play). If the result of measurement exceeds the limit of the admissible range (0 ÷ 0.15 mm), pick up the new, corresponding on thickness, lock ring (see the table).
3. Having collected differential, fix on it the dial measuring instrument of plunger type and measure the size of an axial side play of the viscous coupling. If the result of measurement exceeds the limit of the admissible range (0.62 ÷ 0.86 mm), pick up a new adjusting washer of the corresponding thickness (see the table). |
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Service of assembly of forward interwheel differential
Dismantling
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1. Remove spring lock rings and take two power shafts equipped with vents.
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At assembly shaft have to be established strictly on the former places, - put the corresponding marking. |
2. Turn out 12 fixing bolts and remove a gipoidny gear wheel of the main transfer.
3. Beat out a pin of fastening of an axis of satellites in the direction of a flange of a gipoidny gear wheel.
4. Beat out an axis of satellites and take satellites, side gear wheels and washers.
5. By means of a stripper remove roller bearings. |
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Assembly
Washers of side gear wheels of differential
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detail No. |
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 side gear wheels with washers and satellites, then fill an axis of satellites.
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Washers are established by internal facets to side gear wheels. |
2. Rest a plunger of the dial measuring instrument against tooth of the satellite and measure the size of a gap of gearing of satellites and side gear wheels. If the result of measurement exceeds the limit of the admissible range (0.13 ÷ of 0.18 mm), pick up new, corresponding on thickness, washers (see the table).
3. Achieve combination of openings under a lock pin in an axis of satellites and a box of differential. Begin to knock and zakontrit a new pin.
4. Install roller bearings (40х80х19.75) on a differential box.
5. Establish the conducted gipoidny gear wheel of the main transfer, screw and tighten twelve fixing bolts with the required effort (57 ÷ 67 Nanometers).
6. Establish two shlitsevy power shafts and fix from by means of lock rings. Measure gap size between shaft and an axis of satellites, - if the result of measurement exceeds the limit of the admissible range (0 ÷ 0.2 mm), pick up new, the corresponding thickness, spring lock rings (see the table). |
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Spring lock rings
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detail No. |
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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