4.2. Transmission

POSSIBLE MALFUNCTIONS OF THE TRANSMISSION, THEIR REASON AND METHODS OF ELIMINATION



The transmission has four transfers forward and one transfer of a backing.

Fig. 3.10. Box of transfers synchronized: 1 – main shaft; 2 – forward cover;
3 – special nut; 4,14,17,28 – lock rings; 5 – laying; 6,15,20,30 – bearings;
7 – forward bearing of a secondary shaft; 8 – case; 9 – coupling of the synchronizer III and IV of transfers;
10 – gear wheel of the III transfer; 11 – gear wheel of the II transfer; 12 – coupling of the synchronizer I and II of transfers;
13 – gear wheel of the I transfer; 16 – secondary shaft; 18 – washer; 19 – expansion ring; 21 – special bolt; 22 – dish-shaped spring; 23 – intermediate shaft; 24 – backing gear wheel axis; 25 – backing gear wheel; 26 – stopper; 27 – block of gear wheels of the drive of an intermediate shaft and the III transfer;
29 – cover


Fig. 3.9. The box of transfers synchronized partially: 1 – case;
2 – gear wheel of the drive of an intermediate shaft; 3 – bearing of a promezhutoch-ny shaft; 4 – nut; 5 – intermediate shaft; 6 – bearing cover;
7 – forward cover; 8 – main shaft; 9 – special nut;
10 – forward bearing of a secondary shaft; 11 – synchronizer coupling;
12 – secondary shaft; 13 – gear wheel of the III transfer; 14 – gear wheel of the II transfer; 15 – gear wheel of the I transfer; 16 – back bearing of a secondary shaft; 17 – lock rings; 18 – bolt of fastening of the back bearing of an intermediate shaft; 19 – bearing of the block of gear wheels of a backing; 20 – axis of the block of gear wheels of a backing; 21 – block of gear wheels of a backing; 22 – expansion plug; 23 – gear wheel of the II transfer of an intermediate shaft; 24 – gear wheel of the III transfer of an intermediate shaft; 25 – stopper of a drain opening of a case


On cars the box with the synchronizer only for III and IV (direct) transfers (fig. 3.9, further – the transmission synchronized partially) or with synchronizers for all transfers of the forward course can be established (fig. 3.10, further – the transmission synchronized).
Boxes are assembled interchangeable, but details of these boxes and mechanisms of switching are not interchanged.

Maintenance
In use check the level of oil and replace it in the terms provided by the table of greasing.
At detection of a leak find out the reason and replace faulty details (laying, caps, etc.).
Periodically check fastening of the transmission, and also fastening and adjustment of the mechanism of management of a box on cars of family UAZ-3741.
The moment of an inhaling of bolts and nuts of fastening of the transmission to cases of coupling and the transfer case has to be from 39 to 55 N · m (4,0–5,6 kgfs · l)
The order of adjustment is stated in the section "Repair". Transmissions of adjustments have no.

Repair
 Removal of the transmission from cars of family UAZ-31512
You carry out removal in the following order:
1. Merge oil from the transmission and the transfer case.
2. Uncover the body floor hatch over the transmission.
3. Remove a coupling switching off fork.
4. Remove the cap-type butterdish of the bearing of switching off of coupling and disconnect from it a bearing lubricant hose.
5. Remove the frame cross-piece located under the parking brake mechanism.
6. Remove gear shifting levers from the transmission and the transfer case (an open opening in the transmission close a temporary stopper).
7. Support the engine from below by means of a jack or other device.
8. Turn off and sort back support of an engine mount.
9. Disconnect flanges of driveshafts.
10. Remove the lever of the parking brake system.
11. Disconnect a flexible shaft of a speedometer.
12. Turn off four nuts of fastening of the transmission to a coupling case.
13. Take away the transmission together with the transfer case (unit) to an exit of a main shaft from a coupling case back.
14. Lower the unit down.
You make installation of the unit on the car upside-down.
 Removal of the transmission from cars of a seneystvo of UAZ-3741
You carry out removal in the following order:
1. Merge oil from the transmission and the transfer case.
2. Remove a coupling switching off fork.
3. Remove the cap-type butterdish of the bearing of switching off of coupling and disconnect it from a bearing lubricant hose.
4. Disconnect drafts of gear shifting from the mechanism of gear shifting and the transfer case.
5. Support the engine from below by means of a jack or other device.
6. Turn off and sort back support of an engine mount.
7. Disconnect flanges of driveshafts.
8. Disconnect a cable of the drive of the parking brake mechanism.
9. Disconnect a flexible shaft of a speedometer.
10. Turn off four nuts of fastening of the transmission to a coupling case.
11. Take away the unit to an exit of a main shaft from a coupling case back.
12. Lower the unit down.
You make installation of the unit on the car upside-down.
 Transmission detachment from the transfer case
1. Install the unit vertically on a drum of the parking brake mechanism.
2. Include direct transfer in the transfer case.
3. Turn off three nuts of hairpins and two bolts of fastening of the transmission to the transfer case.

Fig. 3.15. A detachment of a box of transfers from a distributing box


4. Lifting the transmission up, disconnect it from the transfer case (fig. 3.15).
5. After removal of the transmission on the transfer case there is a laying, a suspension bracket plate, the second laying and a persistent ring of the bearing of an intermediate shaft of the transmission.
 Dismantling of the transmission synchronized partially
You carry out dismantling in the following order:
1. Remove a side cover with the switching mechanism.
2. Uncover the bearing of a main shaft.
3. Turn a main shaft a cut towards a gear wheel of the drive of an intermediate shaft and take out a main shaft with rollers and the blocking synchronizer ring.

Fig. 3.16. Removal of the block of gear wheels of a backing


4. Turn out the lock screw of an axis of the block of gear wheels of the distant course and a vypressuyta an axis back, removing the block of gear wheels of a backing (fig. 3.16).
5. Remove the plates fixing the back bearing of a secondary shaft.

Fig. 3.17. Removal of a lock ring of a nave of the synchronizer


6. Remove a lock ring of a nave of the synchronizer (fig. 3.17) and take out a secondary shaft back. At the same time all gear wheels from a shaft will be removed, and the bearing will remain on a shaft.
7. Turn off a special key a cover of the forward bearing of an intermediate shaft.

Fig. 3.18. Removal of an intermediate shaft


8. Turn off a special key a nut of the forward bearing of an intermediate shaft and take out an intermediate shaft together with the bearing (fig. 3.18) back. At the same time gear wheels of the drive II and III of transfers will be removed from a shaft.
9. Turn off a special key a nut of fastening of the bearing of a main shaft which has the left carving.

Fig. 3.19. Removal of the bearing from a main shaft


10. Remove by means of a stripper the bearing from a main shaft (fig. 3.19).
11. Remove the back bearing of an intermediate shaft by means of a stripper. The bolt of fastening of the bearing has the left carving and is stopped by a dish-shaped spring.
 Dismantling of the synchronized transmission
You make dismantling in the following order:
1. Remove a side cover with the switching mechanism.
2. Using a carving opening of M8 in a back end face of an axis of an intermediate gear wheel of a backing, a vypressuyta an axis back, remove a gear wheel.
3. Uncover the bearing of a main shaft.
4. Uncover the forward bearing of an intermediate shaft.
5. Turn out a bolt of fastening of the back bearing of an intermediate shaft (the bolt has the left carving) and remove a dish-shaped spring of a bolt.
6. By means of a stripper remove back bearings of primary and secondary shaft for their lock rings.
7. Remove a lock ring of the back bearing of an intermediate shaft.
8. Install a box so that the intermediate shaft was above, move an intermediate shaft forward against the stop of the block of gear wheels of an intermediate shaft in a case.
9. Give an intermediate shaft together with the back bearing to an exit of an internal holder of the forward bearing from rollers and the back bearing from a case back.
10. Remove the back bearing of an intermediate shaft by means of a stripper.
11. Install the transmission by the hatch under the switching mechanism up.
12. Take out from a transmission case a main shaft, the blocking ring of the IV transfer, a secondary shaft in collecting (supporting an expansion ring of a gear wheel of the I transfer) and an intermediate shaft assembled.
 Dismantling of a secondary shaft
1. Remove a persistent washer and a gear wheel of the I transfer with the needle bearing.
2. Remove lock rings of naves of synchronizers by means of a stripper and a persistent washer.
3. Remove the synchronizer I and II of transfers together with a gear wheel of the II transfer.
4. Remove a lock ring, a spline and the bearing of a gear wheel of the II transfer.
5. Remove the synchronizer III and IV of transfers together with a gear wheel of the III transfer.
6. Remove a lock ring, a spline, the expansion plug and the bearing of a gear wheel of the III transfer.

Fig. 3.20. Mechanism of switching of transfers of cars of family UAZ-31512: 1 – lever of switching of re-dachas; 2 – sealant; 3, 22 – pins; 4 – lever spring; 5 – lever support; 6 – side cover of a box of transfers; 7 – safety lock cover;
8 – lock ring; 9 – safety lock;
10 – safety lock spring; 11 – ball clamp; 12 – clamp spring; 13 – fork of inclusion of I and II transfers; 14 – inclusion fork III and IV transfers; 15 – fork of inclusion of a backing;
16 – screw; 17 – forelock; 18 – backing lamp switch; 19 – stopper; 20 – rod of a fork of inclusion of I and II transfers; 21 – plunger; 23 – fork rod III and IV transfers; 24 – rod of a fork of inclusion of a backing


 Dismantling of the mechanism of switching of cars of family UAZ-31512 (fig. 3.20)
You carry out dismantling in the following order:
1. Unscrew four screws of a support of the lever of switching and remove a support with the lever and a podzhimny spring (this operation becomes before removal of all unit from the car).

Fig. 3.21. Extraction of caps of openings of rods


2. Take three caps of openings of rods on the one hand of a cover (fig. 3.21).
3. Turn off a stopper of a nest of a clamp of a rod of I and II transfers and take out a spring and a ball.
4. Also turn out Rasshplintuyta lock screws of forks.

Fig. 3.22. Vypressovka rods of forks of switching


5. Vypressuyte rods (fig. 3.22) of forks of switching through openings in a cover where caps are removed, and remove forks. At a vypressovka of rods III and IV transfers and a backing do not lose the clamp ball which is thrown out by a spring.
6. Take out springs and balls of clamps of rods.
7. Take out two key plungers through an opening of a clamp of I and II transfers.
8. Unscrew three screws and uncover a safety lock and a returnable spring.
9. Put forward a safety lock plunger outside, remove a lock ring and take out a plunger. At the same time hold a plunger clamp ball from loss.
10. Take out a spring and a ball of a clamp.

Fig. 3.23. Mechanism of switching of transfers of cars of family UAZ-3741: 1 – rod of a fork of inclusion of a backing; 2 – backing fork;
3 – inclusion fork rod III and IV transfers; 4 – fork III and IV transfers; 5 – fork of I and II transfers; 6 – rod of a fork of inclusion of I and II transfers; 7 – forelock-provoloka;
8 – cap; 9 – washer; 10 – shaft of switching of transfers; 11 – side cover; 12 – coupling of switching of transfers; 13 – the blocking spring;
14 – laying; 15 – epiploon cover; 16 – switching lever; 17 – stopper; 18,20 – clamp springs; 19 – key plunger; 21 – clamp ball; 22 – lever of the choice of transfers; 23 – selective lever; 24 – pin; 25 – backing lamp switch; 26 – cap


 Dismantling of the mechanism of switching of cars of family UAZ-3741 (fig. 3.23)
You make dismantling in the following order:
1. Take three caps of openings of rods in one of torets of a cover (see fig. 3.21).
2. Also turn out Rasshplintuyta screws of latching of forks.
3. Turn off a stopper of a nest of a clamp of a rod of I and II transfers and take out a spring and a ball of a clamp.
4. Vypressuyte rods (see fig. 3.22) through openings in a cover where caps are removed, and remove forks. At a vypressovka of rods of III and GU of transfers and a backing do not lose the clamp ball which is thrown out by a spring.
5. Take out springs and balls of clamps of rods; take out two key plungers through an opening of a clamp of I and II transfers.
6. Turn off a nut and remove from shliyets the lever 22 (see fig. 3.23),
7. Beat out a pin 24 fastenings of an axis of the lever 23 down and take out an axis together with the choice lever.
8. Turn off a nut and remove the lever 16.
9. Turn off three bolts, uncover the 15th epiploon and take out a spring. Having lowered a shaft 10 with the coupling 12 and two washers, take out a shaft through a side cavity of a cover.

Note
Before removal of levers 22 and 16 notice mutual position of levers on rollers to install levers in former situation.

 Dismantling of the mechanism of management of gear shifting of cars of family UAZ-3741
You make dismantling in the following order:

Fig. 3.24. Mechanism of management of switching of transfers of cars of family UAZ-3741:
1 – lever of switching of transfers; 2 – mechanism sealant; 3 – the choosing mechanism lever; 4 – the switching mechanism lever; 5 – vertical draft of switching; 6 – intermediate lever of switching;
7 – intermediate lever of the choice; 8 – horizontal draft of the choice; 9 – lever of switching of transfers;
10 – lever of the choice of transfers; 11 – horizontal draft of switching; 12 – arm intermediate levers; 13 – intermediate lever of the choice; 14 – vertical draft of the choice; 15 – press-butterdishes


1. Disconnect drafts of 8 and 11 (fig. 3.24) from levers 9 and 10.
2. Turn off drafts 5 and 14 from levers 6 and 13.
3. Disconnect an arm of 12 intermediate levers.
4. Remove a mechanism arm together with the lever of 1 gear shifting.
5. Wash out details of the mechanism of management.
6. Reveal external survey of an iznosa in levers and drafts.
7. Replace worn-out details.
 Assessment of technical condition of details
After dismantling carefully wash out all details of the transmission in kerosene, blow compressed air and examine.
Transmission case. External survey reveal cracks, chips, breaks of inflows and fixing ushk, a condition of a carving in openings, lack of faces and agnails on the condensed surfaces.
Replace a case having cracks, chips and breaks. Eliminate small malfunctions.
Gear wheels. On teeths should not be having chopped off and забоин. The side surface of teeths should not have traces of a vykrashivaniye and a smyatiya, on face surfaces of gear wheels there should not be zadir.
Landing surfaces should not have the damages and wear breaking centering of details.
Gear wreaths of synchronizers should not have destructions of teeths and electrorivets.
The gear wheel of the I transfer of the transmission synchronized partially should not have the agnails which are exceeding the limit of height of shliyets from inclusion of the II transfer. Smooth out agnails. The vents of this gear wheel interfaced to landing surfaces of a secondary shaft should not have from the internal diameter of flows of metal on the ends. If they are available, connect such gear wheel at assembly to a secondary shaft so that landing was carried out through other vents which were earlier not participating in landing. Replace unusable details.
The main shaft should not have damages on teeths of a wreath of inclusion of the IV transfer. On the surface of swing of the roller bearing there should not be a vykrashivaniye. Vents of a shaft should not have забоин (the conducted clutch plate has to move on them freely). Replace a worn-out shaft.
The secondary shaft should not have zadir and deep рисок on landing surfaces under gear wheels of I, II and Ill of transfers, chips of shliyets and a vykrashivaniye on the surface of swing of the roller bearing. Replace a worn-out shaft.
The intermediate shaft should not have damages of a carving and teeths (smyaty, vykrashivany). Replace a worn-out shaft, the block of gear wheels of a shaft (on the synchronized transmission).

Fig. 3.11. Completing and selection of details of the synchronizer of the transmission synchronized partially: 1 – coupling; 2 – nave. Note. At mutual movement of details of 14 mm the distortions in vents measured in points of A1 and A2 on R40 should not exceed 0,35 mm (as shown)


Synchronizer. Check connection of the coupling 1 (see fig. 3.11 and 3.13) the synchronizer with a nave 2 and at the considerable mutual movements exceeding twice specified in drawings, in the direction, perpendicular detail axes, a coupling set with a nave replace. Selection of a new set you make as directed fig. 3.11 and 3.13.
Replace the synchronizer coupling at damage or wear of teeths. Replace the blocking rings of the synchronizer if a gap between torets of a ring and torets of a wreath of inclusion of transfer less than 0,3 mm and also if the ring is deformed.
Bearings should not have damages of separators, cracks and chips of rings, a vykrashivaniye of racetracks of balls, and also a notable radial and axial side play. Separators of bearings should not have damages. Replace worn-out bearings.
The side cover of the transmission should not have chips, cracks, damages of the condensing surfaces and openings for installation of caps.
Rods have to be rectilinear and not have vykrashivaniye in a zone of operation of locks and clamps. The key pin of a rod III, IV transfers has to move freely in an opening, without dropping out of it. Pin length taking into account wear should not be less than 9,8 mm. Replace worn-out details.

Fig. 3.12. The control sizes of forks of switching of transfers of the transmission synchronized partially: And – a fork of I, II transfers; B – a fork III, IV transfers


Fig. 3.14. Control sizes of forks of switching of transfers of the synchronized transmission: And – a fork of I and II transfers;
B – a fork III and IV transfers


Forks should not have cracks and pognutost. Position of pads of forks concerning a groove of switching has to correspond to the sizes shown in fig. 3.12 and 3.14. If wear of grooves of switching reaches 1 mm, replace a fork.
Other details. Persistent washers of gear wheels and a spline should not have zadir.
Maslootrazhateli have to have regular shape and not touch the next details.
The dish-shaped spring of a bolt of fastening of the back bearing of an intermediate shaft should not have cracks.
The sealing rubber ring of a cover of the forward bearing of an intermediate shaft should not have gaps and cracks.
The cover of a main shaft should not have cracks, breaks and damages of working and landing surfaces.
Pins in a support of the lever of gear shifting should not be shaken in the nests. The rubber sealant of the lever of switching should not have gaps and through cracks.
Replace all worn-out details. At repair of the transmission use these tab. 3.1.
 Assembly of the transmission synchronized partially
You make assembly of the transmission, since subassembly of its knots, in the following order:
Assembly of a main shaft

Fig. 3.25. A main shaft with the ground-in blocking ring: 1 – main shaft; 2 – the blocking ring


1. Grind in on a shaft cone the blocking ring to the size of 0,8-1,25 mm, as shown in fig. 3.25.
2. Establish a maslootrazhatel.
3. Napressuyte the ball bearing on a shaft against the stop in an end face of a maslootrazhatel so that the flute on an external ring of the bearing was displaced from a gear wreath aside.
4. Screw a nut of fastening of the bearing (the left carving) and stop a nut a raskernivaniye in a shaft groove.
5. Install a persistent ring on the ball bearing.
6. Put lubricant in an opening of a shaft and insert rollers (14 pieces).

Fig. 3.26. A main shaft in collecting


7. Insert a lock ring of rollers. The main shaft is assembled shown in fig. 3.26.
Assembly of a secondary shaft
1. Establish a maslootrazhatel.
2. To Napressuyta the two-row ball bearing, having established it by marking towards the transmission.
3. Fix the bearing on a shaft by means of a persistent washer and a lock ring.

Fig. 3.27. A secondary shaft in collecting


The secondary shaft is assembled shown in fig. 3.27.
Assembly of an intermediate shaft
1. Napressuyte against the stop the bearing on the back end of an intermediate shaft so that the flute on an external ring of the bearing was displaced towards a gear wheel.
2. Establish a dish-shaped spring by camber towards a bolt head.
3. Tighten a bolt of fastening of the bearing (the left carving).

Fig. 3.28. An intermediate shaft in collecting


4. Install a persistent ring on the bearing. The intermediate shaft is assembled shown in fig. 3.28.
Assembly of a set of a gear wheel of the third transfer
Grind in the blocking synchronizer ring on a cone of a gear wheel of the III transfer to the size of 0,8-1,25 mm, as shown in fig. 3.25.
Subassembly of the block of gear wheels of a backing with the bearing
1. Establish a lock ring in one of two flutes of an opening of the block of gear wheels.
2. Put consistently persistent ring, the bearing and one more persistent ring in an opening.
3. In a flute reliably establish a lock ring.
Assembly of the synchronizer
1. Pick up a set of the coupling and a nave of the synchronizer with the minimum gaps at free movement according to fig. 3.11 or use the set 451D-1701116-11 which is picked up by manufacturer.

Fig. 3.29. Assembly of the synchronizer


Fig. 3.30. The synchronizer coupling with a nave: 1 – coupling; 2 – nave; 3 – cracker; 4 – sha-rik; 5 –


2. Put three springs (fig. 3.29), three crackers, three balls in a nave and install on a nave the coupling switching. And longer part of a nave have towards the end face of the coupling having a shaped facet (fig. 3.30).
Openings in crackers are executed by step. Establish crackers by the party with openings of smaller diameter and the party of the coupling.
Installation in synchronizers of integral crackers with the acting hemispheres which are carrying out a role of balls is possible.
Assembly of a cover of an intermediate shaft
Establish a rubber ring in a cover flute.

Assembly of the mechanism of gear shifting of cars of family UAZ-31512
You carry out assembly of the mechanism of gear shifting in the following order:
1. Establish a spring and a ball of a clamp of a safety lock in a nest.
2. Squeezing a clamp spring, insert a safety lock plunger into an opening from within a cover against the stop.
3. Establish a lock ring on a plunger.
4. Insert a returnable spring into a plunger body.
5. Close a safety lock plunger a cover with laying and wrap three screws with spring washers.
6. Turn a cover a big flange up and put in nests of clamps of a spring and balls for rods III and IV transfers and a backing rod.

Fig. 3.31. Device for assembly of rods and clamps: and – assembly of a clamp; – installation of a rod


7. Insert into a cover from outside, opposite to a clamp, a backing fork rod, establish on a rod a fork and, utaplivy a ball by means of a mandrel (fig. 3.31), establish a rod on a clamp of neutral situation; in the same way collect consistently all rods and forks, since a backing rod. Between rods put key pins.
8. Fix forks on rods by conic bolts and a zashplintuyta bolts a wire. The Shplintovochny wire should not prevent movement of forks.
9. In an opening of a clamp of a rod of I and II transfers put a ball and a spring and wrap a stopper. Keep in mind that the spring of a clamp of a rod of I and II transfers in a free state is longer than two other springs of clamps of rods.
10. Insert six caps into face openings of the case for rods and a cap raschekanta.
11. Grease the sphere of a support of the lever of the switching collected with pins and put on the sphere the switching lever.
12. Put laying on a cover of the mechanism of switching and establish a conic spring in ring deepening.
13. Establish on a cover a support together with the lever so that the lever entered a spring, and the support the inflow closed an opening in the case and fix a support by four screws with spring washers.
14. Put on a rubber sealant the lever and a support and screw the handle.

Assembly of the mechanism of gear shifting of cars of family UAZ-3741

Fig. 3.32. Installation of a sealing ring of a cover of a shaft of switching


1. Establish a rubber sealing ring (fig. 3.32) in a switching shaft epiploon cover.
2. Establish a rubber sealing ring in an opening under an axis of the selective lever 23 (see fig. 3.23).

Fig. 3.33. Assembly of a shaft of switching pe-redach


3. Install the coupling (fig. 3.33), a persistent washer, a persistent cup of a spring and a spring on a switching shaft.
Insert a shaft into the case of a side cover and establish an epiploon cover with laying, fix a cover by three bolts.

Fig. 3.34. Installation of the selective lever assembled with an axis


4. Install the selective lever assembled with an axis (fig. 3.34) in the cover case so that the lever entered a switching coupling groove. Stop the lever a pin which hammer from below.
5. Turn a side cover the processed flange up and insert into nests of clamps of a spring and balls of a rod III and IV transfers and a backing rod by means of a mandrel (see fig. 3.31).

Fig. 3.35. Assembly of a rod and fork of a backing


Fig. 3.36. Assembly of a rod and fork of switching III and IV transfers


6. Establish a backing fork on a rod from outside, opposite to a clamp, and, having drowned a ball of a clamp (fig. 3.35) in the cover case by means of a mandrel (see fig. 3.31), establish a rod in neutral situation. So consistently collect all rods (fig. 3.36) and forks. Between rods establish key crackers.

Fig. 3.37. Shplintovka a wire of the bolts fixing forks: 1 – bolt; 2 – forelock-provoloka


7. Fix forks on rods by conic bolts and a zashplintuyta their wire (fig. 3.37) which should not prevent movement of forks. When fastening forks the lever of the coupling of switching has to be in a groove of forks.
8. Insert a ball and a spring of a clamp into an opening of a rod of I and II transfers and wrap a stopper. At the same time keep in mind that the spring of a clamp of a rod of I and II transfers in a free state is longer than two other springs of clamps of rods.
9. Establish six caps in face openings of the case of a cover, a cap – in an opening for a shaft of switching and their raschekanta.

Fig. 3.38. Installation of external levers of the choice and switching


10. Install levers of the choice and switching (fig. 3.38) to vents of shaft and fix them by nuts with spring washers.

Fig. 3.39. Position of the lever of the choice and the lever of switching after installation of the mechanism to a box of transfers: And – corresponding to a backing; B – III and IV transfers corresponding to inclusion; In – corresponding to inclusion of I and II transfers; 1 – choice lever; 2 – the switching lever (in neutral situation)


Correctness of position of levers is checked at the neutral provision of gear wheels in the transmission after installation of the mechanism of switching to the transmission according to fig. 3.39.

Assembly of the transmission from subcollected knots
You carry out further assembly of the transmission in the following order:
1. Insert a collected intermediate shaft into a transmission case. Behind consistently put on it an expansion ring, a gear wheel of the II transfer, a gear wheel of the III transfer and a gear wheel of the drive of an intermediate shaft.
2. Establish a shaft (fig. 3.39) with the bearing against the stop of a bearing ring in a case.
3. Establish a washer, the bearing on the forward end of an intermediate shaft and tighten a special nut. You raskernit a nut for latching. Axial movement of gear wheels on a shaft is not allowed.
4. Screw in a forward opening of a case a cover with a rubber sealing ring aflush with a case end face. Do not tighten a cover by excessive effort not to damage a sealing ring.
5. Oil liquid necks II and III transfers of a collected secondary shaft and, inserting it behind into the top opening of a case, consistently put on it a gear wheel of the I transfer, a gear wheel of the II transfer, a gear wheel of the III transfer with a synchronizer ring, a persistent washer, the synchronizer assembled.
6. Besiege the bearing of a secondary shaft together with shaft to a flute in the bearing.
7. Stop all set of gear wheels a spring ring, having established it in a flute on the forward end of a secondary shaft. Gear wheels II and III transfers have to be turned freely by hand.

Fig. 3.40. Installation of an intermediate shaft in a box of transfers


Fig. 3.41. Latching of the bearing of a secondary shaft


8. Stop the back bearing (fig. 3.41) of a secondary shaft two plates with screws.
9. Establish the blocking ring which is ground in to a cone of a main shaft in a synchronizer nave.

Fig. 3.42. Installation of a main shaft in a case of a box of transfers


10. Insert a collected main shaft into a transmission case, having disposed its cut down to a gear wheel of the drive of an intermediate shaft. By means of a mandrel establish a shaft (fig. 3.42) and the bearing against the stop of a bearing ring in a case.
11. Establish on a forward end face of a case laying so that the cut in it coincided with a masloslivny opening.
12. Establish on a main shaft a bearing cover so that the oil channel of a cover coincided with a masloslivny opening of a case.

Fig. 3.43. Installation of a cover of the bearing of a main shaft


13. Fix a cover of the bearing (fig. 3.43) by four bolts with spring washers. Under two left bolts establish a bracket of an ottyazhny spring of the bearing of switching off of coupling. An inhaling of bolts you produce with the moment from 12 to 18 N · m (1,2–1,8 kgfs · м).
14. Grease the bearing of the block of gear wheels of a backing with liquid lubricant, enclose the block of gear wheels a big wreath to an opening of a case and insert an axis into the block through a case opening.
15. Press an axis of the block of gear wheels in a case so that the opening in an axis coincided with a carving opening of M6 in a case wall.

Fig. 3.44. Latching of an axis of the block of gear wheels of a backing


16. Screw the lock screw aflush with the plane of the socket of a case (fig. 3.44).
17. Install the mechanism of switching on the transmission and fix it by bolts with spring washers. Before installation of the mechanism of switching be convinced that gear wheels in the transmission and forks of the mechanism of switching are in neutral situation. An inhaling of bolts you produce with the moment from 12 to 18 N · m (1,2-1,8kgs · м).

Assembly of the synchronized transmission
You make assembly of the transmission, since subassembly of its knots, in the following order:
 Assembly of a main shaft

Fig. 3.45. A main shaft with the ground-in blocking ring: 1 – main shaft;
2 – the blocking ring


1. Grind in on a shaft cone the blocking ring to the size of 0,8-1,25 mm, as shown in fig. 3.45.
2. Press against the stop the ball bearing a sealing ring towards a bearing nut.
3. Screw a nut of fastening of the bearing (the left carving) and stop it a raskernivaniye in a shaft groove.
4. Put lubricant in an opening of a shaft and insert rollers (14 pieces).
 Assembly of the synchronizer

Fig. 3.13. Completing and selection of details of synchronizers of the synchronized transmission: And – the synchronizer I and II of transfers;
B – the synchronizer III and IV of transfers; 1 – coupling; 2 – nave


1. Pick up a set of the coupling and a nave of the synchronizer with the minimum gaps at free movement according to fig. 3.13 or use the sets 469-1701117 and 469-1701138 which are picked up by manufacturer.

Fig. 3.46. The synchronizer coupling with a nave: 1 – coupling; 2 – nave; 3 – cracker; 4 – ball; 5 – directing springs; 6 – spring


2. Put three springs (fig. 3.46), three guides of a spring, three balls and three crackers in a nave and install the coupling on a nave (the coupling I and II of transfers is manufactured for a single whole with a backing gear wheel). Establish crackers by the party with openings of smaller diameter towards the coupling.
 Assembly of a secondary shaft
1. Install the needle bearing of a gear wheel of the III transfer, the expansion plug of the bearing, a lock ring and a spline.

Fig. 3.47. A gear wheel of the III transfer with at-tertym the blocking ring: 1 – gear wheel of the III transfer; 2 – the blocking ring


2. Grind in the blocking synchronizer ring on a cone of a gear wheel of the III transfer to the size 0,8 – 1,25 mm, as shown in fig. 3.47.
3. Oil the bearing gearbox, establish a gear wheel of the III transfer with the blocking ring, a persistent ring, install the synchronizer III and IV of transfers and a lock ring by a section to a nave spline.
4. Grind in the blocking synchronizer rings on cones of gear wheels of I and II transfers to the size of 0,8-1,25 mm, as shown in fig. 3.47.
5. Install the needle bearing of a gear wheel of the II transfer, a lock ring.
6. Oil the bearing gearbox, establish a gear wheel of the II transfer with the blocking ring, a persistent ring, install the synchronizer I and II of transfers.
7. Establish a persistent ring, a lock ring, a gear wheel of the I transfer with the blocking ring and the greased bearing, an expansion ring (maslootrazhatel) establish so that the pin of a secondary shaft got to a groove of an expansion ring (maslootrazhatel).
8. Install the locking plug and fix it (the locking plug will facilitate installation of a secondary shaft assembled in a transmission case).
 Subassembly of a gear wheel of a backing with the bearing
It is made similar to assembly of a gear wheel of a backing with the bearing of the transmission synchronized partially.

Assembly of mechanisms of gear shifting of cars of family UAZ-31512 and UAZ-3741
It is made similar to assembly of mechanisms of switching of the transmission synchronized partially.
 Assembly of the transmission from subcollected knots
You make further assembly of the transmission in the following order:
1. Insert collected (with the block of gear wheels, a lock ring and an internal holder of the roller bearing) an intermediate shaft into a transmission case.
2. Insert a collected secondary shaft into a transmission case, remove the locking plug.
3. Establish (press) the back bearing of a secondary shaft with the lock ring established on it. At a press fitting of a secondary shaft you make an emphasis a mandrel in a shaft neck end face under a synchronizer nave. At a press fitting pay attention to correctness of installation of a persistent washer of a gear wheel of the I transfer.
4. Establish (press) a subcollected main shaft in a transmission case so that the flute under a lock ring of the bearing was drowned in a case.
5. Establish an intermediate shaft into place, entering gear wheels into gearing.
6. Establish (press) the back bearing of an intermediate shaft with the lock ring established on it against the stop of an internal holder of the bearing in an end face of a shaft and a lock ring in a case end face.
7. Establish an external holder of the forward bearing with a separator and rollers on the forward end of an intermediate shaft.
8. Fix the back bearing of an intermediate shaft by a bolt with the dish-shaped spring established on it.
9. Correct a main shaft that the flute under a lock ring left a transmission case, establish a lock ring and besiege a main shaft against the stop of a lock ring in a case.
10. Establish (press) a cover of the forward bearing of an intermediate shaft before coincidence of end faces of a cover and a case.
11. Establish on a forward end face of a case laying so that the cut in it coincided with a masloslivny opening.
12. Establish on a main shaft a bearing cover so that masloslivny the channel coincided with a cut in laying.
13. Fix a cover by four bolts with spring washers. Under two left bolts establish a bracket of an ottyazhny spring of the bearing of switching off of coupling.
14. Fix the back bearing of a secondary shaft on a shaft by means of persistent and lock rings.
15. Insert a backing gear wheel axis into a case opening from the back privalochny plane.
16. Enclose a backing gear wheel in a case so that the axis entered it from outside, an opposite flute under a switching fork.

Fig. 3.48. Installation of an axis of an intermediate gear wheel of a backing: 1 – axis; 2 – plate


17. Press a backing gear wheel axis against the stop in a case according to fig. 3.48.

Assembly of the mechanism of management of gear shifting of cars of family UAZ-3741
You make assembly of the mechanism as it should be, the return to dismantling.
After assembly make adjustment of the mechanism of control of the transmission. You make adjustment change of length of horizontal – 8,11 (see fig. 3.24) and vertical – 5, 14 drafts in the following order:
1. Before adjustment install the lever 9 in neutral situation (N), and the lever 10 – in situation III-IV against the stop in the blocking spring.
2. Put the lever of 1 gear shifting in the position corresponding to the choice of transfers of I and II. In this situation connect and fix drafts of the choice 8 and 14, without allowing pulling up of levers.
3. After that put the lever I in the position corresponding to the choice of transfers of III and IV and also freely connect drafts of switching 5 and 11.
4. Upon termination of adjustment check completeness of inclusion of transfers. For this purpose include the first transfer and be convinced that drafts and levers do not rest against the next details. Make the same check, having included a backing. At the same time pay attention to that the intermediate lever 6 did not rest against a cross-piece of a frame and a mudguard. At the included backing the gap between them has to be 2–3 mm.