TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

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Maxim
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TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

Now I make a repair of two GB+TBassy.

Firstly photos, what has shown "dissection".

GB+TBassy â„–1:
trans shaft - this detail (arrow), was removed with help fingers! Must be so?

retaining ring 4st - shows of both sides. Why it so?
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

....retaining ring 3st - almost normal.
    snap ring - jumped out, from of shaft ditch, the snap ring (arrow) of the 2st pinion. Pinion is lived by independent life!
    pinion 2st - the result of "free life"...
    pinion 1st - also...
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

...syncromesh 1-2 - touch by butt side. Conic not worked. Wear of conic parts on syncro and pinions.
  pinion 3st - wear of conic part.
  shift lug reverse - broken spring
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by alex »

maxim,i cannot remember exactly how the parts were in the gear box.
just one word of warning: take care that different producers made parts for the gear box and there are size differences between parts named the same.

this is how i broke the parts in the gear box after a mechanic assemblied it toghether.

i also remember that a retainig ring would pop out on the main shaft, i believe between 2nd and 3rd. usually from using second gear. the quality of the retaining ring would be very poor and it would litteraly bent.

sorry for not helping u more.
happily mending an Aro 320 D127

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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

Hi Alex! Thank You!

...continue...
Mainshaft end nut was not good tighten. After unlocked, unscrewed by fingers.

In T.B. was broken snap ring on layshaft. It is scraper of the bearing cap. Made metal chips. Also, because broken snap ring, the layshaft pinions was "free". It no is good. The wear all of the sealings and some bearings.

  About  of the â„–1 - all
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

Now, GB+TB â„–2 :

remove from screens of children :o

the bearing of transmission shaft a damaged by constant mesh pinion. Itself pinion lived by "free life". Reason - broken snap ring on layshaft;
the pinion 3st - wear of conic surface, but will be work;
on mainshaft was broken ALL ??? snap rings!
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

2st syncromesh ring touched everything, only not of conic surface;
from 2st pinion is itself separated the conic part... Lightly....;
syncromesh1-2  -  I such see for the first time ??? No comments...;
broken snap ring on layshaft of TrBox, wear sealings and bearings.... >:(.....

:-??

Most ridiculous, that both AROs have got on repair, not because of boxes... :-"
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by alex »

maxim, here sometimes w ecan find the bras rings of the sincro mesh separately. or the whole unit, price was last year round 50-60 euro.
happily mending an Aro 320 D127
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

OPERATIONS FOR REMEDYING GEARBOX & TRANSFER BOX ASSY (INCLUDING THEIR VARIANTS )

TAKING DOWN GEARBOX & TRANSFER BOX ASSY

Taking gearbox & transfer box assy from vehicle should be performed after a certain travel, so that the oil gets warm.
-  Remove transmission tunnel cover.
-  Remove firstly filler plugs of gear & transfer boxes and then respective drain plugs, collecting the drained oil in adequate vessels.
-  Take down both propeller shafts and if existing, the power take-off cardran shaft.
-  Disconnect lead of reverse speed transmitter (switch ).
-  Remove clutch release fork.
-  Remove speedometer flexible shaft (connection on transfer box).
-  Unscrew nuts fastening gearbox on clucth housing.
-  Hold gearbox with a strip, in order ro prevent distortion of its transmission shaft. Draw gearbox backwards, untill transmission shaft gets out from clutch disc hub.
-  Remove from gearbox transmission shaft end plate the clutch throw sleeve.
On refitting gearbox & transfer box assy, perform the above stages in reverse order and tighten nuts with a torque of 2.4 - 4.0 m.daN.(17. 4-29 ft. lbs)
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

SEQUENCE OF DISMANTLING TRANSFER BOX

- Take on of the transfer box on neutral position.
- Unscrew 8 nuts, fastening transfer box,  and remove the latter, disengaging it from gearbox main shaft. Use slim knife, for disengaging gasket, that must remain on gearbox .
- Unmount the control support by unscrewing their fixing screws on the distribution box crankcase.
- Unmount the superior cap -2- (8 bolts M 6, -4-), rear cap -8- (with sensor 4x4) and let the way free to the fixing screws (M 8 ) of the forks on the axles.Unscrew two bolts (M 6)  of the plate guide -1-.
- Remove successively both control shafts, by slight tapping towards the outer ends and their the sealing rings.  Remove then both forks,  after having previously marked their relative position in transfer box housing.
TAKE CARE that the balls, located under the control shafts, do not jumping, not lost, out and do not fall into transfer box housing.
ATENTION : do not damage gaskets when removing caps.
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Last edited by Maxim on 28 Mar 2009, 19:10, edited 1 time in total.
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Re: TROUBLES REMEDYINGS OF GEARBOX AND TRANSFER BOX

Post by Maxim »

Then:
- remove security rings and castellated washers, unscrew the flanges nuts
- remove both flanges
- unscrew bolts, remove all bearing caps, together with their gaskets.

DISMANTLING THE LAYSHAFT
- undo lock washer (20) from the nut (19) and remove both components.
- shift the layshaft forwards, by slight tapping, untill the sealing cap (52) is pushed out from its bore.
- remove snap ring (49) and spacer ring (51) from the layshaft (50) front end.
- now, shift the layshaft backwards by slight tapping, removing it together with bearing (21) from transfer box housing. Remove bearing from shaft by special fitting.
- remove from the housing both layshaft low and high speed gears, together with the spacer sleeve.
- then remove bearing (53).
- check bearings for wear and, if necessary, replace it by a new one.

DISMANTLING REAR AXLE DRIVE SHAFT
- take down connecting flange (14), after removing the security ring, securing nut and castellated washer.
-  check connecting flange for wear in the area of annular oil seal. If the wear is visible, replace the flange with a new one.
- remove speedometer drive cover, together with speedometer drive gear assy and remove also its gasket.
- in case that annular oil ring lip Is damaged, replace it, pressing the new ring up to the cover surface.
- remove the lock plate, securing speedometer shaft sleeve nut.
- remove speedometer shaft sleeve nut,  together with the speedometer drive shaft.
- remove from rear axle drive shaft the speedometer drive pinion (11), and after that the drive pin.
- remove spacer ring, between pinion and bearing.
- depress rear axle drive shaft out bearing, by slight tapping, removing after that the spacer ring and the low speed driven gear.
- check the shaft for coaxiality and wear on the area with bearing needle.
- depress bearing (46) out from the housing by special fitting.

DISMANTLING FRONT AXLE DRIVE SHAFT
- take down connecting flange (44).
- remove bearing cover (39) together with annular seal ring (40). If the latter is damaged, replace it by a new one.
- now, shift the rear drive shaft backwards by slight tapping, removing it together with bearing (23) from transfer box housing.
- remove from transfer box housing both low (37) and high (41) speed driven gears, coupling sleeve (35) and splined hub (34), after having previously marked their mutual positions.
- check both gears for wear and if necessary, replace them. Depress bearing (46) out from the housing by special fitting.
ATENTION tapping only through fitting from soft metal (Al, Cu)
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Last edited by Maxim on 09 Apr 2009, 14:01, edited 1 time in total.

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