Chevrolet Lanos (since 2004 release)
1. Car device
2. Recommendations about operation
3. Malfunctions in way
4. Maintenance
5. Engine
6. Transmission
6.1. Coupling
6.2. Transmission
6.2.1. Features of a design
6.2.2. Possible malfunctions of the transmission, their reason and ways of elimination
6.2.3. Replacement of oil in the transmission
6.2.4. Replacement of epiploons of the transmission
6.2.5. Removal and installation of the transmission
6.2.6. Dismantling and assembly of the transmission and troubleshooting of its details
6.2.7. Repair of a secondary shaft
6.2.8. Repair of a main shaft
6.2.9. Repair of the synchronizer
6.2.10. Repair of differential
6.2.11. Repair of the mechanism of gear shifting
6.2.12. Repair of hinges of the drive of gear shifting
6.2.13. Removal, installation and repair of the coulisse of a control lever transmission
6.2.14. Adjustment of the drive of control of the transmission
6.3. Drives of forward wheels
7. Running gear
8. Steering
9. Brake system
10. Electric equipment
11. Body
12. Wheels and tires
13. Purchase of spare parts
14. A trip on HUNDRED
15. Winter operation of the car
16. Preparation for checkup
17. Advice to the beginning mechanic
18. Appendices
19. Schemes of electric equipment
 








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6.2.6. Dismantling and assembly of the transmission and troubleshooting of its details

It will be required to you: keys "on 10", "on 13", "on 19", "on 24", a set of keys hexagons, screw-drivers with a flat edge (two), kruglogubets, a stripper of lock rings, a stripper of bearings, the hammer, small beards, a chisel.
1. Remove the transmission from the car (see. "Removal and installation of the transmission"). Clear it of dirt and wash up outside.
2. Remove a spring clamp …
3. … also take a gear shifting drive hinge axis. Separate hinge forks.
4. A chisel unbend edges of a lock plate of bolts of fastening of an arm of a back support of the power unit to a transmission case.
5. Turn out three bolts …
6. … remove a lock plate …
7. … and an arm of a back support of the power unit assembled with gear shifting drive hinges.
8. Remove the coupling switching off bearing (see. "Replacement of a fork and bearing of switching off of coupling"), the directing coupling switching off bearing plug (see. "Replacement of epiploons of the transmission") and the rubber sealing ring established under the plug.
9. Unscrew the car speed sensor from the speedometer drive.
10. Turn out a bolt of fastening and remove the speedometer drive.
11. Turn out the backing light switch.
12. Remove a protective cap …
13. … also turn out an opening stopper for oil filling.
14. Turn out four bolts of fastening of the case of the mechanism of gear shifting …
15. … also remove the mechanism, and also the laying established under it.
16. Turn out eleven bolts of fastening of a back cover of the transmission …
17. … then uncover …
18. … and the laying established under a cover.
19. Through an opening for installation of the mechanism of gear shifting include the II transfer, having moved with the screw-driver a fork of inclusion of I and II transfers.
20. Turn out bolts of fastening of an intermediate case …
21. … also remove a case assembled with shaft.
22. Pay attention that in a case the remote washer of an intermediate gear wheel of a backing is established.
23. Turn out two bolts of fastening of an arm of a fork of inclusion of the V transfer …

    
NOTE
Before assembly apply an anaerobic clamp of a carving on a carving part of bolts.

24. … also remove an arm assembled with a fork.
25. Remove crackers from a fork.

    
NOTE
Replace worn-out crackers at assembly new.

26. A special stripper remove a lock ring of the synchronizer V of transfer.
27. Install a three-armed universal stripper on the transfer synchronizer V coupling …
28. … also press from a shaft the coupling assembled with a nave.
29. Remove the blocking synchronizer ring …
30. … the conducted gear wheel of the V transfer …
31. … needle bearing …
32. … and locking ring.
33. Take two persistent half rings.
34. Remove a lock ring of the leading gear wheel of the V transfer …
35. … and two screw-drivers press a gear wheel, using wooden whetstones as pro-rates.
36. Turn out two bolts of fastening of an arm of a doggie …
37. … establish rods of forks consistently in the provision II, V and III of transfers and remove an arm assembled with a doggie.
38. The hammer through a chisel with the dulled sting beat out traffic jams of clamps of rods of forks of gear shifting. Pay attention that the clamp marked with an arrow …
39. … differs from two others. After a vypressovka of traffic jams take from nests of an intermediate case of a spring and clamps of rods.
40. Turn out two screws of fastening of the fixing pin …
41. … remove an arm …
42. … also take a pin from an arm.
43. Remove laying of an intermediate case.
44. Operev the free end of a rod on wooden whetstone, beat out to small beards a pin of fastening of a fork of inclusion of an intermediate gear wheel of a backing …
45. … also remove a rod and a fork.
46. From openings of an intermediate case take a pin of blocking of simultaneous inclusion of two transfers.
47. Beat out a pin of fastening of a fork of switching III and IV transfers …
48. … take a rod and remove a fork.

    
NOTE
Couplings of inclusion of transfers at removal of a fork have to be in neutral situation.

49. Remove a lead with a rod of inclusion of the V transfer.
50. Remove a lead from a rod.
51. A stripper for internal lock rings (working for compression) squeeze a spring lock ring of a secondary shaft and record in such situation.
52. The second stripper for external lock rings (working for a release) unclench a lock ring of a main shaft …
53. … also take a shaft of a main shaft from an intermediate case.
54. Remove an intermediate gear wheel of a backing.
55. Take a shaft of a secondary shaft from a case and remove a shaft assembled, and also a rod and a fork of switching of I and II transfers.
56. A stripper take a lock ring of the bearing of a main shaft from a pro-point of an intermediate case.
57. Take a magnet from a case and clear it of wear products.
58. Vypressuyte an axis of an intermediate gear wheel of a backing from an intermediate case, having clamped an axis in a vice with sponges from soft metal and having shifted a case from an axis easy blows of the hammer to a case through a wooden pro-rate.
59. Turn out ten bolts of fastening of the lower cover of the transmission …
60. … also uncover together with laying.
61. Mark with paint the provision of an adjusting nut of bearings of differential concerning a transmission case.
62. Turn out a bolt of fastening of a clamp of an adjusting nut …
63. … remove a clamp …
64. … and, counting speed, turn out an adjusting nut the screw-driver, as shown in a photo.
65. Remove a sealing ring from a nut.

    
NOTE
Replace strongly pressed out, hardened or torn ring.

66. Vypressuyte from a nut a half shaft epiploon.
67. In need of replacement of bearings of differential turn an adjusting nut, enclose to steam of wooden whetstones and a vypressuyta from a nut an external ring of the bearing of differential.
68. Take a remote ring from an adjusting nut.
69. Turn out five bolts of fastening of a cover of the right bearing of differential, uncover, remove from it a sealing ring, then to a vypressuyta from a cover the epiploon and if necessary an external ring of the bearing the same as pressed off them from an adjusting nut.
70. Take from a transmission case differential assembled.
71. Before survey and troubleshooting carefully wash out and dry transmission details.
72. Examine a transmission case, an intermediate case and a back cover. On them should not be having chopped off. On privalochny surfaces there should not be забоин, рисок, dents, etc. Remove small damages with a fine-grained emery paper. At strong damages replace defective parts.
73. Check seats under bearings. On these surfaces there should not be wear tracks or damage. If there are damages, replace cases.
74. Check a condition of rods of inclusion of transfers. If they are bent or on them there were teases, agnails or developments of holes under clamps, replace rods.
75. Check a condition of forks of gear shifting. If forks are bent or worn-out pads, replace these details.
76. At detection in use oil leaks through epiploons and at wear of their working edges epiploons need to be replaced.
77. Check a condition of bearings. At detection of sinks on racetracks and bodies of swing, traces of cave-in of bodies of swing on racetracks or in case of damage of separators bearings need to be replaced.
78. Replace the damaged or strongly pressed out laying.
79. Clear a magnet of particles of wear of details. If on a magnet there were cracks or its magnetic properties are weakened, replace a magnet.

Collect the transmission in the sequence, the return dismantling, taking into account the following.
1. Before assembly plentifully oil all rubbing details gearbox.
2. Collect all threaded connections …
3. … also establish epiploons with application of an anaerobic clamp of a carving.
4. Before installation of a secondary shaft in an intermediate case squeeze kruglogubets a lock ring and record a wire in the compressed state. Remove a wire after installation of a shaft in a case, having convinced that the ring entered case pro-points without distortions.
5. At installation of differential if did not change its bearings, wrap an adjusting nut of bearings on the same speed, as at an otvorachivaniye, before combination of the tags put when dismantling.
6. If changed differential bearings, after its installation adjust a preliminary tightness of bearings on value of the moment of resistance to a provorachivaniye of bearings, turning or turning off an adjusting nut. For new bearings the moment of resistance has to make 2 N · m (0,2 kgfs · l) at rotation of the conducted gear wheel of the main transfer with a speed of 1 rps. If bearings did not change, then the moment of resistance has to be 1 N · m (0,1 kgfs · м).
7. Before installation of the lower cover of the transmission grease its laying with jellied lubricant.

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6.2.5. Removal and installation of the transmission
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6.2.7. Repair of a secondary shaft