Contents: Disassembling the intermediate shaft ↓ Checking the intermediate shaft ↓ Bearing replacement ↓ Assembling the intermediate shaft ↓ Checking the reverse intermediate…↓
Disassembling the intermediate shaft
Intermediate shaft of the G52 gearbox. 1 - retaining ring, 2 - bearing, 3 - intermediate shaft, 4 - bearing, 5 - retaining ring, 6 - spacer sleeve, 7 - needle bearing, 8 - fifth gear pinion, 9 - synchronizer cracker, 10 - synchronizer spring, 11 - synchronizer sleeve No.3, 12 - synchronizer ring, 13 - synchronizer hub No.3 (fifth gear), 14 - intermediate gear of reverse gear, 15 - shaft of intermediate gear of reverse gear.
Using a screwdriver, remove synchronizer sleeve #3, three crackers and two springs.
Checking the intermediate shaft
1. Checking the radial clearance of the intermediate shaft fifth gear.
a) Install the spacer sleeve, needle bearing and fifth gear on the intermediate shaft.
b) Using a digital indicator, measure the radial clearance of the intermediate shaft fifth gear.
Nominal clearance - 0.009 - 0.032 mm
Maximum clearance - 0.032 mm
2. Using a micrometer, measure the outside diameter of the shaft journal for the needle bearing.
Nominal diameter - 25.98 - 26.00 mm
Minimum diameter - 25.86 mm
3. Checking the synchronizer ring.
a) Rotate and simultaneously press on the synchronizer ring to check its friction properties.
b) Measure the gap between the ring and the synchronizer hub.
Nominal clearance - 1.0 -2.0 mm
Minimum clearance - 0.8 mm
4. Using a feeler gauge, measure the gap between the gear shift fork and the synchronizer sleeve.
Maximum gap - 1.0 mm
Bearing replacement
If necessary, replace the front intermediate shaft bearing.
a) Remove the retaining ring.
b) Remove the bearing using a press.
c) Using a press, install the new bearing assembly.
d) Select a retaining ring of such thickness as to ensure minimum axial clearance. Install the retaining ring.
| Label | Thickness, mm |
| 1 | 2,05-2,10 |
| 2 | 2,10-2,15 |
| 3 | 2,15-2,20 |
| 4 | 2,20 - 2,25 |
| 5 | 2,25 - 2,30 |
| 6 | 2,30-2,35 |
Assembling the intermediate shaft
1. Install synchronizer sleeve No.3 and crackers on the fifth gear pinion.
2. Install the synchronizer springs under the crackers.
Note: the springs must be installed under the crackers in such a way that the end of one spring does not coincide with the end of the other spring, as shown in the figure.
Checking the reverse intermediate gear
1. Using a digital indicator, measure the radial clearance of the reverse gear intermediate gear.
Nominal clearance - 0.04 - 0.08 mm
Maximum gap - 0.13 mm
2. Using a feeler gauge, measure the clearance between the reverse gear intermediate gear and the reverse gear selector pin.
Nominal clearance - 0.05 - 0.27 mm
Maximum gap - 0.5 mm
