ladanivabelgium
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Post by ladanivabelgium on Jul 17, 2012 8:07:36 GMT 2
5th speed gear synchro sleeve 5th/reverse fork
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butasteve
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Post by butasteve on Jul 17, 2012 13:16:59 GMT 2
LadanivaThanx for the prompt response - very much appreciated. Regards Stephen
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spikes
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Post by spikes on Jul 17, 2012 15:55:00 GMT 2
Hi Stephan
I moved your query and the replies to this thread
Marius will close the old thread
Good luck with the gearbox repairs
Spikes
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Post by marius on Jul 17, 2012 16:40:58 GMT 2
What exactly is the problem Steve - did it jump out of 5th gear or did something snap? Hard to tell from here but the fork still looks fine - most of the wear on the fork occurs in the first few kilometers and it is fine after that. There is a dedicated Gearbox Repair thread where we can move all of this into >> locsa.proboards.com/index.cgi?board=technical&action=display&thread=216&page=22PS - by the way most of the argument in the 5th Gear Thread was repeated earlier in the Gearbox Thread Marius
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Post by marius on Jul 17, 2012 17:11:32 GMT 2
Steve naturally I would advise that you get a new fork - however this pic demonstrates the wear and tear on the 5th gear fork. The one at the top did 35 000kms and the one at the bottom did 800kms - both functioned perfectly. The shiny bits are the warn areas. Marius Attachments:
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spikes
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Post by spikes on Jul 17, 2012 19:17:20 GMT 2
I don't think Stephan had a 5th gear to begin with?
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ladanivabelgium
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Post by ladanivabelgium on Jul 17, 2012 19:22:34 GMT 2
marius, the 5th gear selector fork wears out VERY MUCH when the driver puts his hand on the shifter al the time. In that case the sleeve will show signs of wear to and must be replaced. It so happens that i opened a gear box today with those parts worn ( these coincidences never seem to stop ) I will post pictures within a few hours, first i must take some parts for a club member and then it's dinner (after the beers i will drink with the member ;D ) i will be back around 9.30pm
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Post by marius on Jul 17, 2012 19:29:35 GMT 2
Jan I never drive like that so that couldn't have caused the wear as shown on the photograph. I am sure if you drive like that it would make it even worse.
The Russians did make a late modification by inserting a spacer on the selector and my guess is that it is probably to prevent that type of wear. I found a perfect fit for a DIY spacer but whether it is doing the job - I do not know yet.
Marius
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ladanivabelgium
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Post by ladanivabelgium on Jul 18, 2012 7:04:37 GMT 2
it got a bit late yesterday , but here they are: This is from a 80 000 km gear box from a 2003 Niva (with the extra spacer on the 5th selector). Both fork and sleeve are worn pretty much worn: how it should be:
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Post by ronnie on Jul 18, 2012 8:39:26 GMT 2
Hi Jan
Just a quick question. Do you recommend overfilling the gearbox with oil ?.
Ronnie
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ladanivabelgium
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Post by ladanivabelgium on Jul 18, 2012 8:50:41 GMT 2
Ronnie, i put 1,5 L in it and 1,6 L when the GB has been opened and is completely drained of the oil
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Post by marius on Jul 18, 2012 9:06:58 GMT 2
Not only does the fork itself gets warn over time - but the ring gets chowed as well - perhaps even to a greater extend? The red arrow indicates a new ring vs the old ring (blue). Marius Attachments:
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ladanivabelgium
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Post by ladanivabelgium on Jul 18, 2012 9:08:54 GMT 2
marius, that's correct. The sleeve wears out to
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90ladaniva
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Post by 90ladaniva on Jul 18, 2012 13:56:03 GMT 2
Hi guys ,Just a point of interest ,i always use 2 Litres of oil in my Gear Box and ive never had any Problems with it from day one .Cheers Trev .
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Post by Charles on Jul 18, 2012 18:42:52 GMT 2
Trev what oil are you using mate?
Charles
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Post by Charles on Sept 3, 2012 20:27:23 GMT 2
Finished assembling my box today. In neutral it turns easily. If you hold the output shaft and try and turn it it is very tight, but possible. 3rd and 4th turns easily. 1st and 2nd difficult but possible. 5th and reverse nearly impossible. Opening it again tomorrow to find the cause. Any ideas on what I should look for?
Charles
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Post by Ari Bezuidenhout on Sept 4, 2012 7:59:39 GMT 2
Over tensioned the rear NUT?
Ari
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Post by hotstuff on Sept 4, 2012 10:30:19 GMT 2
call me
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Post by Charles on Sept 4, 2012 19:16:01 GMT 2
Found the problem, thanks Mike. Will post more info later.
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ladanivabelgium
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Post by ladanivabelgium on Sept 4, 2012 22:06:12 GMT 2
mike, with all due respect, nobody can benefit from this answer
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Post by Charles on Sept 4, 2012 22:22:32 GMT 2
Mike managed to help me out. The one thrust washer in my box is missing. It is in the parts catalogue but not in the workshop manual. The "new" parts I have needs that and my old ones didnt have it. Charles part 16 Attachments:
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Post by ronnie on Sept 5, 2012 8:30:16 GMT 2
mike, with all due respect, nobody can benefit from this answer Hi Jan Like you I would like to know the answer. Perhaps it is a secret ;D Thanks Charles for passing it on. Ronnie
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Post by marius on Sept 5, 2012 9:08:59 GMT 2
Hi Charles
It seems to be quite an important difference between the various parts. Is the difference on the syncro or on the 5th gear itself - hence the need for the spacer? Perhaps you can illustrate this in a pic?
Marius
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spikes
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Post by spikes on Sept 5, 2012 9:54:10 GMT 2
Finished assembling my box today. In neutral it turns easily. If you hold the output shaft and try and turn it it is very tight, but possible. 3rd and 4th turns easily. 1st and 2nd difficult but possible. 5th and reverse nearly impossible. Opening it again tomorrow to find the cause. Any ideas on what I should look for? Charles " Yesterday at 10:30am, 4x4 DOCTOR (MIKE) wrote: call me
mike, with all due respect, nobody can benefit from this answer
Hi Jan
Like you I would like to know the answer. Perhaps it is a secret Thanks Charles for passing it on.
Ronnie
Read more: locsa.proboards.com/index.cgi?action=display&board=technical&thread=216&page=24#33168#ixzz25ZzTl4LdHi Jan and Ronnie There is no secret ;D Charles posed a general question, got some answers and Mike said "Call me" which Charles did. And the source of the problem has been found. I am sure Charles will post more detail once he has the missing part Spikes
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Post by Charles on Sept 5, 2012 13:05:58 GMT 2
The inside thickness of the 5th gear hub is thinner than the old one. Thus requiring the spacer. As without it the sleeve that slides into the 5th gear just presses the gear solid against the other gears.
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spikes
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Post by spikes on Sept 5, 2012 13:48:43 GMT 2
Thanks Charles
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ladanivabelgium
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Post by ladanivabelgium on Sept 5, 2012 15:35:09 GMT 2
i know of the source of the problem, as Charles mailed me about it, and i gave generally the same answer as Mike did (i think). (there are boxes WITH and boxes WITHOUT spacer). I was just about to post this, but Charles already did
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spikes
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Post by spikes on Sept 5, 2012 18:54:40 GMT 2
Thanks for the input, Jan.
Is there any way the difference can be determined from the outside? Before stripping the box?
Spikes
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Post by Charles on Sept 5, 2012 19:30:24 GMT 2
Spikes the only difference is the 5th gear hub. The older version uses the spacer.
Thanks for the advice guys.
Charles
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Pizzo
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Post by Pizzo on Oct 21, 2012 20:23:25 GMT 2
Hy gents! Thanks to Ruan i've got a 5th gear to put back on my nice niva! I downloaded the Colour Exploded Drawings (pdf) on the forum and i have to say its very usefull! Do you have any tips to do the job without disassemble parts i shouldn't? Thanks soo much again for your help!!! Kind regards Pizzo
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