Overview - Input Shaft
WARNING: This page is about a different variant/trim than selected.
NOTE:
Pay attention to the technical data when installing new gears or the input shaft. Refer to TECHNICAL DATA .
Insert all bearings and synchronizer rings on input shaft with transmission fluid.
Remove the locking ring -item 10- only to replace the roller bearing -item 7- (See Fig 1).
After installing, 3rd through 6th gears must have an axial play of 0.15 to 0.50 mm.
Pay attention to the allocation of the locking ring to the locking collar. Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR TO THE LOCKING COLLAR ALLOCATION .
- Circlip
- Selecting thickness. Refer to Fig 5.
- Transmission Housing
- Ball Bearing
- For the input shaft
- Removing and installing. Refer to OVERVIEW - TRANSMISSION HOUSING -item 18- (See illustration 73).
- Circlip
- Installation position. Refer to Fig 6.
- Plug
- For the input shaft
- Installing. Refer to Fig 2.
- Input Shaft
- Roller Bearing
- Bearing Bracket
- Supports input shaft and input shaft in transmission cover
- Remove any locking compound still in the threaded holes with a thread cutter.
- Different versions
- AllocationNOTE:
Outer roller bearing races on input and output shafts cannot be replaced individually.
Roller bear outer races must not have any radial clearance in bearing bracket.
When replacing the roller bearing on the input- output shaft, for example when replacing the input shaft, the bearing bracket does not have to be replaced.
- Needle Bearing
- For 5th gear
- Installation position. Refer to Figure .
- Circlip
- Identify
- Do not exchange with the locking ring, refer to -item 16- "Circlip".
- Installation position. Refer to Figure .
- Always replace after removing
- Must not be turned by hand in the groove all around the input shaft
- Must not contact the 5th gear wheel >>when turning the gear<<. Refer to Figure - "5th gear wheel -B-".
- 5th Gear Wheel
- Synchronized Spring
- Inserting in 5th gear selector gear. Refer to Figure
- 5th Gear Synchronizer Ring
- Checking for wear. Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR, CHECKING FOR WEAR
- Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR TO THE LOCKING COLLAR ALLOCATION
- Synchronizer Hub for 5th and 6th Gears
- Installation position. Refer to Figure
- Locking Collar for 5th and 6th Gear
- Installation position. Refer to Figure
- Do not interchange with the locking collar for the third and 4th gears. Mark the locking collars
- Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR TO THE LOCKING COLLAR ALLOCATION
- Circlip
- Needle Bearing
- For 6th gear
- 6th Gear Synchronizer Ring
- Checking for wear. Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR, CHECKING FOR WEAR
- Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR TO THE LOCKING COLLAR ALLOCATION
- Synchronized Spring
- Inserting in 6th gear wheel. Refer to Figure
- 6th Gear Wheel
- Thrust Washer
- For 3rd and 6th gear selector gears
- Inner Race/Needle Bearing
- For 3rd gear
- Needle Bearing
- For 3rd gear
- 3rd Gear Wheel
- Synchronized Spring
- Inserting into the 3rd gear wheel. Refer to Figure
- 3rd Gear Synchronizer Ring
- Checking for wear. Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR, CHECKING FOR WEAR
- Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR TO THE LOCKING COLLAR ALLOCATION
- Synchronizer Hub for 3rd and 4th Gears
- Installed position: recessed inner collar faces 4th gear. Refer to Figure
- Locking Collar for 3rd and 4th Gear
- Installation position. Refer to Figure
- Do not interchange with the locking collar for the 5th and 6th gears. Mark the locking collars
- Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR TO THE LOCKING COLLAR ALLOCATION
- Inner Race/Needle Bearing
- For 4th gear
- Needle Bearing
- For 4th gear
- 4th Gear Synchronizer Ring
- Checking for wear. Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR, CHECKING FOR WEAR
- Refer to SYNCHRONIZER RINGS 3RD TO 6TH GEAR TO THE LOCKING COLLAR ALLOCATION
- Synchronized Spring
- Inserting in 4th gear wheel. Refer to Figure
- 4th Gear Wheel
- Thrust Washer
- For 4th gear selector gear
- Inner Race
- For the roller sleeve, refer to -item 37- inside the transmission cover
- Internal Multi-Point Bolt
- 200 Nm
- Coat with Locking Fluid AMV 185 101 A1
- Loosen and tighten with the Socket for internal multi-point bolt XZN 12
- Roller Sleeve
- Install in the transmission cover
- Removing and installing. Refer to OVERVIEW - TRANSMISSION COVER -item 6- (See illustration 72).
-- Install the plug -1- into the input shaft -2- to dimension -a-.
- Dimension -a- = 12.5 mm
- The open side of the plug -arrow- must face the Assembly Mandrel for Gear Selector Rod 10-508.
- If the surface of the input shaft is visibly damaged near the needle bearing in the dual mass flywheel -arrow-, then replace both the input shaft and the needle bearing. Refer to DUAL MASS FLYWHEEL NEEDLE BEARING OR BALL BEARING, REPLACING .
- Check the input shaft near the bearing in the drive plate -arrow- for wear grooves and replace the needle bearing in the drive plate if necessary. Refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING for 2.0L, engine codes CAED, CAEB, CPMB, CPMA, NEEDLE BEARING IN DRIVE PLATE, REPLACING for 3.0L, engine codes CCBA, CGXC, CTUB, or NEEDLE BEARING IN DRIVE PLATE, REPLACING for 3.2L, engine code CALA .