Overview - Output Shaft
Pay attention to the technical data when installing new gears or the output shaft. Refer to TRANSMISSION/ENGINE ALLOCATION .
Insert all needle bearings and synchronizer rings with transmission fluid.
When replacing synchronizer rings, the intermediate ring and synchronizer ring for the respective gear must be replaced together.
If the synchronizer rings are not to be replaced, make sure they are reallocated to their original gear.
- Transmission Housing
- Ball Bearing
- For the output shaft
- Removing and installing. Refer to OVERVIEW - TRANSMISSION HOUSING -item 14- "Ball Bearing".
- Plate
- to lock the ball bearing in the transmission housing on
- Thrust Washer
- Reverse Gear Synchronizer Hub
- Can be manually removed from the output shaft
- Reverse Gear Inner Race
- Reverse Gear Intermediate Ring
- Synchronizer Ring for Reverse Gear
- Reverse Gear Wheel
- with reverse gear locking collar
- Locking collar and reverse gear selector gear, Disassembling and Assembling. Refer to Fig 2
- Bolt
- Tightening specification. 24 Nm
- Needle Bearing
- For reverse gear
- Inner Race/Needle Bearing
- For reverse gear
- Removing. Refer to WHEEL SET, DISASSEMBLING AND ASSEMBLING - "1st gear wheel -E- along with the inner race/needle bearing for reverse gear -C- and the thrust washer -D-" (See Figure).
- Installing. Refer to WHEEL SET, DISASSEMBLING AND ASSEMBLING - "thrust washer -B- and install the heated inner race -C- for the needle bearing reverse gear wheel " (See Figure).
- Thrust Washer
- For 1st gear and reverse gear selector gears
- 1st Gear Wheel
- 1st Gear Inner Race
- Intermediate Ring for 1st Gear
- Synchronizer Ring for 1st Gear
- Needle Bearing
- For 1st gear
- Inner Race/Needle Bearing
- For the 1st gear selector gear
- Removing. Refer to WHEEL SET, DISASSEMBLING AND ASSEMBLING - "2nd gear wheel -E- along with the inner race/needle bearing for 1st gear -C- and the synchronizer hub/locking collar -D- " (See Figure).
- Installing. Refer to Figure
- Locking Collar/Synchronizer Hub For 1st And 2nd Gears
- Assembling locking collar/synchronizer hub; refer to Fig 7
- Removing. Refer to WHEEL SET, DISASSEMBLING AND ASSEMBLING - "2nd gear wheel -E- along with the inner race/needle bearing for 1st gear -C- and the synchronizer hub/locking collar -D- " (See Figure).
- Installing. Refer to Figure
- 2nd Gear Synchronizer Ring
- 2nd Gear Intermediate Ring
- 2nd Gear Inner Race
- 2nd Gear Wheel
- Needle Bearing
- For 2nd gear
- Inner Race/Needle Bearing
- Thrust Washer
- For 2nd gear wheel
- Bearing Bracket
- Roller Bearing
- Output Shaft
- with splines for 5th and 6th gears
- Needle Bearing or Bearing Bushing
- 3rd Gear Wheel
- 4th Gear Wheel
- Circlip
- Transmission Cover
- Output Wheel/Drive Wheel
- With tapered roller bearing and gear carrier
- Spur Gear Bearing, Servicing. Refer to OVERVIEW - SPUR GEAR FOR BEARING AND CENTER DIFFERENTIAL
- Reverse Gear Wheel
- Locking collar
- Thrust piece
-- Slide locking collar over reverse gear selector gear.
Installed position:
- The pointed gear teeth -arrow A- on the locking collar and the helical-cut gear teeth -arrow B- on the reverse gear wheel will face the opposite direction after being assembled.
- Thrust piece notches -3- on the reverse gear wheel -arrow C- and locking collar -arrow D- must be centered over each other.
-- Next, place the thrust pieces -3- in reverse gear selector gear notches and press the thrust pieces into the locking collar notches -arrow D-.
- Reverse gear synchronizer ring: The tabs -arrow 1- have a smooth surface.
- Reverse gear intermediate ring: The friction surface -arrows 2- are coated with sintered lining (brass colored).
- Reverse gear inner race: Does not have inner friction surface -arrow 3-.
- Synchronizer ring for 1st and 2nd gear: The tabs each have two ridges -arrow 4-. Identification for the 1st and 2nd gear synchronizer ring; refer to Fig 4.
- Intermediate ring for 1st and 2nd gear: The friction surfaces -arrows 5- are coated with carbon (black).
- Inner race for 1st and 2nd gear: The inner friction surface -arrow 6- is coated with carbon (black).
- 1st gear synchronizer ring: The "19100" -arrow 1- label means that the clutch spline has an angle (∠) of 19°.
- 2nd gear synchronizer ring: The "17101" -arrow 1- label means that the clutch spline has an angle (∠) of 17°. Also, in each case, 3 x 3 gear teeth are missing on this synchronizer ring -arrows 3-.
The reverse gear synchronizer ring is smaller on the inside diameter and bears the identifying label of "15100".
-- Check the outer friction surface -arrow- for scoring or signs of wear, replace if necessary.
-- Press inner race onto gear wheel taper and measure gap dimension -a- using a Feeler Gauge.
| Gap Dimension -a- | Wear Limit |
|---|---|
| 1st and 2nd gear - inner race | 0.6 mm |
-- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
-- Place inner race, intermediate ring and synchronizer ring on selector gear taper and >>turn<<.
>>Turn<< means: turn the synchronizer rings just about one turn while pressing on the rings at the same time.
-- Then measure the gap dimension -a- with a Feeler Gauge.
| Gap Dimension -a- | Wear Limit |
|---|---|
| 1st, 2nd and reverse gears | 0.7 mm |
Replace inner race, intermediate ring and synchronizer ring for the respective gear together.
-- Mount the locking collar -1- over the synchronizer hub -2- so that the wire tooth spacing on the locking collar -arrow A- and on the synchronizer hub -arrow B- align with each other.
- Locking collar installation position: The bevel -arrow C- or the side with the greater outside diameter faces the 2nd gear wheel.
- Synchronizer hub installation position: The notch -arrow D- or the "label" must face the 2nd gear wheel.
-- Then place thrust pieces -3- in synchronizer hub and press thrust pieces into notches -arrow E- in the locking collar.