Section 25 (6-Speed Manual Transmission 0A3 All Wheel Drive, Internal Component Servicing)
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- 00 - Technical data
- 34 - Controls, housing
- Transmission, disassembling and assembling
- Overview
- Assembly overview
- Torsen housing and torsen differential, removing and installing - assembly overview
- Transmission cover and selector shaft, removing and installing
- First, second and reverse gears, removing and installing - assembly overview
- Input shaft, hollow shaft, drive pinion and selector rods, removing and installing - assembly overview
- Assembly sequence
- Notes
- Transmission, disassembling
- Transmission, assembling
- Notes
- Synchronizer rings for 1st, 2nd and reverse gears, checking for wear
- Differentiation of reverse gear synchronization rings - A - and 1st/2nd gear - B -
- Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
- 1st and 2nd gear locking collar installation location
- Assembly of locking collar/synchronizer hub for 1st and 2nd gear
- Assemble locking collar and reverse gear selector gear
- Determine thickness of circlip - 1 - and shim(s) - 2 - as follows:
- Input shaft grooved ball bearing, replacing in uninstalled but not disassembled transmission
- Torsen housing, disassembling and assembling
- Torsen housing, disassembling and assembling
- Notes
- Press off flange shaft (torsen housing with vibration dampener)
- Press off flange shaft (torsen housing without vibration dampener)
- Pressing in flange shaft
- As of serial number 42987 - Flange shaft with nut - arrow A - and sealing ring with additional dust lip - arrow B -
- Pry off sealing ring
- Differentiation of sealing rings
- Sealing ring - up to serial number 42986 - installing
- Sealing ring - as of serial number 42987 - with additional dust lip, installing
- Pressing out ball bearing for flange shaft
- Pressing in ball bearing for flange shaft
- Torsen housing, disassembling and assembling
- Transmission cover, servicing
- Transmission cover, servicing
- Notes
- Press needle bearing out of transmission cover
- Press needle bearing into transmission cover
- Remove ball sleeve from transmission housing
- Press ball sleeve into transmission cover
- Ball sleeve press-in depth in transmission cover
- Remove roller sleeve from transmission cover
- Carefully press new roller sleeve into transmission cover to stop.
- Secure needle bearing and roller housing in transmission cover with peen
- Transmission cover, servicing
- Transmission housing, servicing
- Transmission housing, servicing
- Notes
- Remove input shaft needle bearing from transmission housing
- Drive input shaft needle bearing into transmission housing
- Measure needle bearing drive-in depth and secure needle bearing with peening
- Remove selector shaft ball sleeve
- Drive on selector shaft ball sleeve and secure with peening
- Breather tube installation dimension
- Selector shaft sealing ring, removing from disassembled transmission
- Selector shaft sealing ring, removing from assembled transmission
- Selector shaft ball sleeve, driving on
- Driving in selector shaft seal
- Input shaft grooved ball bearing, removing from disassembled transmission
- Drive input shaft grooved ball bearing in to stop
- Remove selector rod ball sleeve - C -
- Drive in selector rod ball sleeve
- Drive-in depth for ball sleeves in transmission housing
- Transmission housing, servicing
- Transmission, disassembling and assembling
- 35 - Gears, shafts
- Input shaft
- Input shaft, assembly overview
- Input shaft, disassembling and assembling - assembly sequence
- Notes
- Synchronizer rings for 3rd to 6th gears, checking for wear
- Installation location of synchronizer rings for 3rd to 6th gears
- Assembly of locking collar/synchronizer hub for 5th and 6th gear
- Pressing on synchronizer hub with locking collar for 5th and 6th gears
- Inner race/needle bearing - arrow A - for 6th gear selector gear, pressing on
- Inner race/needle bearing - arrow A - for 3rd gear selector gear, pressing on
- 3rd/4th gear synchronizer hub installation location
- Pressing on synchronizer hub for 3rd and 4th gears
- 3rd/4th gear locking collar installation location
- Assembly of locking collar/synchronizer hub for 3rd and 4th gear
- Inner race/needle bearing for 4th gear selector gear, pressing on
- Determine thickness of circlip - 1 - and shim - 2 - as follows:
- Drive pinion and hollow shaft
- Drive pinion and hollow shaft, assembly overview
- Drive pinion, disassembling and assembling
- Notes
- Flange shaft mounting needle bearing, removing from drive pinion
- Flange shaft mounting needle bearing, driving in flush in drive pinion
- Pressing off inner race/tapered roller bearing
- Double angular contact ball bearing, pressing off
- Double angular contact ball bearing, pressing on
- Pressing on inner race/tapered roller bearing
- Shim " S 5 " for positioning inner race/tapered ball bearing, redetermining
- Hollow shaft, disassembling and assembling
- Shim " S 6 " for positioning 2nd gear selector gear, redetermining
- Torsen differential bearing, servicing
- Input shaft
- 39 - Front final drive, differential
- Flange shaft seals, replacing
- Differential, removing and installing
- Differential, disassembling and assembling
- Differential, disassembling and assembling
- Notes
- Pulling outer race for right tapered roller bearing out of transmission housing
- Right tapered roller bearing outer race, driving into transmission housing
- Tapered roller bearing inner races, removing
- Pressing off left and right tapered roller bearing inner race
- Left tapered roller bearing outer race, removing from final drive cover
- Left tapered roller bearing outer race, pressing into final drive cover
- Driving ring gear from housing
- Heat ring gear to approx. 100°C and install
- Differential planetary gear axle, removing
- Differential planetary gears, installing
- Differential, disassembling and assembling
- Pinion and ring gear, adjusting