Input Shaft Assembly Overview: Notes
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Removing the input shaft from the output shaft and the bearing bracket. Refer to SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW .
Disassembling and assembling input shaft - assembly sequence. Refer to INPUT SHAFT .
NOTE:
When installing new gears or input shaft, note technical data. Refer to Specifications .
Insert all bearings and synchronizer rings on input shaft with transmission fluid.
Remove the locking ring -10- only to replace the roller bearing -7-.
After installing, the 3rd through 6th gears must have an axial play of 0.15 to 0.50 mm.
- Securing Ring
- Determining thickness TRANSMISSION, ASSEMBLY SEQUENCE
- Transmission Housing
- Ball Bearing
- For input shaft
- Removing and installing -18- TRANSMISSION HOUSING
- Securing Ring
- Observe installed location TRANSMISSION HOUSING
- Sealing Plug
- For input shaft
- Installing INPUT SHAFT ASSEMBLY OVERVIEW .
- Input Shaft
- With splines for the 1st, 2nd and Reverse gear
- There is a plug in the hole, near the clutch plate splines -5-
- Install the plug when replacing the input shaft INSTALLING THE PLUG -1- IN THE INPUT SHAFT .
- Checking the input shaft for wear CHECKING THE INPUT SHAFT FOR WEAR .
- Roller Bearing
- Always replace
- For input shaft
- Pressing off PRESS ROLLER BEARING OFF INPUT SHAFT. .
- Pressing on CHECKING SYNCHRONIZER RING FOR WEAR .
- Bearing Bracket
- Supports input shaft and input shaft in transmission cover
- -3- SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW .
- Needle Bearing
- For 5th gear
- Installation location CHECKING SYNCHRONIZER RING FOR WEAR .
- Securing Ring
- Identify
- Do not exchange with the locking ring -16-
- Installation location CHECKING SYNCHRONIZER RING FOR WEAR .
- 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 CHECKING SYNCHRONIZER RING FOR WEAR .
- 5th Gear Wheel
- Must not contact the locking ring when turning the gear -10- CHECKING SYNCHRONIZER RING FOR WEAR .
- Spring
- Inserting in 5th gear selector gear INSERTING SPRING INTO SELECTOR GEAR .
- Synchronizer Ring for 5th Gear
- Checking for wear CHECKING SYNCHRONIZER RING FOR WEAR .
- Synchronizer Hub for 5th and 6th Gears
- Installed position: the shorter spline faces the 6th gear up to the groove INSTALLED POSITION: LOCKING COLLAR AND 5TH/6TH GEAR SYNCHRONIZER HUB .
- Locking Collar for 5th and 6th Gear
- Installed position: the groove faces the 6th gear INSTALLED POSITION: LOCKING COLLAR AND 5TH/6TH GEAR SYNCHRONIZER HUB .
- Securing Ring
- Identify
- Do not exchange with the locking ring -10-
- Determining thickness DETERMINING THE 5TH AND 6TH GEAR SYNCHRONIZER HUB LOCKING RING .
- Needle Bearing
- For 6th gear
- Synchronizer Ring for 6th Gear
- Checking for wear CHECKING SYNCHRONIZER RING FOR WEAR .
- Spring
- Inserting in 6th gear wheel INSERTING SPRING INTO SELECTOR GEAR .
- 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
- Spring
- Inserting in 3rd gear selector gear INSERTING SPRING INTO SELECTOR GEAR
- Synchronizer Ring for 3rd Gear
- Checking for wear CHECKING SYNCHRONIZER RING FOR WEAR .
- Synchronizer Hub for 3rd and 4th Gears
- Installed position: shoulder faces 4th gear INSTALLED POSITION: LOCKING COLLAR -2- AND REVERSE GEAR WHEEL -1- .
- Locking Collar for 3rd and 4th Gear
- Installed position: the groove faces the 4th gear SHIFT FORK GROUP, INPUT SHAFT, 1ST, 2ND AND REVERSE GEAR OUTPUT SHAFTS ASSEMBLY OVERVIEW .
- Inner Race/Needle Bearing
- For 4th gear
- Needle Bearing
- For 4th gear
- 4th Gear Synchronizer Ring
- Checking for wear INSERTING SPRING INTO SELECTOR GEAR .
- Spring
- Inserting in 4th gear wheel INSERTING SPRING INTO SELECTOR GEAR .
- 4th Gear Wheel
- Thrust Washer
- For 4th gear selector gear
- Inner Race
- For the roller sleeve -37- inside the transmission cover
- Bolt
- 200 Nm
- Coat with locking fluid AMV 185 101 A1
- Roller Sleeve
- Install in the transmission cover
- Removing and installing -6- TRANSMISSION COVER