Output Shaft Parts
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NOTE:
Snap rings of different sizes and thicknesses are used. For this reason, the individual snap rings must be marked (e.g. with numbers). The thickness of the individual snap ring must be determined again if a directly affected component is replaced.
OUTPUT SHAFT PARTS
| No. | Designation | Qty. | Removal | Installation | ||||
|---|---|---|---|---|---|---|---|---|
| -1- (2) | Tapered roller bearing - inner race | 1 | Press off via the reverse gear wheel using a suitable separating device (e.g. Kukko 17/2). | Heat to approx. 100°C and press on using a suitable tubular piece (e.g. special tool 30-100). Press again after heat exchange. | ||||
| -2- (2) | Loose gear wheel, reverse gear | 1 | Insert spring before assembly. | |||||
| -3- (2) | Synchronizing ring | 1 | Mark for refitting. | Check for wear. Fit with the same gear wheel. Press off inner race of tapered roller bearing. Use the outer race to do this. (see INSTRUCTIONS FOR DISASSEMBLY AND ASSEMBLY (TRANSMISSION G86) ) | ||||
| -4- (2) | Selector sleeve | 1 | Install selector sleeves in correct position. The slanted side is facing the reverse-gear loose gear wheel in the case of the selector sleeve for 5th and reverse gear. The slanted side is facing the 2nd-gear loose gear wheel in the case of the selector sleeve for 1st and 2nd gear. See INSTRUCTIONS FOR DISASSEMBLY AND ASSEMBLY (TRANSMISSION G86) | |||||
| -5- (2) | Needle-roller bearing | 1 | Mark for refitting. | Always fit with reverse-gear loose gear wheel. | ||||
| -6- (2) | Blue snap ring* | 1 | Mark for refitting. | Re-measure if necessary. | ||||
| -7- (2) | Synchronizing element | 1 | Press off together with 5th-gear loose gear wheel using a suitable separating device (e.g. Kukko 17/2). | Heat to approx. 100°C and press on. The high collar is facing the 5th-gear loose gear wheel. | ||||
| -8- (2) | Synchronizing ring, 5th gear | 1 | Mark for refitting. | See | ||||
| -9- (2) | Loose gear wheel, 5th gear(1)(2) | 1 | Insert spring before assembly. | |||||
| -10- (2) | Brown snap ring* | 1 | Mark for refitting. | Must always be 2.00 mm thick. | ||||
| -11- (2) | Needle-roller bearing(1) | 1 | Mark for refitting. | Always fit with 5th-gear loose gear wheel. | ||||
| -12- (2) | Snap ring(1) | 1 | Mark for refitting. | Re-measure if necessary. | ||||
| -13- (2) | Fixed gear wheel, 4th gear(1) | 1 | Press off with thrust plate VW 402. | Heat to approx. 100°C and press on in the correct position so that the groove and high collar are facing 3rd gear. | ||||
| -14- (2) | Snap ring* | 1 | Mark for refitting. | Re-measure if necessary. | ||||
| -15- (2) | Fixed gear wheel, 3rd gear | 1 | Press off with thrust plate VW 402. | Heat to approx. 100°C and press on in the correct position so that the groove is facing 4th gear. | ||||
| -16- (2) | Loose gear wheel, 2nd gear | 1 | Insert spring before assembly. | |||||
| -17- (2) | Synchronizing ring, 2nd gear | 1 | Mark for refitting. | Check for wear. Fit with 2nd-gear gear wheel. | ||||
| -18- (2) | Selector sleeve | 1 | Slant is facing 2nd gear. | |||||
| -19- (2) | Needle-roller bearing | 1 | Mark for refitting. | Always fit with 2nd-gear loose gear wheel. | ||||
| -20- (2) | Blue snap ring* | 1 | Mark for refitting. | Must always be 2.5 mm thick. | ||||
| -21- (2) | Blue snap ring* | 1 | Mark for refitting. | Re-measure if necessary. | ||||
| -22- (2) | Synchronizing element | 1 | Press off together with 1st-gear loose gear wheel using a suitable separating device (e.g. Kukko 17/2). | Heat to approx. 100°C and press on. The high collar is facing the 2nd-gear loose gear wheel. | ||||
| -23- (2) | Synchronizing ring, 1st gear | 1 | Mark for refitting. | Check for wear. Fit with the same gear wheel. | ||||
| -24- (2) | Loose gear wheel, 1st gear | 1 | Insert spring before assembly. | |||||
| -25- (2) | Needle-roller bearing | 1 | Mark for refitting. | Always fit with 1st-gear loose gear wheel. | ||||
| -26- (2) | Snap ring* | 1 | Mark for refitting. | Always fit with 1st-gear loose gear wheel. | ||||
| -27- (2) | Tapered roller bearing - inner race | 1 | Press off with outer race of tapered roller bearing and thrust plate VW 401 and Press off with outer race of tapered roller bearing and thrust plate VW 402. | Heat to approx. 100°C and press on using a suitable tubular piece (e.g. special tool VW 415a). Press again after heat exchange. | ||||
| -28- (2) | Output shaft(1) | 1 | This is paired with the crown wheel (drive set). Re-adjust if replaced; see Refer to ADJUSTING THE DRIVE SET (TRANSMISSION G 86) . |
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| -29- (2) | Tapered roller bearing - outer race | 1 | See Refer to DISASSEMBLING AND ASSEMBLING THE TRANSMISSION HOUSING . |
See Refer to DISASSEMBLING AND ASSEMBLING THE TRANSMISSION HOUSING . |
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| -30- (2) | Adjusting shim S3 | X | See Refer to DISASSEMBLING AND ASSEMBLING THE TRANSMISSION HOUSING . |
See Refer to DISASSEMBLING AND ASSEMBLING THE TRANSMISSION HOUSING . |
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| -31- (2) | Retaining sleeve | 1 | See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
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| -32- (2) | Tapered roller bearing - outer race | 1 | See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
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| -33- (2) | Adjusting shim S4 | X | See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
See | ||||
| -34- (2) | Thrust plate | 1 | See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
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| -35- (2) | Rubber washer | 1 | See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
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| -36- (2) | Transmission case cover | 1 | See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
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| -37- (2) | Transmission housing | 1 | See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
See Refer to DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER . |
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