Input shaft, disassembling and assembling: Notes
WARNING: This page is about a different variant/trim than selected.
NOTE:
When installing new gears, consult specifications, see CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, CAPACITIES .
Vehicles with 2.0 liter, 85 kW (115 hp) engine: the input shaft incorporates larger dimensions for the following:
- Splines for clutch disc
- Input shaft oil seal
- Front needle bearing
The following list pertains to Fig 1.
- Bolt
- M17
- Always replace
- 150 N.m (111 ft lb)
- Removing and installing, see TRANSMISSION HOUSING COVER AND 5TH GEAR, REMOVING AND INSTALLING
- Dished washer
- Operating sleeve/synchronizer hub for 5th gear
- Removing ASSEMBLING
- Installing, see Available circlips
- Installation position and assembly, see Installation position of 5th gear operating sleeve
- Stop ring
- Prevents locking keys from moving out of position
- Removing, see Removing stop ring
- Installing, see Installing stop ring
- Spring
- 5th gear operating sleeve
- Installation position, see Installation position of 5th gear operating sleeve
- Synchronizer hub
- Locking key
- Socket-head bolt
- M7 x 24
- 15 N.m (11 ft lb)
- Deep groove ball bearing
- Pressing off, see Pressing off deep groove ball bearing
- Pressed into transmission housing during installation of input shaft, see TRANSMISSION HOUSING, SERVICING
- Tension bracket
- Secures deep groove ball bearing
- 4th gear
- 4th gear synchronizer ring
- Check for wear, see Checking synchronizer ring
- Circlip
- Always replace
- Do not overstretch
- Must seat properly in groove
- Operating sleeve/synchronizer hub for 3rd/4th gear
- Pressing off, see Pressing off operating sleeve and synchronizer hub for 3rd and 4th gear
- Synchronizer hub identification, see Identification of 3rd/4th gear synchronizer hub
- Assembling, see Assembling 3rd/4th gear operating sleeve and synchronizer hub
- Installation position, see Installation position of 3rd/4th gear operating sleeve and synchronizer hub
- Pressing on, see Pressing on 3rd/4th gear operating sleeve and synchronizer hub
- Operating sleeve
- Synchronizer hub
- Locking key
- Spring
- Input shaft
- Different diameter for vehicles with 2.0 liter, 85 kW (115 hp) engine note, INPUT SHAFT, DISASSEMBLING AND ASSEMBLING
- Clutch housing
- Bores modified for larger input shaft on vehicles with 2.0 liter, 85 kW (115 hp) engine
- Input shaft needle bearing
- Removing and installing, see CLUTCH HOUSING, SERVICING
- Seal for clutch pushrod
- Can be replaced without disassembling transmission (transmission removed)
- Removing, see Prying out oil seal for clutch pushrod
- Installation position, see Installation positions of oil seal and bushing
- Installing, see Driving in oil seal for clutch pushrod
- Bushing
- Installation position, see Installation positions of oil seal and bushing
- Extracting, see Extracting bushing for clutch pushrod
- Can be replaced without disassembling transmission (transmission removed)
- Installing, see Driving in clutch pushrod bushing to shoulder
- 3rd gear
- 3rd gear synchronizer ring
- Friction surface coated with molybdenum, check for wear, see Checking synchronizer ring
- Transmission housing
- Input shaft shim
- Input shaft adjustment not required
- Original adjustment shim should be reinstalled after repairs
- If no shim was installed, reassemble without shim
- When bearing or clutch housing/transmission housing is replaced, shim installation is not required.
- Removing and installing input shaft, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- Thrust washer
- Installation position, see Installation position of 5th gear thrust washer
- After installing 5th gear synchronizer ring -31-, place 5th gear -30- on synchronizer hub -7-
- 5th gear
- 5th gear synchronizer ring
- Check for wear, see Checking synchronizer ring