Output shaft, disassembling and assembling: Notes
WARNING: This page is about a different variant/trim than selected.
NOTE:
- Tapered roller bearings are only to be replaced as a set. After replacement, adjust the output shaft, see OUTPUT SHAFT, ADJUSTING .
- When installing new gears, consult Technical data, see CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, CAPACITIES .
- Removing and installing output shaft, see DISASSEMBLY AND ASSEMBLY SEQUENCE .
- Output shaft applications, see OUTPUT SHAFT APPLICATIONS .
The following have been modified for vehicles with the 2.0 liter, 85 kW (115 hp) engine:
- Increased hub spline diameter for 4th gear item.
- Additional groove and circlip for 4th gear, on 3rd gear side item.
The following list pertains to Fig 1.
- Transmission housing cover
- Needle bearing
- Removing and installing, see TRANSMISSION HOUSING COVER, SERVICING
- Attachment bolt
- Circlip for 5th gear
- Always replace
- Must seat firmly in groove
- Thrust washer
- Not installed on vehicles with 2.0 liter, 85 kW (115 hp) engine
- Retainer plate for 5th gear
- Installed only on vehicles with 2.0 liter, 85 kW (115 hp) engine
- 5th gear
- Installing, see Available circlips
- Modified retainer on vehicles with 2.0 liter, 85 kW (115 hp) engine, see Retainer plate for 5th gear (for vehicles with 2.0 liter, 85 kW/115 hp engine only)
- Transmission housing
- Needle bearing
- Removing and installing, see TRANSMISSION HOUSING, SERVICING
- Circlip for 4th gear
- Always replace
- Must seat firmly in groove
- 4th gear
- Removing and installing, see DISASSEMBLY AND ASSEMBLY SEQUENCE
- Vehicles with 2.0 liter, 85 kW (115 hp) engine: additional circlip on 3rd gear side item
- Larger internal diameter for modified output shaft
- Circlip for 4th gear
- Additional on vehicles with 2.0 liter, 85 kW (115 hp) engine
- Circlip for 3rd gear
- Always replace
- Must seat firmly in groove
- Recheck for thickness, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- Increased diameter on vehicles with 2.0 liter, 85 kW (115 hp) engine, see AVAILABLE CIRCLIPS
- 3rd gear
- Installation position, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- Adjusting axial clearance, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- 2nd gear
- Needle bearing for 2nd gear
- Extracting inner race, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- Pressing on inner race, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- 2nd gear synchronizer ring
- Friction surface coated with molybdenum
- Check for wear, see Checking synchronizer rings
CAUTION:- When replacing synchronizer rings, always refer to parts catalog microfiche for the correct parts application.
- Synchronizer rings that are being reused must not be interchanged.
- Operating sleeve/synchronizer hub for 1st/2nd gear
- Assembling, see Assembling operating sleeve and synchronizer hub for 1st and 2nd gear and Assembling synchronizer hub and operating sleeve
- Removing and installing, see Disassembly and assembly sequence
- Spring
- Operating sleeve
- Synchronizer hub
- Locking key
- 1st gear synchronizer ring
- Check for wear, see Checking synchronizer rings
- Identification, see MARKING OF 1ST GEAR SYNCHRONIZER RING WITH 110° tooth angle
- 1st gear
- Thrust washer
- Installation position, see ASSEMBLING
- Shim S3
- Adjustment summary, see ADJUSTMENT SUMMARY
- Outer race of small tapered roller bearing
- Extracting from clutch housing, see Extracting outer race of small tapered roller bearing from clutch housing
- Installing, see Driving outer race of small tapered roller bearing into clutch housing
- Inner race of small tapered roller bearing
- Pressing off, see Pressing off inner race of small tapered roller bearing
- Pressing on, see Pressing on inner races of small and large tapered roller bearings
- Clutch housing
- Output shaft
- Matched to final drive gear
- Vehicles with 2.0 liter, 85 kW (115 hp) engine: additional groove for 4th gear circlip, see OUTPUT SHAFT APPLICATIONS
- Adjust when replacing, see OUTPUT SHAFT, ADJUSTING
- Inner race of large tapered roller bearing
- Pressing off, see Pressing off inner race of large tapered roller bearing
- Pressing on, see Pressing on inner races of small and large tapered roller bearings
- Bearing cover
- With outer race of large tapered roller bearing and stop for reverse idler gear
- Bearing cover and outer race are single unit
- Do not press out outer race
- Hex-head bolt
- Tightening torque: 25 N.m (18 ft lb) plus additional 1/4 turn (90°)