Overview - Output Shaft, 1ST To 4TH Gears: Notes
Secure the transmission on the assembly stand. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .
To install, warm the inner races/tapered roller bearing and synchronizer hub to approximately 100 °C (212 °F) using Inductive Heater :VAS6414 . Wear protective gloves.
Install a collar bushing instead of thrust washers, refer to -item ) Thrust Washer-, and retaining ring -item ) Retaining Ring- on transmissions with reinforcement measures. The output shaft components, 1st through 4th gear, 4th gear wheel and the needle bearing for the 4th gear wheel were adapted. Refer to Fig 2.
Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to OUTPUT SHAFT 1ST THROUGH 4TH GEAR, ADJUSTING .
Replace both tapered roller bearings together.
- Clutch Housing
- Oil Deflector Ring
- Dished Washer
- Removing. Refer to Removing Dished Washer Out Of Shaft .
- Installing. Refer to Installing Dished Washer Into Output Shaft .
- Outer Race/Tapered Roller Bearing
- Removing. Refer to Removing Tapered Roller Bearing .
- Installing. Refer to Installing Outer Race/Tapered Roller Bearing Into Clutch Housing .
- Inner Race / Tapered Roller Bearing
- Removing. Refer to Removing Inner Race/Tapered Roller Bearing .
- Installing. Refer to Installing Inner Race/Tapered Roller Bearing .
- Output Shaft
- For 1st through 4th gear
- There are different versions. Refer to Differentiation Of Output Shafts
- Allocate according to the transmission code letters.
- Adjusting. Refer to OUTPUT SHAFT 1ST THROUGH 4TH GEAR, ADJUSTING .
- Needle Bearing
- For 2nd gear
- 2nd Gear Wheel
- 2nd Gear Inner Race
- Replace if there are wear grooves
- Installation position. Refer to Figure
- 2nd Gear Outer Race
- Check the inner friction surface for wear. Refer to Checking The Inner Contact Surface For Wear .
- Check the outer friction surface for wear. Refer to Checking The Outer Contact Surface For Wear .
- Installation position. Refer to Figure
- 2nd Gear Synchronizer Ring
- Check the inner running surface for grooves and radial wear
- Installation position. Refer to Figure
- Locking Collar with Synchronizer Hub for 1st and 2nd Gears
- After removing circlip, refer to -item ) Circlip-, remove the 2nd gear wheel. Refer to Pressing Off Gear Locking Collar/Synchro-Hub .
- Disassembling. Refer to Figure.
- Assembling the locking collar/synchronizer hub. Refer to Figure and. Refer to Assembling Gear Locking Collar/Synchro-Hub
- Installation position. Refer to Locking Collar/ Synchro-Hub .
- Installing. Refer to Installing The Locking Collar .
- Circlip
- 1st Gear Synchronizer Ring
- Check the inner running surface for grooves and radial wear
- Installation position. Refer to Figure
- 1st Gear Outer Race
- Check the inner friction surface for wear. Refer to Checking The Inner Contact Surface For Wear .
- Check the outer friction surface for wear. Refer to Checking The Outer Contact Surface For Wear .
- Installation position. Refer to Figure
- 1st Gear Inner Race
- Replace if there are wear grooves
- Installation position. Refer to Figure
- Needle Bearing
- For 1st gear
- 1st Gear Wheel
- Mount on the output shaft. Refer to Install Gear With Needle Roller Bearing .
- Thrust Washer
- For 1st and 4th gears
- Quantity: 2
- The tab on the thrust washer must fit into the hole in the output shaft.
- Not installed on transmissions with reinforcement measures
- Retaining Ring
- Holds the thrust washers in place on the output shaft. Refer to -item ) Thrust Washer-.
- Not installed on transmissions with reinforcement measures
- Collar Bushing
- For the 4th gear needle bearing
- only installed on transmissions with reinforcement measures. Refer to Fig 2
- Allocate according to the transmission code letters.
- Needle Bearing
- For 4th gear
- There are different versions. Refer to Variations of the Needle Bearing and Gear Wheels for 4th Gear .
- Allocate according to the transmission code letters.
- 4th Gear Wheel
- There are different versions. Refer to Variations of the Needle Bearing and Gear Wheels for 4th Gear .
- Allocate according to the transmission code letters.
- 4th Gear Synchronizer Ring
- Brass or steel
- Checking for wear. Refer to Checking The 4TH Gear Sunchronizer Ring For Wear .
- Locking Collar with Synchronizer Hub for 3rd and 4th Gears
- After removing the locking ring remove the 4th gear wheel. Refer to -item ) Circlip-. Refer to Removing 3RD And 4TH Gear Synchro-Hub/Locking Collar .
- Disassembling. Refer to Figure.
- Installed position: locking collar/synchronizer hub. Refer to Installation Position 3RD And 4TH Gear Locking Collar/Synchro-Hub .
- Assembling the locking collar/synchronizer hub. Refer to Figure and Assembling Gear Locking Collar/Synchro-Hub .
- Installing. Refer to Installing Gear Synchro-Hub With Locking Collar .
- Circlip
- 3rd Gear Synchronizer Ring
- Check the inner running surface for grooves and radial wear
- Installation position. Refer to Installing Synchronizer Ring (1ST Gear) .
- 3rd Gear Outer Race
- Check the inner friction surface for wear. Refer to Checking The Inner Contact Surface For Wear .
- Check the outer friction surface for wear. Refer to Checking The Outer Contact Surface For Wear .
- Installation position. Refer to Installing Synchronizer Ring (1ST Gear) .
- 3rd Gear Inner Race
- Replace if there are wear grooves
- Installation position. Refer to Installing Synchronizer Ring (1ST Gear) .
- Needle Bearing
- For 3rd gear
- 3rd Gear Wheel
- Mount on the output shaft. Refer to Installing Gear With Needle Roller Bearing .
- Inner Race / Tapered Roller Bearing
- Removing. Refer to Removing Inner Race/Tapered Roller Bearing .
- Installing. Refer to Installing Inner Race/Tapered Roller Bearing .
- Circlip
- Determine again when replacing inner race/tapered roller bearing. Refer to -item ) Inner Race / Tapered Roller Bearing-, and output shaft, refer to -item ) Output Shaft-.
Refer to Determining Circlip .
- Determine again when replacing inner race/tapered roller bearing. Refer to -item ) Inner Race / Tapered Roller Bearing-, and output shaft, refer to -item ) Output Shaft-.
- Outer Race/Tapered Roller Bearing
- Removing. Refer to Removing Tapered Roller Bearing From Transmission Housing .
- Installing. Refer to Installing Tapered Roller Bearing Into Transmission Housing .
- Shim
- Selecting thickness. Refer to OUTPUT SHAFT 1ST THROUGH 4TH GEAR, ADJUSTING .
- Transmission Housing
Allocate Transmission with Reinforcement Measures Using the Codes
Reinforcement Measures on Manual Transmission 0FB near 4th Gear Wheel
The following components are affected.
- Output Shaft
Characteristics. Refer to Differentiation Of Output Shafts
- Collar Bushing
Characteristics. Refer to Variations of the Needle Bearing and Gear Wheels for 4th Gear .
- 4th Gear Needle Bearing
Characteristics. Refer to Variations of the Needle Bearing and Gear Wheels for 4th Gear .
- 4th Gear Wheel
Characteristics. Refer to Variations of the Needle Bearing and Gear Wheels for 4th Gear .
Never mix components for reinforced 4th gear transmissions and 4th gear transmissions without reinforcement.
To remove and install modified components, follow instructions in repair information. Refer to OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS .