Input Shaft Assembly Overview
Input Shaft Assembly Overview
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 ] 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 ] Input Shaft.
• When installing new gears or input shaft, note technical data.
• 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.
1 Securing Ring
• Determining thickness => [ Determine the Locking Ring for the Input Shaft as Follows: ] Transmission, Assembly Sequence
2 Transmission Housing
3 Ball Bearing
• For input shaft
• Removing and installing - 18 - => [ Ball Bearing ] Transmission Housing
4 Securing Ring
• Observe installed location => [ Installed Position: Locking
Rings for the Ball Bearings ] Transmission Housing
5 Sealing Plug
• For input shaft
• Installing
6 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
• Checking the input shaft for wear
7 Roller Bearing
• Always replace
• For input shaft
• Pressing off => [ Press roller bearing off input shaft. ] Input Shaft
• Pressing on => [ Install the roller bearing all the way onto
the input shaft. ] Input Shaft
8 Bearing Bracket
• Supports input shaft and input shaft in transmission cover
• - 3 - => [ Bearing Bracket ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts Assembly Overview
9 Needle Bearing
• For 5th gear
• Installation location => [ needle bearing on
the 5th gear wheel and carefully guide id over the locking ring. When doing this, do not lay the needle bearing on the collar on the input shaft. ] Input Shaft
10 Securing Ring
• Identify
• Do not exchange with the locking ring - 16 -
• Installation location => [ needle bearing on
the 5th gear wheel and carefully guide id over the locking ring. When doing this, do not lay the needle bearing on the collar on the input shaft. ] Input Shaft
• 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 => [ 5th gear wheel. ] Input Shaft
11 5th Gear Wheel
• Must not contact the locking ring when turning the gear - 10 - => [ 5th gear wheel. ] Input Shaft
12 Spring
• Inserting in 5th gear selector gear => [ Inserting Spring into Selector
Gear ] Input Shaft
13 Synchronizer Ring for 5th Gear
• Checking for wear => [ Checking Synchronizer Ring for
Wear ] Input Shaft
14 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 ] Input Shaft
15 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 ] Input Shaft
16 Securing Ring
• Identify
• Do not exchange with the locking ring - 10 -
• Determining thickness => [ Determining the 5th and 6th
gear synchronizer hub locking ring ] Input Shaft
17 Needle Bearing
• For 6th gear
18 Synchronizer Ring for 6th Gear
• Checking for wear => [ Checking Synchronizer Ring for
Wear ] Input Shaft
19 Spring
• Inserting in 6th gear wheel => [ Inserting Spring into Selector
Gear ] Input Shaft
20 6th Gear Wheel
21 Thrust Washer
• For 3rd and 6th gear selector gears
22 Inner Race/Needle Bearing
• For 3rd gear
23 Needle Bearing
• For 3rd gear
24 3rd Gear Wheel
25 Spring
• Inserting in 3rd gear selector gear => [ Inserting Spring into Selector
Gear ] Input Shaft
26 Synchronizer Ring for 3rd Gear
• Checking for wear => [ Checking Synchronizer Ring for
Wear ] Input Shaft
27 Synchronizer Hub for 3rd and 4th Gears
• Installed position: shoulder faces 4th gear => [ Installed Position: Locking
Collar and 3rd/4th Gear Synchronizer Hub ] Input Shaft
28 Locking Collar for 3rd and 4th Gear
• Installed position: the groove faces the 4th gear => [ Installed Position: Locking
Collar and 3rd/4th Gear Synchronizer Hub ] Input Shaft
29 Inner Race/Needle Bearing
• For 4th gear
30 Needle Bearing
• For 4th gear
31 4th Gear Synchronizer Ring
• Checking for wear => [ Checking Synchronizer Ring for
Wear ] Input Shaft
32 Spring
• Inserting in 4th gear wheel => [ Inserting Spring into Selector
Gear ] Input Shaft
33 4th Gear Wheel
34 Thrust Washer
• For 4th gear selector gear
35 Inner Race
• For the roller sleeve - 37 - inside the transmission cover
36 Bolt
• 200 Nm
• Coat with locking fluid (AMV 185 101 A1)
37 Roller Sleeve
• Install in the transmission cover
• Removing and installing - 6 - => [ Roller Sleeve ] Transmission Cover
Installing the Plug - 1 - in the Input Shaft
- Install the plug - 1 - into the input shaft - 2 - to dimension - a -.
• Dimension - a - = 12.5 mm
• The open side of the plug - arrow - must face the assembly mandrel (10-508).
Checking the Input Shaft for Wear
• If the surface of the input shaft is visibly damaged near the needle bearing in the dual mass flywheel - arrow -, then replace both the input shaft and the needle bearing. Refer to => [ Dual Mass Flywheel Needle Bearing, Sachs and LuK ] Dual Mass Flywheel Needle Bearing, Sachs and LuK.
• Check the input shaft near the bearing in the drive plate - arrow - for scoring. Replace the needle bearing in the drive plate if necessary.
