Output Shaft Assembly Overview
Output Shaft Assembly Overview
Shift fork group, input shaft, 1st, 2nd and reverse gear output shafts, removing and installing. 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.
Output shaft, disassembling and assembling. Refer to => [ Output Shaft ] Output Shaft.
• When installing new gears or output shaft, note technical data.
• Insert all needle bearings and synchronizer rings with transmission fluid.
• When replacing synchronizer rings, the intermediate ring and synchronizer ring for the respective gear must be replaced together.
• If the synchronizer rings are not to be replaced, make sure they are reallocated to their original gear.
1 Sealing Cap
• With oil guide
• For output shaft
• Removing and installing, refer to => [ Transmission, Assembly Sequence ] Transmission, Assembly Sequence
2 Bolt
• 200 Nm
• For output shaft
• Coat with locking fluid (AMV 185 101 A1)
3 Transmission Housing
4 Ball Bearing
• For output shaft
• Removing and installing - 15 - => [ Ball Bearing ] Transmission Housing
5 Securing Ring
• Observe installed location, refer to => [ Transmission Housing ] Transmission Housing
6 Synchronizer Hub for Reverse Gear
• Removing and installing, refer to => [ Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
7 Spring
• Insert into the hole on the reverse gear synchronizer hub
8 Reverse Gear Synchronizer Ring
• Checking for wear
9 Locking Collar for Reverse Gear
• Installation location
10 Reverse Gear Wheel
• Installation location
11 Needle Bearing
• For reverse gear
12 Inner Race/Needle Bearing
• For reverse gear
• Removing and installing, refer to => [ Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
13 Thrust Washer
• For 1st gear and reverse gear selector gears
14 1st Gear Wheel
15 Inner Race for 1st Gear
• Installation location => [ Installation Position: 1st and
2nd Gear Synchronizer Rings ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Distinguishing 1st and 2nd gear inner races
• Checking for wear
• Replace if grooved or scored
16 Intermediate Ring for 1st gear
• Installation location => [ Installation Position: 1st and
2nd Gear Synchronizer Rings ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Checking for wear
17 Synchronizer Ring for 1st Gear
• Installation location => [ Installation Position: 1st and
2nd Gear Synchronizer Rings ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Checking for wear
• Replace if grooved or scored
18 Needle Bearing
• For 1st gear
19 Securing Ring
• Determining thickness => [ locking ring for
the 1st/2nd gear synchronizer hub. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
20 Thrust Piece
• Quantity: 3
• Installing
21 Synchronizer Hub for 1st and 2nd Gear
• Installation location
22 Locking Collar for 1st and 2nd Gear
• Installation location
23 Synchronizer Ring for 2nd Gear
• Installation location => [ Installation Position: 1st and
2nd Gear Synchronizer Rings ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Checking for wear
• Replace if grooved or scored
24 Intermediate Ring for 2nd Gear
• Installation location => [ Installation Position: 1st and
2nd Gear Synchronizer Rings ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Checking for wear
25 Inner Race for 2nd Gear
• Installation location => [ Installation Position: 1st and
2nd Gear Synchronizer Rings ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Distinguishing 1st and 2nd gear inner races
• Replace if grooved or scored
26 2nd Gear Wheel
27 Needle Bearing
• For 2nd gear
28 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
29 Roller Bearing
• For output shaft
• Pressing off => [ Removing the Roller Bearing
from the Output Shaft ] Output Shaft
• Pressing on => [ Installing the Roller Bearing
on the Output Shaft ] Output Shaft
30 Output Shaft
• With splines for 5th and 6th gears
31 Needle Bearing
• For the rear flange shaft bearing in the output shaft
• Pulling out => [ Flange Shaft Mounting Needle
Bearing, Removing from Output Shaft ] Output Shaft
• Driving in => [ Flange Shaft Mounting Needle
Bearing, Driving in Flush in the Output Shaft ] Output Shaft
32 3rd Gear Wheel
• Pressing off => [ Removing the 3rd Gear Wheel ] Output Shaft
• Installed position: the higher inside collar faces 4th gear
• Pressing on => [ Pressing on Gear-Wheel for 3rd
Gear ] Output Shaft
33 Spacer Sleeve
34 4th Gear Wheel
• Pressing off => [ Removing the 4th Gear Wheel ] Output Shaft
• Installed position: the higher inside collar faces the spur gear - 37 -
• Pressing on => [ Pressing on Gear-Wheel for 4th
Gear ] Output Shaft
35 Securing Ring
• Determining thickness => [ Determine the 4th Gear Wheel
Locking Ring. ] Output Shaft
36 Transmission Cover
37 Spur Gear
• With tapered roller bearing and gear carrier
• Spur Gear Bearing, Servicing, refer to => [ Spur Gear and Center Differential Bearing, Servicing ] Spur Gear and Center Differential Bearing, Servicing
Installed Position: Locking Collar - 2 - and Reverse Gear Wheel - 1 -
• The pointed teeth - arrow A - in the locking collar - 2 - face opposite the reverse gear selector gear drive splines - arrow B -- 1 -.
Checking Synchronizer Ring for Wear
- Press the synchronizer ring - E - into the locking collar and then measure the gap dimension - a - using a depth gauge - D - at - A -, - B - and - C -.
- Add measured values and divide by 3.
Determined value must not exceed 0.5 mm.
Characteristics of the 1st Gear - A - and 2nd Gear - B - Inner Races
- A - the friction surface on the inside of the 1st gear inner race has a coating - arrow 1 - and is conical.
- B - there is no friction surface on the inside of the 2nd gear inner race - arrow 2 - and is cylindrical.
Checking Inner Race of 1st Gear for Wear
- Check the outer friction surface - arrow - for scoring or signs of wear, replace if necessary.
- Press inner race onto taper of selector gear and measure gap dimension - a - using a feeler gauge.
Checking Intermediate Ring of 1st and 2nd Gear for Wear
- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
- Place inner race, intermediate ring and synchronizer ring on selector gear taper and turn.
• Turn means: turn the synchronizer rings just about one turn while pressing on the rings at the same time.
- Then measure gap - a - with a feeler gauge.
• Replace inner race, intermediate ring and synchronizer ring for the respective gear together.
Assembly of Locking Collar/Synchronizer Hub for 1st and 2nd Gear
- Mount the locking collar - 1 - over the synchronizer hub - 2 - so that the wire tooth spacing on the locking collar - arrow A - and on the synchronizer hub - arrow B - align with each other.
• Synchronizer hub installed position: the higher inside collar - arrow C - is facing the 2nd gear wheel.
- Then place thrust pieces - 3 - in synchronizer hub and press thrust pieces into notches - arrows D - in locking collar.