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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






1 Bolt

20 Nm plus an additional 45° turn

For attaching the shift fork group - 2 - to the bearing bracket - 3 -

2 Shift Fork Group

Disassembling and assembling, refer to => [ Gearshift Rails and Selector Forks ] Gearshift Rails and Selector Forks

3 Bearing Bracket

Supports input shaft and input shaft in transmission cover

Clean threaded holes of locking compound, for example with a thread cutter

Outer roller bearing races on input and output shafts cannot be replaced individually.

Roller bear outer races must not have any radial clearance in bearing bracket.

4 Input Shaft

Disassembling and assembling, refer to => [ Input Shaft Assembly Overview ] Input Shaft Assembly Overview

5 Output Shaft

With 3rd and 4th gears

1st, 2nd and reverse gears, 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.

Disassembling and assembling, refer to => [ Output Shaft ] Output Shaft

6 Needle Bearing

For 2nd gear

7 2nd Gear Wheel

8 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=> [ Characteristics of the 1st Gear and 2nd Gear Inner Races ] Output Shaft Assembly Overview

9 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

10 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

11 Locking Collar/Synchronizer Hub for 1st and 2nd Gear

Pulling off => [ 2nd gear wheel ,
the synchronizer hub and the 1st/2nd gear locking collar. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts

Installed position: the higher inside collar faces 2nd gear => [ Assembly of Locking Collar/Synchronizer
Hub for 1st and 2nd Gear ] Output Shaft Assembly Overview

Pressing on => [ Installing the 1st/2nd Gear
Synchronizer Hub ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts

12 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

13 Needle Bearing

For 1st gear

14 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

15 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

16 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=> [ Characteristics of the 1st Gear and 2nd Gear Inner Races ] Output Shaft Assembly Overview

17 1st Gear Wheel

18 Thrust Washer

For 1st gear and reverse gear selector gears

19 Inner Race/Needle Bearing

For reverse gear

Pulling off => [ 1st gear wheel with
the reverse gear synchronizer hub and the reverse gear wheel inner race. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts

Pressing on => [ thrust washer and
then install the heated inner race for the reverse gear
needle bearing. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts

20 Needle Bearing

For reverse gear

21 Reverse Gear Wheel

22 Locking Collar for Reverse Gear

Installation location => [ Installed Position: Locking
Collar and Reverse Gear Wheel ] Output Shaft Assembly Overview

23 Reverse Gear Synchronizer Ring

Checking for wear => [ Checking Synchronizer Ring for
Wear ] Output Shaft Assembly Overview

24 Synchronizer Hub for Reverse Gear

With a spring

Pulling off => [ 1st gear wheel with
the reverse gear synchronizer hub and the reverse gear wheel inner race. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts

Pressing on => [ Install the reverse gear synchronizer
hub with the spring installed ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts