Drive Pinion & Hollow Shaft, Disassemble & Assemble Overview

Special tools and equipment
- VW401 thrust plate
- VW402 thrust plate
- VW407 punch
- VVV411 punch
- VW412 thrust disc
- 415A tube
- 416B tube
- 418A tube
- 429 thrust ring
- VW4471 thrust pad
- VW454 thrust tube
- VW519 sleeve
- VW771 slide hammer-complete set
- 40-103 sleeve
- 2010 sleeve
- 3062 thrust pad
- 3128 bushing puller
- Kukko 17/2 separating tool
- Kukko 21/1 puller

Notes:
- When installing new gears or the final drive set, consult technical data, Refer to Manual Transaxle/Transmission, Application and ID.

- Adjustments are required when replacing components marked by 1), See List of adjustments, Refer to Differential Manual Transaxle, Adjustments.

1. Transmission housing
2. Shim S3
3. Double tapered roller bearing outer race 1)
- Replace together with item 5
- Pulling out refer to Fig. 1
- Pressing in refer to Fig. 3
4. Drive pinion
- Matched to ring gear, always replace together as a set
- Adjusting drive pinion and ring gear, Refer to Differential Manual Transaxle, Adjustments.
5. Double tapered roller bearing inner race 1)
- Always replace
- Damaged when removed
- Pressing off refer to Fig. 2
- Pressing on refer to Fig. 4
6. Circlip
- Redetermine thickness if double roller bearing is replaced refer to Fig. 5
7. Needle bearing for hollow shaft 1)
- For drive pinion in hollow shaft
- Lubricate with MOS2 grease
8. Hollow shaft 1)
9. Needle bearing for 1st gear
10. Needle bearing for 1st gear
11. 1st gear
12. Spring
- Inserting in 1st gear refer to Fig. 16
- Application of spring to gear, Refer to Parts Supplier.
13. Synchronizer - ring for 1st gear
- Checking for wear refer to Fig. 17
14. Synchronizer - hub for 1st and 2nd gear
- Pressing off refer to Fig. 14
- Pressing on refer to Fig. 18
15. Circlip
- Identification
- Allocation, refer to Fig. 15, item -1-
- Re-determining thickness if synchronizer hub is replaced refer to Fig. 5
16. Needle ,bearing for 2nd gear
17. Operating sleeve for 1st and 2nd gear
- Allocation refer to Fig. 19
18. Synchronizer - ring for 2nd gear
- Checking for wear refer to Fig. 17
19. Spring
- Inserting in 2nd gear refer to Fig. 16
- Application of spring to gear, Refer to Parts Supplier.
20. 2nd gear
21. Circlip
- Identification
- Allocation refer to Fig. 15 item -2-
22. 3rd gear
- Pressing off refer to Fig. 13
- Pressing on refer to Fig. 20
23. Circlip
- Identification
- Allocation refer to Fig. 15, item -3-
- Re-determining thickness if 3rd gear is replaced refer to Fig. 5
24. 4th gear
- Pressing off refer to Fig. 12
- Pressing on refer to Fig. 21
25. Circlip
- Identification
- Allocation - Fig. 15, item -4-
- Redetermining thickness if 4th gear is replaced refer to Fig. 5
26. Needle bearing
27. 5th gear
28. Spring
- Inserting in 5th gear refer to Fig. 16
- Application of spring to gear, Refer to Parts Supplier.
29. Synchronizer - ring for 5th gear
- Checking for wear refer to Fig. 17
30. Circlip
- Identification
- Allocation refer to Fig. 15, item -5-
31. Synchronizer - hub for 5th gear and reverse gear
- Pressing off refer to Fig. 11
- Pressing on refer to Fig.22
32. Circlip
- Identification
- Allocation refer to Fig. 15, item -6-
- Redetermining thickness if synchronizer hub is replaced refer to Fig. 5
33. Needle bearing
- For reverse gear
34. 5th and reverse gear operating sleeve
- Allocation refer to Fig. 23
35. Synchronizer- ring for reverse gear
- Checking for wear refer to Fig. 17
36. Spring
- Insert in reverse gear refer to Fig. 16
- Application of spring to gear, Refer to Parts Supplier.
37. Reverse gear
38. Circlip
- Identification
- Allocation refer to Fig. 15, item -7-
39. Tapered roller bearing inner race 1)
- Pressing off refer to Fig. 9
- Pressing on refer to Fig. 10
40. Bushing
- To secure small tapered roller bearing outer race
- Pulling out refer to Fig. 6
- Does not need to be installed after small tapered roller bearing has been replaced
41. Tapered roller bearing outer race 1)
- Pressing out refer to Fig. 7
- Pressing in refer to Fig. 8
42. Shim S4
43. Ring
- Holds rubber washer
- Application, Refer to Parts Supplier.
44. Rubber washer
- Compensates length variations
- Application, Refer to Parts Supplier.
45. Transmission - cover