Pinion Shaft and Hollow Shaft Assembly Overview
Pinion Shaft and Hollow Shaft Assembly Overview
• When installing new gears or the drive set, consult technical data => [ Transmission Identification ] Transmission Identification.
• When installing new gears, consult technical data.
• Install all needle bearing on the hollow shaft with transmission oil.
• Adjustments are required when replacing components marked with 1). List of adjustments => [ Adjustment Overview ] Adjustment Overview.
1 Transmission housing 1)
2 Adjustment shim "S3"
• Adjustment overview => [ Adjustment Overview ] Adjustment Overview
3 Outer race/double tapered roller bearing 1)
• Pulling out => [ Removing the Outer Race/Double Tapered Roller
Bearing ] Pinion and Hollow Shaft
• installing => [ Warming up the Transmission Housing for Installing
the Outer Race/Double Tapered Roller Bearing ] Pinion and Hollow Shaft and => [ Installing Outer Race/Double Tapered Roller
Bearing ] Pinion and Hollow Shaft
4 Pinion1)
• Is mated with ring gear, always replace together as a set
• Pinion and ring gear, adjusting => [ Pinion Shaft and Ring Gear ] Pinion Shaft and Ring Gear
5 Inner race/double tapered roller bearing 1)
• Is damaged during removal
• Replace
• Pressing off => [ Removing Inner Race/Double Tapered Roller Bearing ] Pinion and Hollow Shaft
• Pressing on => [ Installing the Inner Race/Double Tapered Roller
Bearing ] Pinion and Hollow Shaft
6 Securing ring
• Re-determining thickness when replacing double tapered roller bearing => [ Determining Circlip ] Pinion and Hollow Shaft
7 Large needle bearing
• for pinion in hollow shaft
• Coat with transmission fluid
8 Hollow shaft
• Disassembling and assembling => [ Hollow shaft, disassembling and assembling ] Hollow shaft, disassembling and assembling
9 Small needle bearing
• for pinion in hollow shaft
• Coat with transmission fluid
10 Large needle bearing for 1st gear
11 Small needle bearing for 1st gear
12 1st gear wheel
• check the axial play with a feeler gauge (0.20 to 0.50 mm) after installing => [ Checking the gear wheels for axial play ] Hollow shaft, disassembling and assembling
13 Inner race for 1st gear
• Location => [ Installation position of synchronizer rings
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
• Checking for wear => [ Checking inner race of 1st gear for wear ] Hollow shaft, disassembling and assembling
• Replace if grooved or scored
14 Intermediate ring for 1st gear
• Location => [ Installation position of synchronizer rings
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
• Checking for wear => [ Checking intermediate ring of 1st and 2nd gear
for wear ] Hollow shaft, disassembling and assembling
15 Synchronizer ring for 1st gear
• Location => [ Installation position of synchronizer rings
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
• Checking for wear => [ Checking intermediate ring of 1st and 2nd gear
for wear ] Hollow shaft, disassembling and assembling
• Replace if grooved or scored
16 Locking collar for 1st and 2nd gear
• Mark the installation position of the synchronizer hub before removing
• Assembling locking collar/synchronizer hub => [ Assembly of locking collar/synchronizer hub
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
17 Thrust piece
• Installing thrust pieces (3x) => [ Assembly of locking collar/synchronizer hub
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
18 Synchronizer hub for 1st and 2nd gear
• Installation position: High inner collar faces 2nd gear wheel
• Pressing off => [ Pressing off synchronizer hub for 1st and 2nd
gears ] Hollow shaft, disassembling and assembling
• Pressing on => [ Pressing on synchronizer hub for 1st and
2nd gears ] Hollow shaft, disassembling and assembling
• Assembling locking collar/synchronizer hub => [ Assembly of locking collar/synchronizer hub
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
19 Securing ring
• identify
• Installation position => [ Installation position of circlips ] Hollow shaft, disassembling and assembling, - 1 -
• determine when replacing the 1st/2nd gear synchronizer hub or the hollow shaft => [ Determining Circlip ] Pinion and Hollow Shaft
20 Needle bearing
• For 2nd gear
21 Synchronizer ring for 2nd gear
• Location => [ Installation position of synchronizer rings
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
• Checking for wear => [ Checking intermediate ring of 1st and 2nd gear
for wear ] Hollow shaft, disassembling and assembling
• Replace if grooved or scored
22 Intermediate ring for 2nd gear
• Location => [ Installation position of synchronizer rings
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
• Checking for wear => [ Checking intermediate ring of 1st and 2nd gear
for wear ] Hollow shaft, disassembling and assembling
23 Inner race for 2nd gear
• Location => [ Installation position of synchronizer rings
for 1st and 2nd gear ] Hollow shaft, disassembling and assembling
• Checking for wear => [ Checking intermediate ring of 1st and 2nd gear
for wear ] Hollow shaft, disassembling and assembling
• Replace if grooved or scored
24 2nd gear wheel
• check the axial play with a feeler gauge (0.20 to 0.50 mm) after installing => [ Checking the gear wheels for axial play ] Hollow shaft, disassembling and assembling
25 Securing ring
• identify
• Installation position => [ Installation position of circlips ] Hollow shaft, disassembling and assembling, - 2 -
26 Inner race/tapered roller bearing 1)
• Pressing off => [ Remove the inner race/tapered roller bearing
with the 2nd gear wheel. ] Hollow shaft, disassembling and assembling
• Pressing on => [ Pressing on inner race/tapered roller bearing ] Hollow shaft, disassembling and assembling
27 Securing ring
• identify
• Installation position => [ Installation position of circlips ] Hollow shaft, disassembling and assembling, - 3 -
28 Thrust washer
• for reverse gear wheel
• Pressing off => [ Install the reverse gear wheel thrust washer ] Hollow shaft, disassembling and assembling
• Pressing on => [ Install the reverse gear wheel thrust washer. ] Hollow shaft, disassembling and assembling
29 Outer race/tapered roller bearing 1)
• Pulling out => [ Removing Outer Race/Tapered Roller Bearing
from the Bearing Housing ] Pinion and Hollow Shaft
• Installing => [ Installing Outer Race/Tapered Roller Bearing
into the Bearing Housing ] Pinion and Hollow Shaft
30 Adjustment shim "S4"
• Adjustment overview => [ Adjustment Overview ] Adjustment Overview
31 Bearing housing 1)
32 Needle bearing
• for reverse gear wheel
33 Reverse gear wheel
• check the axial play with a feeler gauge (0.20 to 0.50 mm) after installing
34 Spring
• install into the reverse gear wheel => [ Inserting spring into selector gear ]
35 Reverse gear synchronizer ring
• Checking for wear => [ Checking synchronizer ring for wear ]
36 Synchronizer hub for reverse gear
• Installation position: High inner collar faces 3rd gear drive gear
37 Locking collar for reverse gear
• Mark the installation position of the synchronizer hub before removing
• Installation position: the cone faces the reverse gear synchronizer ring
38 3rd gear wheel
• Installation position: the sanded side face the reverse gear synchronizer hub
39 Securing ring
• identify
• Installation position => [ Installation position of circlips ] Hollow shaft, disassembling and assembling, - 4 -
• determine when replacing the 3rd gear wheel, the reverse gear synchronizer or the hollow shaft => [ Determining Circlip ] Pinion and Hollow Shaft
40 4th gear wheel
• Installation position: High inner collar faces 5th gear drive gear
41 5th gear wheel
• Installation position: High inner collar faces 4th gear drive gear
42 Spacer sleeve
43 6th gear wheel
• Installation position: the higher inner collar faces the spacer sleeve => [ (Item 42) Spacer sleeve ]
44 Securing ring
• identify
• Installation position => [ Installation position of circlips ] Hollow shaft, disassembling and assembling, - 5 -
• determine the spacer sleeve or hollow shaft when replacing the 4th to 6th gear wheels => [ Determining Circlip ] Pinion and Hollow Shaft
45 Needle bearing
• for hollow shaft mounting in transmission cover
• Removing and installing => [ (Item 3) Needle bearing ] Transmission Cover Assembly Overview
46 Internal multi-point bolt - 24 Nm
47 Mounting plate
• secures the needle bearing inside the transmission cover, refer to => [ (Item 45) Needle bearing ]
48 Transmission cover
Inserting spring into selector gear
The bent end of the spring - arrow - must be hooked into the hole in the selector gear.
Checking synchronizer ring for wear
- Press the synchronizer ring into the locking collar and measure the gap - a - with a feeler gauge in positions - A -, - B - and - C -.
- Add measured values and divide by 3.
Determined value must not exceed 0.45 mm.