Pinion Shaft Assembly Overview
Pinion Shaft Assembly Overview
• Refer to technical data, refer to => [ Code Letters, Allocation, Transmission Ratios, Capacities ] Code Letters, Allocation, Transmission Ratios, Capacities, when installing new gear wheels or the final drive gear set.
• Refer to technical data when installing new gear wheels.
• Lubricate all needle bearings on output shaft with gear oil before installing.
• Adjustment work is required when replacing the parts marked with 1). Table of adjustments, refer to => [ Adjustment Table ] Adjustment Table.
1 Transmission housing 1)
• Disassembling and assembling, refer to => [ Transmission Housing ] Transmission Housing.
2 Shim "S3"
• Table of adjustments, refer to => [ Adjustment Table ] Adjustment Table.
3 Tapered roller bearing outer race 1)
• Pulling out, refer to => [ Pulling tapered roller bearing outer race out of transmission housing ] Pinion Shaft
• Pressing in, refer to => [ Heating transmission housing in order to install tapered roller bearing outer race ] Pinion Shaft and => [ Pressing tapered roller bearing outer race
into transmission housing ] Pinion Shaft
4 Pinion shaft (output shaft) 1)
• Is mated with crown wheel, always replace together as a set.
• Adjusting crown wheel and pinion shaft, refer to => [ Pinion Shaft and Crown Wheel Adjusting General Information ] Pinion Shaft and Crown Wheel Adjusting General Information.
5 Tapered roller bearing inner race 1)
• Will be damaged during removal.
• Replace.
• Pressing off, refer to => [ Pressing off tapered roller bearing inner race ] Pinion Shaft
• Pressing on, refer to => [ Pressing on tapered roller bearing inner race ] Pinion Shaft
6 Circlip
• Redetermine thickness if taper roller bearing is replaced, refer to => [ Determining thickness of circlip ] Pinion Shaft
7 Needle bearing
• For 1st gear.
8 1st speed selector gear
• Check axial clearance after installing using feeler gauge => [ Checking axial play of 1st speed selector gear ] Pinion Shaft (0.20 to 0.50 mm).
9 Inner ring for 1st gear
• Installation position, Refer to => [ Installation position of synchronizing rings
for 1st and 2nd gear: ] Pinion Shaft
• Checking for wear, refer to => [ Checking 1st gear inner ring for wear ] Pinion Shaft
• Replace if scored or if there are visible traces of wear.
10 Intermediate ring for 1st gear
• Installation position, refer to => [ Installation position of synchronizing rings for 1st and 2nd gear: ] Pinion Shaft
• Checking for wear, refer to => [ Checking 1st and 2nd gear intermediate ring for wear ] Pinion Shaft
11 Synchro-ring for 1st gear
• Installation position, refer to => [ Installation position of synchronizing rings
for 1st and 2nd gear: ] Pinion Shaft
• Checking for wear, refer to => [ Checking 1st and 2nd gear intermediate ring for wear ] Pinion Shaft
• Replace if scored or if there are visible traces of wear.
12 Locking collar for 1st and 2nd gear
• Mark position in relation to synchronizing hub prior to removing.
• Assembling locking collar/synchronizing hub, refer to => [ Assembling 1st and 2nd gear locking collar/synchronizing hub ] Pinion Shaft
13 Locking piece
• Install locking pieces (Quantity: 3), refer to => [ Assembling 1st and 2nd gear locking collar/synchronizing
hub ] Pinion Shaft
14 Synchronizing hub for 1st and 2nd gear
• Installation position: high inside collar faces 2nd speed selector gear.
• Pressing off, refer to => [ Pressing off 1st and 2nd gear synchronizing hub ] Pinion Shaft
• Pressing on, refer to => [ Pressing on 1st and 2nd gear synchronizing hub ] Pinion Shaft
• Assembling locking collar/synchronizing hub, refer to => [ Assembling 1st and 2nd gear locking collar/synchronizing hub ] Pinion Shaft
15 Circlip
• Mark
• Installation position, refer to => [ Installation position of circlips ] Pinion Shaft, - item 1 -
• Redetermine thickness when replacing 1st and 2nd gear synchronizing hub or pinion shaft, refer to => [ Determining thickness of circlip ] Pinion Shaft
16 Needle bearing
• For 2nd gear.
17 Synchro-ring for 2nd gear
• Installation position, refer to => [ Installation position of synchronizing rings for 1st and 2nd gear: ] Pinion Shaft
• Checking for wear, refer to => [ Checking 1st and 2nd gear intermediate ring for wear ] Pinion Shaft
• Replace if scored or if there are visible traces of wear.
18 Intermediate ring for 2nd gear
• Installation position, refer to => [ Installation position of synchronizing rings for 1st and 2nd gear: ] Pinion Shaft
• Checking for wear, refer to => [ Checking 1st and 2nd gear intermediate ring for wear ] Pinion Shaft
19 Inner ring for 2nd gear
• Installation position, refer to => [ Installation position of synchronizing rings for 1st and 2nd gear: ] Pinion Shaft
• Checking for wear, refer to => [ Checking 1st and 2nd gear intermediate ring for wear ] Pinion Shaft
• Replace if scored or if there are visible traces of wear.
20 2nd speed selector gear
• Check axial clearance after installing using feeler gauge => [ Checking axial play of 2nd speed selector gear ] Pinion Shaft (0.20 to 0.50 mm).
21 Circlip
• Mark
• Installation position, refer to => [ Installation position of circlips ] Pinion Shaft, - item 2 -.
22 Tapered roller bearing inner race 1)
• Pressing off, refer to => [ Pressing off tapered roller bearing inner race with 2nd speed selector gear ] Pinion Shaft
• Pressing on, refer to => [ Pressing on tapered roller bearing inner race ] Pinion Shaft
23 Circlip
• Mark
• Installation position, refer to => [ Installation position of circlips ] Pinion Shaft, - item 3 -.
24 Thrust washer
• For reverse selector gear.
• Pressing off, refer to => [ Pressing off thrust washer for reverse selector gear ] Pinion Shaft
• Pressing on, refer to => [ Pressing on thrust washer for reverse selector gear ] Pinion Shaft
25 Tapered roller bearing outer race 1)
• Pulling out, refer to => [ Pulling tapered roller bearing outer race out of bearing housing ] Pinion Shaft
• Pressing in, refer to => [ Pressing tapered roller bearing outer race into bearing housing ] Pinion Shaft
26 Shim "S4"
• Table of adjustments, refer to => [ Adjustment Table ] Adjustment Table.
27 Bearing housing 1)
28 Needle bearing
• For reverse selector gear.
29 Reverse selector gear
• Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm).
30 Spring
• Insert into reverse selector gear, refer to => [ Inserting spring in selector gear ]
31 Synchronizing ring for reverse gear
• Checking for wear, refer to => [ Checking synchro-ring for wear ]
32 Reverse gear synchronizing hub
• Installation position: high inside collar faces 3rd gear wheel.
33 Reverse gear locking collar
• Mark position in relation to synchronizing hub prior to removing.
• Installation position: taper faces reverse gear synchro-ring.
34 3rd gear wheel
• Installation position: machined side faces reverse gear synchronizing hub.
35 Circlip
• Mark
• Installation position, refer to => [ Installation position of circlips ] Pinion Shaft, - item 4 -
• Redetermine thickness when replacing 3rd gear wheel, reverse gear synchronizing hub or pinion shaft. Refer to => [ Determining thickness of circlip ] Pinion Shaft
36 4th gear wheel
• Installation position: high inside collar faces 5th gear wheel.
37 5th gear wheel
• Installation position: high inside collar faces 4th gear wheel.
38 Spacer sleeve
39 6th gear wheel
• Installation position: high inside collar faces spacer sleeve => [ (Item 38) Spacer sleeve ].
40 Circlip
• Mark
• Installation position, refer to => [ Installation position of circlips ] Pinion Shaft, - item 5 -.
• Redetermine thickness when replacing gear wheels for 4th to 6th gear, the spacer sleeve or pinion shaft, refer to => [ Determining thickness of circlip ] Pinion Shaft
41 Needle bearing
• Bearing for pinion shaft in transmission cover.
• Removing and installing => [ (Item 3) Roller bearing ] Transmission Cover Assembly Overview.
42 Multi-point socket head bolt, 24 Nm
43 Retaining plate
• Secures needle bearing => [ (Item 41) Needle bearing ] in transmission cover.
44 Transmission cover
Inserting spring in selector gear
The bent end of spring - arrow - must be hooked into hole in selector gear.
Checking synchro-ring for wear
- Press synchro-ring into locking collar and measure gap - a - at positions - A -, - B - and - C - using feeler gauge.
- Add measured values and divide by 3.
The determined value should not exceed 0.45 mm.