Input Shaft Assembly Overview
Input Shaft Assembly Overview
Input shaft disassembling and assembling, refer to => [ Input Shaft ] Input Shaft.
• When installing new gears, note technical data. Refer to =>
Manual Transmission
• When replacing synchronizer rings, the intermediate ring and synchronizer ring for the respective gear must be replaced together.
• Insert all bearings and synchronizer rings on input shaft with transmission fluid.
• The twelve point nut => [ (Item 7) Twelve point nut, 75 Nm ] has left threads, turn clockwise to loosen this nut.
• On transmissions with spring loaded shift forks, refer to => [ 3rd/4th gear selector rod with spring-loaded shift fork. ] Input Shaft, Hollow Shaft, Drive Pinion and Selector Rod Assembly Overview, items 8, 11 to 14, 18 to 21, 25, 28 to 31 and 34 to 37 were changed.
1 Circlip
2 Grooved ball bearing
• Replacing with transmission removed, refer to => [ Input Shaft Grooved Ball Bearing, with Transmission Removed ] Input Shaft Grooved Ball Bearing, With Transmission Removed.
• Replacing with transmission disassembled => [ (Item 10) Grooved ball bearing ] Transmission Housing Assembly Overview.
3 Transmission housing
4 Needle bearing
• Removing and installing => [ (Item 1) Needle bearing ] Transmission Housing Assembly Overview.
5 Circlip
• Determine thickness.
6 Washer
• Determine thickness.
7 Twelve point nut, 75 Nm
• Has left threads.
8 Drive gear for 4th gear
9 Needle bearing
• For 4th gear.
10 Inner race/needle bearing
• For 4th gear selector gear.
11 Inner race for 4th gear
• Installed location, refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Replace if grooved or scored.
12 Intermediate ring for 4th gear
• Installed location, refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Checking for wear, refer to => [ Synchronizer rings for 3rd to 6th gears, checking for wear ] Input Shaft
13 Synchronizer ring for 4th gear
• Installed location, refer to => [ Installation location of synchronizer rings
for 3rd to 6th gears ] Input Shaft
• Checking for wear, refer to => [ Synchronizer rings for 3rd to 6th gears, checking for wear ] Input Shaft
• Replace if grooved or scored.
14 Locking collar for 3rd and 4th gear
• Assembling locking collar/synchronizer hub, refer to => [ Assembly of locking collar/synchronizer hub for 3rd and 4th gear ] Input Shaft
15 Locking piece
• Installation position: insert with convex side in locking collar, refer to => [ Assembly of locking collar/synchronizer hub
for 3rd and 4th gear ] Input Shaft
• Installing locking pieces (Quantity: 3), refer to => [ Assembly of locking collar/synchronizer hub for 3rd and 4th gear ] Input Shaft
16 Thrust plate
• Installing thrust pieces (3x), refer to => [ Assembly of locking collar/synchronizer hub for 3rd and 4th gear ] Input Shaft
17 Synchronizer hub for 3rd and 4th gears
• Pressing off, refer to => [ Press of 3rd, 5th and 6th gear selector gears together with synchronizer hub and inner races/needle bearings. ] Input Shaft.
• Pressing on, refer to => [ Pressing on synchronizer hub for 3rd and
4th gears ] Input Shaft
• Installation position: small shoulder on collar faces toward 3rd gear, refer to => [ 3rd/4th gear synchronizer hub installation
location ] Input Shaft
• Assembling locking collar/synchronizer hub, refer to => [ Assembly of locking collar/synchronizer hub for 3rd and 4th gear ] Input Shaft
18 Synchronizer ring for 3rd gear
• Installed location, refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Checking for wear, refer to => [ Synchronizer rings for 3rd to 6th gears, checking for wear ] Input Shaft
• Replace if grooved or scored.
19 Intermediate ring for 3rd gear
• Installed location. refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Checking for wear, refer to => [ Synchronizer rings for 3rd to 6th gears, checking for wear ] Input Shaft
20 Inner race for 3rd gear
• Installed location, refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Replace if grooved or scored.
21 Drive gear for 3rd gear
22 Needle bearing
• For 3rd gear.
23 Inner race/needle bearing
• For 3rd gear selector gear.
24 Thrust washer
• For 3rd and 6th gear selector gears.
25 Selector gear for 6th gear
26 Needle bearing
• For 6th gear.
27 Inner race/needle bearing
• For 6th gear selector gear.
28 Inner race for 6th gear
• Installed location, refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Replace if grooved or scored.
29 Intermediate ring for 6th gear
• Installed location, refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Checking for wear, refer to => [ Synchronizer rings for 3rd to 6th gears, checking for wear ] Input Shaft
30 Synchronizer ring for 6th gear
• Installed location, refer to => [ Installation location of synchronizer rings
for 3rd to 6th gears ] Input Shaft
• Checking for wear, refer to => [ Synchronizer rings for 3rd to 6th gears, checking for wear ] Input Shaft
• Replace if grooved or scored.
31 Locking collar for 5th and 6th gear
• Assembling locking collar/synchronizer hub, refer to => [ Assembly of locking collar/synchronizer hub for 5th and 6th gear ] Input Shaft
32 Synchronizer hub for 5th and 6th gears
• Installation position: High inner collar faces 5th gear, gear wheel
• Pressing off, refer to => [ Press of 3rd, 5th and 6th gear selector
gears together with synchronizer hub and inner races/needle bearings. ] Input Shaft.
• Pressing on, refer to => [ Pressing on synchronizer hub with locking collar for 5th and 6th gears ] Input Shaft
• Assembling locking collar/synchronizer hub, refer to => [ Assembly of locking collar/synchronizer hub for 5th and 6th gear ] Input Shaft
33 Thrust plate
• Installing thrust pieces (3x), refer to => [ Assembly of locking collar/synchronizer hub for 5th and 6th gear ] Input Shaft
34 Synchronizer ring for 5th gear
• Installed location, refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Checking for wear, refer to => [ Synchronizer rings for 3rd to 6th gears, checking for wear ] Input Shaft
• Replace if grooved or scored.
35 Intermediate ring for 5th gear
• Installed location, refer to => [ Installation location of synchronizer rings for 3rd to 6th gears ] Input Shaft
• Checking for wear, refer to => [ Synchronizer rings for 3rd to 6th gears, checking for wear ] Input Shaft
36 Inner race for 5th gear
• Installed location, refer to => [ Installation location of synchronizer rings
for 3rd to 6th gears ] Input Shaft
• Replace if grooved or scored.
37 Drive gear for 5th gear
38 Needle bearing
• For 5th gear.
39 Roller bearing
• For input shaft.
• Do not interchange with hollow shaft roller bearing.
• Pressing off, refer to => [ Place bearing bracket over
roller bearing on input shaft so that the rollers are not pressed out of the bearing cage. ] Input Shaft.
• Pressing on, refer to => [ Press roller bearing onto input shaft to stop, shoulder of faces toward roller bearing when doing so. ] Input Shaft.
40 Bearing bracket
• Roller bearing outer race => [ (Item 39) Roller bearing ] cannot be replaced individually, replace bearing bracket if worn.
• Roller bearing outer race must not have any radial play in bearing bracket.
41 Input shaft
• Differentiation of input shafts, refer to => [ Differentiation of Input Shafts ]
• Change: with additional PTFE washer for 5th gear needle bearing system, refer to => [ Differentiation of Input Shafts ] , allocate components via.
42 Roller sleeve
• For input shaft mounting in transmission cover.
• Always replace.
• Removing and installing => [ (Item 6) Roller sleeve ] Transmission Cover Assembly Overview.
43 Transmission cover
Differentiation of Input Shafts
Dimension x = 31 mm on an input shaft without PTFE washer
Dimension x = 29 mm on an input shaft with PTFE washer - A -
• After removing 5th gear needle bearing, slide PTFE washer - A - onto input shaft - arrow - to stop.