Output Shaft Overview
Output Shaft Overview
Shift fork group, input shaft, 1st, 2nd and reverse gear output shafts, removing and installing, refer to => [ Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts Overview ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts Overview.
Assembly sequence - remove and install the shift fork group, driveshaft, first, second and reverse gears on the output shaft; 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.
Output shaft, disassembling and assembling, refer to => [ Output Shaft ] Output Shaft.
• When installing new gears or the output shaft, note technical data.
• Insert all needle bearings and synchronizer rings with transmission fluid.
• When replacing synchronizer rings, the intermediate ring and synchronizer ring for the respective gear must be replaced together.
• If the synchronizer rings are not to be replaced, make sure they are reallocated to their original gear.
1 Transmission Housing
2 Ball Bearing
• For the output shaft
• Replace => [ (Item 14) Ball Bearing ] Transmission Housing
3 Plate
• To lock the ball bearing in the transmission housing on
4 Thrust Washer
5 Reverse Gear Synchronizer Hub
• Can be manually removed from the output shaft
6 Reverse Gear Inner Race
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins; refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Replace if there are grooves or scoring
7 Reverse Gear Intermediate Ring
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins, refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Checking for wear, refer to => [ Intermediate Ring for 1st, 2nd and
Reverse Gears, Checking for Wear ]
8 Synchronizer Ring for Reverse Gear
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins, refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Checking for wear, refer to => [ Intermediate Ring for 1st, 2nd and
Reverse Gears, Checking for Wear ]
• Replace if there are grooves or scoring
9 Reverse Gear Wheel
• With reverse gear locking collar
• Locking collar and reverse gear selector gear, disassembling and assembling, refer to => [ Assemble Locking Collar and Reverse
Gear Selector Gear ]
10 Bolt
• Tightening specification => [ (Item 13) Bolt ] Transmission Housing
11 Needle Bearing
• For reverse gear
12 Inner Race/Needle Bearing
• For reverse gear
• Removing => [ 1st gear wheel along with the inner race/needle bearing for reverse
gear and the thrust washer. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Installing => [ Mount the thrust washer and install the heated inner race for the needle bearing reverse gear wheel. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
13 Thrust Washer
• For 1st gear and reverse gear selector gears
14 1st Gear Wheel
15 1st Gear Inner Race
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins, refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Checking for wear, refer to => [ Checking Inner Race for 1st Gear and
2nd Gear for Wear ]
• Replace if there are grooves or scoring
16 Intermediate Ring for 1st Gear
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins, refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Checking for wear, refer to => [ Intermediate Ring for 1st, 2nd and
Reverse Gears, Checking for Wear ]
17 Synchronizer Ring for 1st Gear
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins, refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Identification, refer to => [ Identification for the 1st and 2nd Gear
Synchronizer Ring ]
• Checking for wear, refer to => [ Intermediate Ring for 1st, 2nd and
Reverse Gears, Checking for Wear ]
• Replace if there are grooves or scoring
18 Needle Bearing
• For 1st gear
19 Inner Race/Needle Bearing
• For the 1st gear selector gear
• Removing => [ Remove the 2nd gear wheel along with the inner race/needle bearing for 1st gear and the synchronizer hub/locking collar. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Installing, refer to => [ Heat the Inner Race/Needle Bearing for 1st Gear Wheel up to Approximately 100 °C (212 °F)
and Install. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
20 Locking Collar/Synchronizer Hub for 1st and 2nd Gears
• Assembling locking collar/synchronizer hub, refer to => [ Assembly of Locking Collar/Synchronizer
Hub for 1st and 2nd Gears ]
• Removing => [ Remove the 2nd gear wheel along with the inner race/needle bearing for 1st gear and the synchronizer hub/locking collar. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Installing, refer to => [ Installing the Synchronizer Hub with
Locking Collar for 1st and 2nd Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
21 2nd Gear Synchronizer Ring
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins, refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Identification, refer to => [ Identification for the 1st and 2nd Gear
Synchronizer Ring ]
• Checking for wear, refer to => [ Intermediate Ring for 1st, 2nd and
Reverse Gears, Checking for Wear ]
• Replace if there are grooves or scoring
22 Intermediate Ring for 2nd Gear
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins, refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Checking for wear, refer to => [ Intermediate Ring for 1st, 2nd and
Reverse Gears, Checking for Wear ]
23 2nd Gear Inner Race
• Installed position, refer to => [ Installation location of Synchronizer Rings
for 1st, 2nd and Reverse Gears ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
• Differentiating the spring pins, refer to => [ Differentiation of Reverse Gear Synchronization
Rings and 1st/2nd Gear ]
• Checking for wear, refer to => [ Checking Inner Race for 1st Gear and
2nd Gear for Wear ]
• Replace if there are grooves or scoring
24 2nd Gear Wheel
25 Needle Bearing
• For 2nd gear
26 Inner Race/Needle Bearing
• For selector gear of 2nd gear
• Removing, refer to => [ Remove the Roller Bearing with Inner
Ring/Needle Bearing for 2nd Gear and Thrust Washer from the Output Shaft ] Output Shaft
• Installing, refer to => [ Inner Race/Needle Bearing, 2nd Gear
Wheel, Installing ] Output Shaft
27 Thrust Washer
• For selector gear of 2nd gear
28 Bearing Bracket
• Supports input shaft and input shaft in transmission cover
• => [ (Item 3) Bearing Bracket ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts Overview
29 Roller Bearing
• For the output shaft
• Removing, refer to => [ Remove the Roller Bearing with Inner
Ring/Needle Bearing for 2nd Gear and Thrust Washer from the Output Shaft ] Output Shaft
• Installing, refer to => [ Installing the Roller Bearing on the
Output Shaft ] Output Shaft
30 Output Shaft
• With splines for 5th and 6th gears
31 Needle Bearing
• For the rear flange shaft bearing in the output shaft
• Removing, refer to => [ Flange Shaft Mounting Needle Bearing, Removing
from Output Shaft ] Output Shaft
• Installing, refer to => [ Flange Shaft Mounting Needle Bearing, Installing
Flush into the Output Shaft ] Output Shaft
32 3rd Gear Wheel
• Removing, refer to => [ Removing the 3rd Gear Wheel ] Output Shaft
• Installed position: High inner collar faces 4th gear
• Installing, refer to => [ Heat the 3rd Gear Wheel to a Maximum
150 °C (302 °F) and Install All the Way to the Stop ] Output Shaft
33 4th Gear Wheel
• Removing, refer to => [ Removing the 4th Gear Wheel ] Output Shaft
• Installed position: High inner collar faces the 3rd gear
• Installing, refer to => [ Removing 4th Gear Wheel ] Output Shaft
34 Locking Ring
35 Transmission Cover
36 Output Wheel/Drive Wheel
• With tapered roller bearing and gear carrier
• Spur gear bearing, servicing, refer to => [ Spur Gear and Center Differential Bearing ] Spur Gear and Center Differential Bearing
Assemble Locking Collar and Reverse Gear Selector Gear
1. Reverse gear wheel
2. Locking collar
3. Thrust piece
- Slide locking collar over reverse gear selector gear.
Installed position:
• The pointed gear teeth - arrow A - on the locking collar and the helical-cut gear teeth - arrow B - on the reverse gear wheel will face the opposite direction after being assembled.
• Thrust piece notches - 3 - on the reverse gear wheel - arrow C - and locking collar - arrow D - must be centered over each other.
- Next, place the thrust pieces - 3 - in reverse gear selector gear notches and press the thrust pieces into the locking collar notches - arrow D -.
Differentiation of Reverse Gear Synchronization Rings - A - and 1st/2nd Gear - B -
1. Synchronizer ring for reverse gear: tabs - arrow 1 - have a smooth surface.
2. Reverse gear intermediate ring: friction surfaces - arrow 2 - are coated with sintered linings (brass colored).
3. Reverse gear inner race: has no inner friction surface - arrow 3 -.
4. Synchronizer ring for 1st and 2nd gear: tabs have 2 ridges each - arrow 4 -. Identification for the 1st and 2nd gear synchronizer ring; refer to => [ Identification for the 1st and 2nd Gear
Synchronizer Ring ].
5. Intermediate ring for 1st and 2nd gear: The friction surfaces - arrows 5 - are coated with carbon (black).
6. Inner race for 1st and 2nd gear: The inner race - arrow 6 - is coated with carbon (black).
Identification for the 1st and 2nd Gear Synchronizer Ring
1. Synchronizer ring for 1st gear: The identifying label of "19100" - arrow 1 - means that the clutch spline's angle (angle) is 19°.
2. Synchronizer ring for 2nd gear: The identifying label of "17101" - arrow 2 - means that the clutch spline's angle (angle) is 17°. Also, in each case, 3 x 3 gear teeth are missing on this synchronizer ring - arrows 3 -.
• The reverse gear synchronizer ring is smaller on the inside diameter and bears the identifying label of "15100".
Checking Inner Race for 1st Gear and 2nd Gear for Wear
- Check the outer friction surface - arrow - for scoring or signs of wear, replace if necessary.
- Press inner race onto taper of selector gear and measure gap dimension - a - using a feeler gauge.
Intermediate Ring for 1st, 2nd and Reverse Gears, Checking for Wear
- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
- Place inner race, intermediate ring and synchronizer ring on selector gear taper and turn.
• Screw in means: Turn synchronizer ring approximately one turn while pressing on the ring at the same time.
- Then measure the gap dimension - a - with a feeler gauge.
• Replace inner race, intermediate ring and synchronizer ring for the respective gear together.
Assembly of Locking Collar/Synchronizer Hub for 1st and 2nd Gears
- Mount the locking collar - 1 - over the synchronizer hub - 2 - so that the wire tooth spacing on the locking collar - arrow A - and on the synchronizer hub - arrow B - align with each other.
• Locking collar installed position: The bevel - arrow C - or the side with the greater outside diameter faces the 2nd gear wheel.
• Installed position of synchronizer hub: The notch - arrow D - or the "labeling" must face the 2nd gear wheel.
- Then place thrust pieces - 3 - in synchronizer hub and press thrust pieces into notches - arrow E - in the locking collar.