Left Flange Shaft, Clutch Module, Side Shaft, Gearshift Shaft and Transmission Cover Assembly Overview

Left Flange Shaft, Clutch Module, Side Shaft, Gearshift Shaft and Transmission Cover Assembly Overview






1 Clutch Module

• Removing and installing, refer to => [ Clutch Module ] Clutch Module

• Servicing together with the clutch manufactured by Sachs, refer to => [ Clutch, Sachs Assembly Overview ] Clutch, Sachs Assembly Overview

• Servicing together with the clutch manufactured by LuK, refer to => [ Clutch, LuK Assembly Overview ] Clutch, LuK Assembly Overview

2 Clutch Release Lever with Release Bearing and Spring

• Removing and installing, refer to => [ Clutch Release Lever with Release Bearing and Guide Sleeve ] Clutch Release Lever With Release Bearing and Guide Sleeve

• Disassembling and assembling, refer to => [ Clutch Release Mechanism Assembly Overview ] Clutch Release Mechanism Assembly Overview

3 Bolt

• 8 Nm

• Quantity: 2

• Insert with locking fluid (AMV 185 101 A1)

4 Securing Plate

• Not installed on all versions

• Installed position: the recess for the bolts - 3 - faces the clutch module

• Deleted from 02.2008

• Also deleted when installing a new guide sleeve - 8 - => [ Guide Sleeve ] Clutch Release Mechanism Assembly Overview

5 Guide Sleeve

• If present, remove any grease from the guide sleeve

6 Input Shaft Seal

• Removing and installing, refer to => [ Input Shaft Seal ] Input Shaft Seal

7 Securing Ring

• Determining thickness => [ Determine the Locking Ring for the Input Shaft as Follows: ] Transmission, Assembly Sequence

• Insert in input shaft surrounding groove

8 Transmission Housing

• Input and Output shafts with shift Rails and Shift Forks, Removing and Installing, refer to => [ Input Shaft, Output Shaft, Reverse Drive Gear and Shift Rails/Shift Forks Assembly Overview ] Input Shaft, Output Shaft, Reverse Drive Gear and Shift Rails/Shift Forks Assembly Overview

• For servicing, refer to => [ Transmission Housing ] Transmission Housing

• Differential, Removing and Installing, refer to => [ Differential Assembly Overview ] Differential Assembly Overview

9 Oil Drain Plug

• 45 Nm

10 Bolt

• 200 Nm

• For output shaft

• Insert with locking fluid (AMV 185 101 A1)

11 Sealing Cap

• Always replace

• With oil guide

• For output shaft

12 Bolt

• Always replace

• 10 Nm plus an additional 45° turn

• Aluminum bolts (M8; 22 mm long)

• Quantity: 4

13 Selector Shaft with Selector Cover

• Different versions are installed (with and without a transmission neutral position sensor (G701))

• Allocate according to transmission code, refer to the electronic parts catalog ETKA

14 O-Ring

• Always replace

15 Bolt

• 20 Nm plus an additional 30° turn

• Steel bolts (M8; 30 mm long)

• Quantity: 3

• For the bearing bracket to the transmission cover

• Insert with locking fluid (AMV 185 101 A1)

16 Transmission Range Gear Recognition Switch (F208)

• 20 Nm

17 Side Shaft

• With helical gear wheel

18 Bolt

• Always replace

• 150 Nm + 90° additional turn

• For the side shaft to the pinion

• Bolt head, 21 mm (12-point)

19 End Shield

• Pay attention to the installed position to the transmission cover, refer to => [ Transmission, Assembly Sequence ] Transmission, Assembly Sequence

20 Spur Gear

• Side shaft/pinion drive wheel

21 Needle Bearing

• For the spur gear - 20 -

• Mount on the output shaft

22 Transmission Cover

• For servicing, refer to => [ Transmission Cover ] Transmission Cover

23 Bolt

• 15 Nm plus an addition 90° turn

• Steel bolt (M8; 50 mm long)

• Quantity: 1

24 Bolt

• Always replace

• 10 Nm plus an additional 90° turn

• Aluminum bolts (M8; 35 mm long)

• Quantity: 16

25 Oil Fill Plug

• 45 Nm

26 Bolt

• Always replace

• 10 Nm plus additional 45° turn

• Aluminum bolt (M8; 22 mm long)

• For the transmission neutral position sensor (G701) or the plug and at the same time for the cover/gearshift shaft to the transmission cover

• Not installed on all versions

27 Transmission Neutral Position Sensor (G701) or Cap

• Transmission neutral position sensor for vehicles with the Start/Stop System

• A cap is installed in place of the transmission neutral position sensor (G701)

• Allocate according to transmission code, refer to the electronic parts catalog ETKA

• It is not necessary to remove the cap with disassembling and assembling the transmission, if a cap is installed in place of the transmission neutral position sensor (G701).

28 O-Ring

• Always replace

• On transmissions with a transmission neutral position sensor (G701) or a cap

29 Alignment Bushing

• Quantity: 2

30 Bolt

• 15 Nm plus an additional 45° turn

• Steel bolts (M8; 25 mm long)

• Quantity: 3

31 Flange Shaft, Left

• With bracket