Manual Transmission/Transaxle: Testing and Inspection

Eliminating transmission symptoms - Reworking transmission (jumps out of 2nd gear)

General information

Symptom

Jumps out of 2nd gear.

Concerns, causes and remedial action

Concerns

Vehicles with the transmission type listed below are affected:

- G8620
- G9600/G9601
- G9630/G9631

Cause

2nd gear does not engage correctly (100%) due to tolerances between the shift fork and the gear wheel for 2nd gear.

Remedial action

Information
In the event of a complaint, it is absolutely essential that you contact the "Technical Hotline" to discuss measures and specifications before carrying out any further work.

In the event of a complaint and following consultation with the specialists manning the "Technical Hotline", the adjustment dimension S5 on the output shaft must be increased by 0.40 mm - contrary to the specification in the Workshop Manual. This will move the output shaft (gear wheel for 2nd gear) towards the shift fork.

Tools and materials

Information
Since there are several ways of combining the adjusting shims, we recommend that you keep a complete set of adjusting shims in stock.

996.302.114.00 -> Shim, 0.50 mm thick

996.302.114.01 -> Shim, 0.55 mm thick

996.302.114.02 -> Shim, 0.60 mm thick

996.302.114.03 -> Shim, 0.65 mm thick

996.302.114.04 -> Shim, 0.70 mm thick

996.302.114.05 -> Shim, 0.75 mm thick

996.302.114.06 -> Shim, 0.80 mm thick

996.302.114.07 -> Shim, 0.85 mm thick

996.302.114.08 -> Shim, 0.90 mm thick

996.302.114.09 -> Shim, 0.95 mm thick

Reworking transmission

Information
To correct the total thickness S5 of the adjusting shims (2nd gear), the transmission or output shaft must be disassembled.

^ Procedure for determining shim thickness S5:





Figure 1

^ Several adjusting shims can also be fitted in order to achieve the new, required adjustment dimension (increase of 0.4 mm).

Example:

Measured thickness -S5- of the adjusting shims fitted:

- 1 x 0.90-mm thick adjusting shim.

=> This gives a new nominal dimension for S5 with a total thickness of 1.30 mm.

Make up the new nominal dimension (total thickness) -S5- using the adjusting shims:

- 2 x 0.65-mm thick adjusting shim (total = 1.30 mm).

Overview of fixed gear wheels on output shaft





Figure 2

1 - Inner bearing ring

2 - Fixed gear wheel, 5th gear

3 - Fixed gear wheel, 6th gear

4 - Fixed gear wheel, 3rd gear

5 - Fixed gear wheel, 4th gear

6 - Tensioning plate

7 - Adjusting shim S4

8 - Adjusting shim S5

9 - Angular-contact ball bearing

10 - Output shaft