Removing Input and Output Shaft

Removing input and output shaft

Overview





No. Designation Qty.
1 Cylindrical-roller bearing 1
2 Thrust plate 1
3 Loose gear wheel, 1st gear 1
4 Friction ring 1
5 Tapered ring 1
6 Synchronising ring 1
7 Needle-roller bearing 1
8 Bearing inner race 1
9 Shift collar 1
10 Guide sleeve 1
11 Driver dog 3
12 Ball 3
13 Spring 3
14 Synchronising ring 1
15 Tapered ring 1
16 Friction ring 1
17 Loose gear wheel, 2nd gear 1
18 Needle-roller bearing 1
19 Bearing inner race 1
20 Thrust plate 1
21 Fixed gear wheel, 3rd gear 1
22 Oil tube (model year 2004) 1
23 Locking element 2
24 Shift rod (1st/2nd gear) 1
25 Intermediate locking element 2
26 Shift rod (reverse gear) 1
27 Selector shaft 1
28 Shift rod (5th/6th gear) 1
29 Tensioning plate 1
30 Hexagon nut 7
31 Shift rod (3rd/4th gear) 1
32 Cylindrical-roller bearing 1
33 Screw plug 4
34 Spring 4
35 Ball 4
36 Adjusting shim S3 X
37 Transmission housing 1
38 Oil pump drive wheel (G96/96; model year 2004) Spacer sleeve (G96/90; model year 2000) 1
39 Fixed gear wheel, 4th gear 1




Removing shafts
1. Unscrew screw plugs (no. 33 in overview) of the locking elements and remove springs (no. 34 in overview) and ball (no. 35 in overview).
2. Pull out reverse gear shift rod (no. 26 in overview) and shift rods for 5th/6th gear (no. 28 in overview) towards the front. Pay attention to the intermediate lock (no. 25 in overview) and locking elements (no. 23 in overview) during this procedure.
3. Remove differential lock.
4. Remove oil tube (no. 22 in overview).
5. Remove cylindrical-roller bearing (no. 32 in overview) from input shaft using a puller.
6. Pull loose gear wheel for 1st gear (no. 3 in overview) off the input shaft with the thrust plate (no. 2 in overview) and cylindrical-roller bearing (no. 1 in overview).
7. Pull off the fixed wheel for 3rd gear (no. 21 in overview) with 1st/2nd gear synchronization (nos. 16 to 4 in overview) and loose gear wheel for 2nd gear (no. 17 in overview).

Note!
^ A specific disassembly of the synchronization in assembled state is recommended as this may prevent the loss of small parts.

8. Unscrew nuts (no. 30 in overview) and remove tensioning plate (no. 29 in overview) with shafts and remaining gear wheels.
9. Remove drive wheel of the oil pump or spacer sleeve (no. 38 in overview) and fixed wheel for 4th gear (no. 39 in overview) and take output shaft out of the tensioning plate.