Installing Input and Output Shaft
Installing input and output shaftInstalling shafts
Note!
^ An overview diagram of the installation is provided in the chapter Disassembling transmission under.
1. Insert output shaft -A- with adjusting shim S5 -B and adjusting shim S4 -C- into tensioning plate -F-.
2. Push fixed gear wheel for 4th gear -D- onto output shaft. The large collar faces the tensioning plate.
3. Connect oil pump drive wheel or spacer sleeve -E-.
4. Affix adjusting shim S3 -A- in the transmission housing with viscous grease.
5. Insert input and output shaft into the transmission housing with tensioning plate and tighten nuts.
Tightening torque: 25 Nm (19 ft. lbs.)
6. Push fixed gear wheel for 3rd gear (no. 21 in overview) onto the output shaft. The large collar faces the thrust plate (no. 20 in overview).
7. Push thrust plate onto the output shaft.
8. Heat bearing inner race (no. 19 in overview) to 120°C and push onto output shaft.
9. Push needle-roller bearing (no. 18 in overview) onto bearing inner race.
10. Check synchronization of 1st/2nd gear. To do this, place the friction ring, the tapered ring and the synchronizing ring on the gear wheel. Measure the gap -A- with a feeler gauge. Perform test for 1st and 2nd gear.
Installation dimension (new): 1.5 to 2.0 mm
Wear dimension: 1.2 mm
11. Push loose gear wheel for 2nd gear (no. 17 in overview) onto needle-roller bearing.
12. Insert friction ring (no. 16 in overview), tapered ring (no. 15 in overview) and synchronizing ring (no. 14 in overview) into the guide sleeve (no. 10 in overview) and push onto output drive. In doing so, the recess of the inner toothing of the guide sleeve must align with the oil bore of the output shaft.
13. Heat bearing inner race (no. 8 in overview) to 120°C and push onto output shaft.
14. Fit shift collar (no. 9 in overview) with shift rod for 1st/2nd gear (no. 24 in overview). The turned groove -A- in the shift collar must face the loose gear wheel for 2nd gear.
Note!
^ The dotting marks on the shift collar must be centered with respect to the recesses in the guide sleeve.
15. When setting the shift collar in place, ensure that the dotting marks on the shift collar are centered with respect to the recesses in the guide sleeve.
1 Shift collar
2 Ball
3 Driver dog
4 Spring
A Recognition groove
B Dotting mark
C 2nd gear - side
E 1st gear - side
16. Fit spring (no. 11 in overview), ball (no 12 in overview) and driver dog (no. 13 in overview). To do this, push the shift collar in the direction of the loose gear wheel for 2nd gear.
17. Fit the synchronizing ring (no. 6 in overview), the tapered ring (no. 5 in overview) and the friction ring (no. 4 in overview).
18. Push needle-roller bearing (no. 7 in overview) onto bearing inner race.
19. Push loose gear wheel for 1st gear (no. 3 in overview) and thrust plate (no. 2 in overview) onto output shaft.
20. Heat cylindrical-roller bearing (no. 1 in overview) to 20°C and push onto output shaft.
21. Heat cylindrical-roller bearing (no. 32 in overview) to 120°C and push onto input shaft.
22. Fit oil tube (no. 22 in overview). Use new micro-encapsulated screw.
Tightening torque: 6 Nm (4.5 ft. lbs.)
23. Fit shift rods, selector shaft and locking elements. Affix locking elements with viscous grease if necessary. Ensure that the rollers on the selector shaft are complete.
1 Shift rod for 3rd/4th gear
2 Locking element (short)
3 Shift rod for 5th/6th gear
4 Intermediate lock
5 Locking element (long)
6 Reverse gear shift rod
7 Intermediate lock
8 Locking element (short)
9 Shift rod for 1st/2nd gear
24. Fit locking elements (nos. 33, 34 and 35 in overview).
Note!
^ Do not move the shift rods past the neutral lock or gear lock during or after fitting as otherwise the small locking elements and the balls of the lock can fall into the transmission.
Tightening torques