Output Shaft Assembly Overview
Output Shaft Assembly Overview
• The output shaft is disassembled as follows: Set separating device under the 2nd gear shift gear => [ (Item 21) 2nd gear shift gear ] and press off as described in => [ Pressing off 3rd and 4th gear synchronizer
hub/locking collar, 2nd, 3rd and 4th gear shift gears with needle bearing
sleeve ] Output Shaft Remove circlip => [ (Item 17) Circlip ]. Pull off locking collar with 1st and 2nd gear synchronizer hub as described in => [ Pressing off locking collar with synchronizer
hub and bearing mount ] Output Shaft
• When installing new drive gears or input shaft, observe => and technical data => [ Code Letters, Allocation, Ratios, Capacities ] Code Letters, Allocation, Ratios, Capacities.
• Always replace both taper roller bearings together as a set.
1 Hex nut, 25 Nm + an additional 90°
• 4 nuts for bearing mount
2 Clutch housing
3 Shim
• For output shaft
• Adjustment overview => [ Adjustment Overview ] Adjustment Overview.
4 Small tapered roller bearing outer race
• Pulling out => [ Pulling off small outer race/tapered roller
bearing ] Output Shaft
• Pressing in => [ Pressing in small outer race/tapered roller
bearing ] Output Shaft
5 Small inner race/tapered roller bearing
• Pulling off => [ Pulling off small inner race/tapered roller
bearing ] Output Shaft
• Pressing on => [ Pressing on small tapered roller bearing inner
race ] Output Shaft
6 Output shaft
• Adjusting => [ Output Shaft, Adjusting ] Output Shaft, Adjusting.
7 Large tapered roller bearing inner race
• Pulling off => [ Pulling off large inner race/tapered roller
bearing ] Output Shaft
• Pressing on => [ Pressing on inner race of large taper roller
bearing ] Output Shaft
8 Seal
• Place seals (4x) on bolts for bearing mount
9 Bearing mount
• With large tapered roller bearing outer race and bolts
• Only change outer race together with large tapered roller bearing and bearing mount
10 Thrust washer
• Shoulder on thrust washer faces toward tapered roller bearing
11 Shift gear for 1st gear
12 Needle bearing
• For 1st gear
13 Synchronizer ring
• (Inner race for 1st gear)
• Installed position => [ Installed position of inner race, outer race
and synchronizer ring for 1st gear ] Output Shaft
• Checking for wear => [ Checking inner race of 1st and 2nd gear for
wear ] Output Shaft
• Checking tabs for signs of wear
14 Outer race for 1st gear
• Installed position => [ Installed position of inner race, outer race
and synchronizer ring for 1st gear ] Output Shaft
• Checking for wear => [ Checking synchronizer ring of 1st gear and
2nd gear for wear ] Output Shaft
• Replace if scored or show signs of wear
15 Synchronizer ring for 1st gear
• Installed location => [ Installed position of inner race, outer race
and synchronizer ring for 1st gear ] Output Shaft
• Checking for wear => [ Checking synchronizer ring of 1st gear and
2nd gear for wear ] Output Shaft
16 Locking sleeve with synchronizer hub for 1st and 2nd gears
• After removing circlip => [ (Item 17) Circlip ] , press off with bearing mount => [ Pressing off locking collar with synchronizer
hub and bearing mount ] Output Shaft
• Disassembling => [ Disassembling and assembling locking collar
and synchronizer hub for 1st and 2nd gear ] Output Shaft
• Assembling locking collar/synchronizer hub=> [ Disassembling and assembling locking collar
and synchronizer hub for 1st and 2nd gear ] Output Shaft
• Assembly of locking collar/synchronizer hub with hollow locking pieces => [ Assembling locking collar/synchronizer hub
of 1st and 2nd gear in conjunction with hollow locking pieces ] Output Shaft
• Assembly of locking collar/synchronizer hub with locking pieces that are not hollow => [ Assembling sliding sleeve/synchronizer 1st
and 2nd gear in conjunction with engaging pieces that are not hollow ] Output Shaft
• Installed location => [ Installation position of locking collar/synchronizer
hub for 1st and 2nd gear ] Output Shaft
• Pressing on => [ Pressing on locking collar/synchronizer hub
for 1st and 2nd gear ] Output Shaft
17 Circlip
18 Synchronizer ring for 2nd gear
• Checking for wear => [ Checking synchronizer ring of 1st gear and
2nd gear for wear ] Output Shaft
• Insert so that cut-outs engage in engagement pieces of locking collar=> [ (Item 16) Locking sleeve with synchronizer hub for 1st and 2nd gears ]
19 Outer race for 2nd gear
• Insert into synchronizer ring => [ (Item 18) Synchronizer ring for 2nd gear ]
• Installed position => [ Installation position of 2nd gear outer race ] Output Shaft
• Replace if scored or show signs of wear
20 Synchronizer ring
• (Inner race for 2nd gear)
• Checking for wear => [ Checking synchronizer ring of 1st gear and
2nd gear for wear ] Output Shaft
• Checking tabs for signs of wear
• Installed position => [ Installation position of synchronizer ring
(2nd gear inner race) ] Output Shaft
21 2nd gear shift gear
• Installed location => [ Installation position of 2nd gear shift gear ] Output Shaft
22 Needle bearing
• For 2nd gear
23 Thrust washer
24 Inner race
• For needle bearing 3rd gear
• Pressing off with 2nd gear => [ Pressing off 3rd and 4th gear synchronizer
hub/locking collar, 2nd, 3rd and 4th gear shift gears with needle bearing
sleeve ] Output Shaft
• Pressing on => [ Pressing on sleeve for 3rd gear needle bearing ] Output Shaft
• Replace together with needle bearing
25 Needle bearing
• For 3rd gear
• Replace together with inner race
26 Shift gear for 3rd gear
27 Synchronizer ring for 3rd gear
• Checking for wear => [ Checking synchronizer ring of 3rd and 4th gears
for wear ] Output Shaft
28 Locking collar with synchronizer hub for 3rd and 4th gear
• Pressing off with 2nd gear => [ (Item 21) 2nd gear shift gear ] and 3rd gear => [ (Item 26) Shift gear for 3rd gear ] => [ Pressing off 3rd and 4th gear synchronizer
hub/locking collar, 2nd, 3rd and 4th gear shift gears with needle bearing
sleeve ] Output Shaft
• Disassembling => [ Disassembling and assembling locking collar
and synchronizer hub for 3rd and 4th gear ] Output Shaft
• Assembling locking collar/synchronizer hub => [ Disassembling and assembling locking collar
and synchronizer hub for 3rd and 4th gear ] Output Shaft
• Assembly of locking collar/synchronizer hub with hollow locking pieces => [ Assembling locking collar/synchronizer hub
of 3rd and 4th gear in conjunction with hollow locking pieces ] Output Shaft
• Assembly of locking collar/synchronizer hub with locking pieces that are not hollow => [ Assembling locking collar/synchronizer hub
of 3rd and 4th gear in conjunction with locking pieces that are not hollow ] Output Shaft
• Installation position of locking collar/synchronizer hub => [ Installation position of locking collar/synchronizer
hub for 3rd and 4th gear ] Output Shaft
• Pressing on => [ Pressing on synchronizer hub with locking collar
for 3rd and 4th gears ] Output Shaft
29 Inner race
• For needle bearing 4th gear
• Pressing off with locking collar with synchronizer hub for 3rd and 4th gear => [ (Item 28) Locking collar with synchronizer hub for 3rd and 4th gear ] => [ Pressing off 3rd and 4th gear synchronizer
hub/locking collar, 2nd, 3rd and 4th gear shift gears with needle bearing
sleeve ] Output Shaft
• Pressing on => [ Pressing on sleeve for 4th gear needle bearing ] Output Shaft
• Replace together with needle bearing
30 Needle bearing
• For 4th gear
• Replace together with inner race
31 Synchronizer ring for 4th gear
• Checking for wear => [ Checking synchronizer ring of 3rd and 4th gears
for wear ] Output Shaft
32 Shift gear for 4th gear
33 Thrust washer
34 Needle bearing
• For output shaft
• Removing and installing => [ Driving out needle bearing ] Transmission and Clutch Housing
35 Transmission housing
36 Inner race
• For needle bearing/output shaft
• Pressing off => [ Pressing off 3rd and 4th gear synchronizer
hub/locking collar, 2nd, 3rd and 4th gear shift gears with needle bearing
sleeve ] Output Shaft
• Pressing on => [ Pressing on sleeve for output shaft needle bearing ] Output Shaft
37 5th gear drive gear
• Removing and installing => [ Transmission ] Transmission.
38 Plate spring
• Installed position => [ Installed Position of Plate Springs for 5th
Gear Synchronizer Hub and Drive Gear Securing Bolts ] Transmission
39 Bolt M10, 80 Nm
• Always replace
• Removing and installing => [ Transmission ] Transmission.