Transmission Component Overviews
Transmission Component Overviews
l - => [ Transmission Housing and Shift Unit ]
ll - => [ Input Shaft, Output Shafts, Differential and Selector Rods ]
• Metal and plastic sealing caps are installed for the input shaft.
• The plastic sealing cap does not require the circlip - A -.
Transmission Housing and Shift Unit
1 Bolt
• 33 Nm
2 Flange Shaft with Pressure Spring
• Removing and installing, refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
• Assembling, refer to => [ Differential ] Service and Repair.
3 Circlip
• For the metal cover.
• Installed from transmission build date 21 January 2008.
• Not used with the plastic sealing cap.
4 Sealing Cap
• Made of metal or plastic.
• Made of metal: secured with a circlip => [ (Item 3) Circlip ] from transmission build date 21 January 2008.
• Made of plastic: the circlip => [ (Item 3) Circlip ] was discontinued.
• Refer to the Parts Catalog.
5 Locking Ring
• For the grooved ball bearing/input shaft, see => [ (Item 1) Locking Ring ] Input Shaft.
6 Backup Lamp Switch (F4)
• 20 Nm
• Shortly after the series introduction of the transmission, equipped with a permanent seal => [ (Item 7) Seal ].
7 Seal
• Not installed on all transmissions.
• Always replace.
8 Oil Drain Plug
• Tightening specification, refer to => [ Different Versions of the Oil Fill
and Drain Plugs ] Service and Repair.
9 Seal
• Always replace.
10 Bolt
• 6 Nm
• Not available in the US/Canadian market.
11 Transmission Neutral Position Sensor (G701)
• Not available in the US/Canadian market.
12 Locking Screw
• 45 Nm
• For the gear shift unit shaft.
13 Bolt
• Always replace, refer to the Parts Catalog.
• There are different bolts and tightening specifications:
• Internal hex round head = through transmission build date 6 December 2009, aluminum M8 bolt = 8 Nm and 180° (1/2) additional turn.
• Internal hex round head = through transmission build date 7 December 2009, aluminum M9 bolt = 15 Nm and 180° (1/2) additional turn.
• Outer hex head = steel bolt = 15 Nm and 90° (1/4) additional turn.
• Steel bolt allocation, refer to => [ If the Steel Bolts (outer hex head)
are the Replacement Part, Pay Attention to the Allocation: ].
14 Bolt
• Always replace, refer to the Parts Catalog.
• There are different bolts and tightening specifications
• Internal hex round head = through transmission build date 6 December 2009, aluminum M8 bolt = 8 Nm + 180° (1/2) additional turn.
• Internal hex round head = through transmission build date 7 December 2009, aluminum M9 bolt = 15 Nm + 180° (1/2) additional turn.
• Outer hex head = steel bolt = 15 Nm + 90° (1/4) additional turn.
• Steel bolt allocation, refer to => [ If the Steel Bolts (outer hex head)
are the Replacement Part, Pay Attention to the Allocation: ].
15 Gear Shift Unit
• Overview, refer to => [ Shift Unit Overview ] Shift Unit Overview.
• Removing with the transmission installed:
• Remove the battery and the battery tray.
• The locking pin => [ (Item 6) Locking Pin ] Transmission Housing for adjusting the shift mechanism must not be engaged
• Remove the cables and the transmission shift lever. Refer to => [ Shift and Selector Cables ] Shift Mechanism Overviews.
• Remove the locking screw => [ (Item 12) Locking Screw ] and remove the shift mechanism.
16 Bolt
• 20 Nm
• Always replace.
17 O-ring
• Always replace.
18 Clutch Housing
• Disassembly and assembly, refer to => [ Clutch Housing ] Clutch Housing.
19 Transmission Housing
• Disassembly and assembly, refer to => [ Transmission Housing ] Transmission Housing.
If the Steel Bolts (outer hex head) are the Replacement Part, Pay Attention to the Allocation:
A Bolt with a permanent washer
B Bolt without a washer
C Bolt with a permanent washer
Input Shaft, Output Shafts, Differential and Selector Rods
1 Output Shaft, 1st to 4th Gears
• Disassembling and Assembling, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
• Installed position, refer to => [ Selector Shafts with Forks, Installed
Position ].
2 Selector Shaft with Selector Fork, for 1st and 2nd Gear
• Installed position, refer to => [ Selector Shafts with Forks, Installed
Position ].
3 Selector Shaft with Selector Fork, for 3rd and 4th Gear
• Installed position, refer to => [ Selector Shafts with Forks, Installed
Position ].
4 Output Shaft, 5th, 6th and Reverse Gears
• Disassembling and Assembling, refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.
• Installed position, refer to => [ Selector Shafts with Forks, Installed
Position ].
5 Selector Shaft with Selector Fork, for 5th and 6th Gear
• Installed position, refer to => [ Selector Shafts with Forks, Installed
Position ].
6 Selector Fork, Reverse Gear
• Installed position, refer to => [ Selector Shafts with Forks, Installed
Position ].
• Differences, refer to => [ Reverse Gear Selector Fork Differentiation ] Shift Forks.
• Disassembling and assembling, refer to => [ Shift Forks ] Shift Forks.
7 Input Shaft
• Disassembling and assembling, refer to => [ Input Shaft ] Input Shaft.
• Always replace the grooved ball bearing on the input shaft => [ (Item 6) Grooved Ball Bearing ] Input Shaft.
8 Reverse Shaft
• With the thrust washer.
9 Thrust Washer
10 Breather Assembly
• Attaches to the clutch slave cylinder => [ (Item 14) Clutch Slave Cylinder with Release Bearing ].
11 Clutch Housing
• Disassembling and assembling, refer to => [ Clutch Housing ] Clutch Housing.
12 Input Shaft Seal
• Removing and installing, refer to => [ Clutch Housing ] Clutch Housing.
13 O-ring
• Installs on the line connection.
• Lubricate with brake fluid before installing.
14 Clutch Slave Cylinder with Release Bearing
15 Bolt
• Quantity: 3
• Always replace.
• Without locking fluid, 12 Nm (slave cylinder with metal housing only).
• With locking fluid, 15 Nm (for plastic clutch slave cylinders).
• Carefully tighten diagonally in small stages so that the slave cylinder bolt tabs do not break off.
16 Bolt
• 33 Nm
17 Flange Shaft with Pressure Spring
• Removing and installing, refer to one of the following:
=> [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
=> [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
• Assembling, refer to => [ Differential ] Service and Repair.
18 Differential
• Disassembling and assembling, refer to => [ Differential ] Service and Repair.
Selector Shafts with Forks, Installed Position
1 Input shaft
2 Output shaft, 1st to 4th gears
3 Output shaft, 5th, 6th and reverse gears
4 Reverse shaft
A Selector shaft with selector fork, for 3rd and 4th gear
B Selector shaft with selector fork, for 1st and 2nd gear
C Selector shaft with selector fork, for 5th and 6th gear
D Reverse gear selector fork 1
1 On some transmissions, the mounting for the reverse gear selector fork and the selector shaft for 5th and 6th gear - C - are different. Refer to => [ Reverse Gear Selector Fork Differentiation ] Shift Forks.