Output Shaft Overview
Output Shaft Overview
• Disassemble the output shaft as follows: place the separating device under the 2nd gear - item 21 - and remove it as described. Refer to => [ Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft. Remove the locking ring - item 17 -. Remove the locking collar and the 1st/2nd gear synchronizer hub as described. Refer to => [ Removing the Locking Collar with the Synchronizer Hub and Bearing Support ] Output Shaft.
• Refer to the Parts Catalog and to => [ Codes Letters, Allocation and Capacities ] Codes Letters, Allocation and Capacities, when installing new gears or a new input shaft.
• Replace both tapered roller bearings together.
• Heat the toothed gear and synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414). Wear safety gloves.
1 Nut
• 25 Nm + 90° (1/4) additional turn.
• Always replace.
• 4 nuts for the bearing support.
2 Clutch Housing
3 Adjusting Shim
• For the output shaft.
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.
4 Small Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Remove the Small Outer Race/Tapered Roller Bearing ] Output Shaft.
• Installing, refer to => [ Installing the Small Outer Race/Tapered Roller Bearing ] Output Shaft.
5 Bearing Inner Race/Small Tapered Roller Bearing
• Removing, refer to => [ Removing the Bearing Inner Race/Small Tapered Roller Bearing ] Output Shaft.
• Installing, refer to => [ Installing the Bearing Inner Race/Small Tapered Roller Bearing ] Output Shaft.
6 Output Shaft
• Adjusting, refer to => [ Output Shaft, Adjusting ] Output Shaft, Adjusting.
7 Bearing Inner Race/Large Tapered Roller Bearing
• Removing, refer to => [ Removing the Bearing Inner Race/Large Tapered Roller Bearing ] Output Shaft.
• Installing, refer to => [ Installing the Bearing Inner Race/Large Tapered Roller Bearing ] Output Shaft.
8 Seal
• Place the four seals on the bearing support studs.
• Always replace.
9 Bearing Support
• With the large outer race/tapered roller bearing and bolts.
• Replace the outer race only together with the large tapered roller bearing and bearing support.
10 Thrust Washer
• The collar on the thrust washer faces the tapered roller bearing.
11 1st Gear
12 Needle Bearing
• For 1st gear.
13 Synchronizer Ring
• (Inner race for 1st gear)
• Installed position, refer to => [ Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring ] Output Shaft.
• Checking for wear, refer to => [ Checking the Inner Race for 1st and 2nd Gears for Wear ] Output Shaft.
• Check for scoring.
14 1st Gear Outer Race
• Installed position, refer to => [ Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring ] Output Shaft.
• Checking for wear, refer to => [ Checking the 1st and 2nd Gears Synchronizer Rings for Wear ] Output Shaft.
• Replace if there are grooves or scoring.
15 1st Gear Synchronizer Ring
• Installed position, refer to => [ Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring ] Output Shaft.
• Checking for wear, refer to => [ Checking the 1st and 2nd Gears Synchronizer Rings for Wear ] Output Shaft.
16 Locking Collar with Synchronizer Hub for 1st and 2nd Gears
• After removing the locking ring - item 17 -, remove with the bearing support, refer to => [ Removing the Locking Collar with the Synchronizer Hub and Bearing Support ] Output Shaft.
• Disassembling, refer to => [ Disassembling and Assembling the Locking Collar and Synchronizer Hub for 1st and 2nd Gears ] Output Shaft.
• Assembling the operating sleeve/synchronizer hub, refer to => [ Disassembling and Assembling the Locking Collar and Synchronizer Hub for 1st and 2nd Gears ] Output Shaft, => [ Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears together with the Locking Pieces that are Hollow on the Inside ] Output Shaft and => [ Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears together with the Locking Pieces that are not Hollow ] Output Shaft.
• Installed position, refer to => [ Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears ] Output Shaft.
• Installing, refer to => [ Heating and Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears ] Output Shaft.
17 Locking Ring
18 2nd Gear Synchronizer Ring
• Checking for wear, refer to => [ Checking the 1st and 2nd Gears Synchronizer Rings for Wear ] Output Shaft.
• Insert it so that the holes engage into engagement pieces of locking collar - item 16 -.
19 2nd Gear Outer Race
• Insert into synchronizer ring - item 18 -.
• Installed position, refer to => [ Installed Position of the 2nd Gear Outer Race ] Output Shaft.
• Replace if there are grooves or scoring.
20 Synchronizer Ring
• (Inner race for 2nd gear)
• Checking for wear, refer to => [ Checking the 1st and 2nd Gears Synchronizer Rings for Wear ] Output Shaft.
• Check for scoring.
• Installed position, refer to => [ Installed Position: Synchronizer Ring (2nd Gear Inner Race) ] Output Shaft.
21 2nd Gear
• Installed position, refer to => [ Installed Position: 2nd Gear ] Output Shaft.
22 Needle Bearing
• For 2nd gear.
23 Thrust Washer
24 Sleeve for the 3rd Gear Needle Bearing
• Removing with the 2nd gear, refer to => [ Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft.
• Installing, refer to => [ Installing the Sleeve for the 3rd Gear Needle Bearing ] Output Shaft.
25 Needle Bearing
• For 3rd gear.
26 3rd Gear
27 3rd Gear Synchronizer Ring
• Checking for wear, refer to => [ Checking the 3rd/4th Gear Synchronizer Ring for Wear ] Output Shaft.
28 Locking Collar with Synchronizer Hub for 3rd and 4th Gears
• Remove with 2nd gear - item 21 - and 3rd gear - item 26 -. Refer to => [ Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft.
• Disassembling, refer to => [ Disassembling and Assembling the Locking Collar and Synchronizer Hub for 3rd/4th Gears ] Output Shaft.
• Assembling the operating sleeve/synchronizer hub. Refer to => [ Disassembling and Assembling the Locking Collar and Synchronizer Hub for 3rd/4th Gears ] Output Shaft, => [ Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears together with the Locking Pieces that are Hollow on the Inside ] Output Shaft and => [ Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears together with the Locking Pieces that are not Hollow ] Output Shaft.
• Installed position: locking collar/synchronizer hub. Refer to => [ Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears ] Output Shaft.
• Installing, refer to => [ Heating and Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears ] Output Shaft.
29 Sleeve
• For the 4th gear needle bearing.
• Removing with the locking collar and the 3rd/4th gear synchronizer hub - item 28 -. Refer to => [ Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft.
• Installing, refer to => [ Installing the Sleeve for the 4th Gear Needle Bearing ] Output Shaft.
30 Needle Bearing
• For 4th gear.
31 4th Gear Synchronizer Ring
• Checking for wear, refer to => [ Checking the 3rd/4th Gear Synchronizer Ring for Wear ] Output Shaft.
32 4th Gear
33 Thrust Washer
34 Needle Bearing
• For the output shaft.
• Removing and installing, refer to - item 2 - in => [ Transmission and Clutch Housings Overview ] Transmission and Clutch Housings Overview.
35 Transmission Housing
36 Sleeve
• For the needle bearing/output shaft.
• Removing, refer to => [ Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft.
• Installing, refer to => [ Installing the Sleeve for the Needle Bearing/Output Shaft ] Output Shaft.
37 5th Gear
• Removing individually, refer to => [ Transmission Housing Cover and 5th Gear ] Transmission Housing Cover and 5th Gear.
• Remove with the transmission housing. Refer to => [ Transmission ] Transmission.
38 Plate Spring
• Installed position, refer to => [ Installed Position of the Concave Washers for 5th Gear and the 5th Gear Synchronizer Hub Bolts ] Transmission.
39 Bolt
• Tightening specification, see - item 4 - in => [ Transmission Housing Cover and 5th Gear ] Transmission Components Overview.
• Always replace.
• Removing and installing, refer to => [ Transmission ] Transmission.