Transmission Components Overview
Transmission Components Overview
I - => [ Transmission Housing Cover and 5th Gear ]
II - => [ Transmission Housing and Shift Mechanism ]
III - => [ Input Shaft, Output Shaft, Differential and Shift Rods ]
Transmission Housing Cover and 5th Gear
1 Bolt
• 18 Nm
• For the cover to the transmission housing.
2 Transmission Housing Cover
• With a magnet, refer to => [ Transmission Housing Cover with a Magnet ].
• If the transmission housing cover is removed and installed with the transmission installed, drain and fill the transmission fluid. Refer to => [ Transmission Fluid, Checking and Filling ] Service and Repair.
• Please note that a small amount of fluid leaks out when removing the cover.
3 Gasket
4 Bolt
• 80 Nm + 90° (1/4) additional turn.
• Always replace.
• Hold with the adapter on the concave washer bolt head in position
• Remove the liquid locking fluid residue from the threaded holes for the synchronizer hub and 5th gear drive gear bolt using a thread tap. Otherwise, there is the danger that the bolt could shear off.
5 Concave Washer
• Installing, refer to => [ Installed Position of the Concave Washers for 5th Gear and the 5th Gear Synchronizer Hub Bolts ] Transmission.
6 Bolt
• 25 Nm
• For the selector fork base to the transmission housing.
7 Base for Selector Fork
8 5th Gear Selector Fork
• Disassembly and Assembly, refer to => [ Selector Forks ] Selector Forks.
• Adjusting, refer to => [ Adjusting 5th Gear ] Transmission.
9 Spring
• Offset version.
• Installing, refer to => [ Installation of Offset Springs ] Input Shaft.
10 5th Gear Locking Collar
• Installed position, refer to => [ Assembling the 5th Gear Locking Collar/Synchronizer Hub ] Input Shaft.
• Adjusting, refer to => [ Adjusting 5th Gear ] Transmission.
11 Locking Pieces
• Quantity: 3
• Installed position, refer to => [ 5th Gear Synchronizer ] Input Shaft.
12 Synchronizer Hub with Gear and 5th Gear Synchronizer Ring
• Remove together with the transmission housing. Refer to => [ Transmission ] Transmission.
• Removing individually, refer to => [ Transmission Housing Cover and 5th Gear ] Transmission Housing Cover and 5th Gear.
• Disassembly and Assembly, refer to => [ Assembling the 5th Gear Locking Collar/Synchronizer Hub ] Input Shaft.
13 Needle Bearing
• For the 5th gear selector gear.
14 5th Gear
• Remove together with the transmission housing. Refer to => [ Transmission ] Transmission.
• Removing individually, refer to => [ Transmission Housing Cover and 5th Gear ] Transmission Housing Cover and 5th Gear.
• Installed position, refer to => [ 5th Gear, Installed Position: ] Transmission.
Transmission Housing Cover with a Magnet
The magnet - A - can be inserted only into a cover with a recess - arrow -.
The magnet is held in place by the bolt for the 5th gear selector fork base when the cover is installed.
Transmission Housing and Shift Mechanism
1 Countersunk Bolt
• 25 Nm
2 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.
3 Inner TORX(R) Bolt
• 25 Nm
• Always replace.
• For the reverse shaft support.
• Self-locking.
4 Inner TORX(R) Bolt
• 30 Nm
• Always replace.
• For the reverse shaft support.
• Self-locking.
5 O-ring
• Always replace.
6 Support Pin
7 Bolt
• 25 Nm
8 Bolt
• 25 Nm
9 Sealing Cap
10 Socket Head Bolt
• 25 Nm
• for the reverse shaft support.
• Always replace.
11 Bolt
• 5 Nm
12 Transmission Neutral Position Sensor (G701)
• Not available in the US/Canadian market.
13 Transmission Housing
• Remove together with 5th gear. Refer to => [ Transmission ] Transmission.
• Disassembly and assembly, refer to => [ Transmission and Clutch Housings ] Transmission and Clutch Housings.
14 Clutch Housing
• Disassembly and assembly, refer to => [ Transmission and Clutch Housings ] Transmission and Clutch Housings.
15 Bolt
• 25 Nm + 90° (1/4) additional turn.
• Always replace.
16 Gear Shift Unit
• Disassembly and assembly, refer to => [ Shift Unit ] Shift Unit.
17 Bolt
• 25 Nm
Input Shaft, Output Shaft, Differential and Shift Rods
1 Differential
• Disassembly and assembly, refer to => [ Differential ] Service and Repair.
2 Seal
• Quantity: 4
• Always replace.
3 Output Shaft
• Disassembly and assembly, refer to => [ Output Shaft ] Output Shaft.
4 Reverse Gear Shaft Support
• Disassembly and assembly, refer to => [ Reverse Shaft ] Reverse Shaft.
5 Reverse Shaft
• Disassembly and assembly, refer to => [ Reverse Shaft ] Reverse Shaft.
6 Input Shaft
• Disassembly and assembly, refer to => [ Input Shaft ] Input Shaft.
7 Reverse Gear Selector Fork
• Disassembly and assembly, refer to => [ Selector Forks ] Selector Forks.
• Installed position, refer to "Assembly" in the => [ Transmission ] Transmission.
8 Inner TORX(R) Bolt
• 25 Nm
9 Selector Fork with Rail
• Disassembly and assembly, refer to => [ Selector Forks ] Selector Forks.
10 Clutch Housing
• Disassembly and assembly, refer to => [ Transmission and Clutch Housings ] Transmission and Clutch Housings.
11 Nut
• 25 Nm 90° (1/4) additional turn.
• Always replace.
• 4 nuts, for the output shaft bearing support.
12 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.
13 Countersunk Bolt
• 25 Nm