Transmission Component Overviews
Transmission Component Overviews
I - => [ Transmission Housing Cover and 5th Gear ]
II - => [ Transmission Housing and Gear Shift Unit ]
III - => [ Input Shaft, Output Shafts, Differential and Shift Forks ]
Transmission Housing Cover and 5th Gear
1 Bolt
• 18 Nm
• For the cover to the transmission housing.
2 Transmission Housing Cover
• From 11.10 with a magnet. Refer to => [ Transmission Housing Cover with a Magnet ].
• Note that fluid will leak out when the cover is removed with the transmission installed.
• Therefore the fluid must be drained and then filled again later. Refer to => [ Transmission Fluid, Checking, Draining and Filling ] Service and Repair.
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
• Clean the synchronizer hub and 5th gear drive gear threaded holes of locking fluid residue with a thread tap. Otherwise, there is the danger that the bolt could shear off.
5 Concave Washer
• Installing, refer to => [ Installed Position of the Plate Springs for the 5th Gear Synchronizer Hub and Drive Gear 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 assembling, refer to => [ Selector Forks ] Selector Forks.
9 Spring
• Offset version.
• Installing, refer to => [ Installation of the Offset Springs ] Input Shaft.
10 5th Gear Locking Collar
• Installed position, refer to => [ Assembling 5th Gear Locking Collar/Synchronizer Hub ] Input Shaft.
• Adjusting, refer to => [ Adjusting the 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 5th Gear Locking Collar/Synchronizer Hub ] Input Shaft.
13 Needle Bearing
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 installed only to a cover with a recess - arrow -.
The magnet is held in place by the bolt for the 5th gear selector fork bus when the cover is installed.
Transmission Housing and Gear Shift Unit
1 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, Seal with Sleeve (One-Piece) ] Final Drive, Differential (0A4 Manual Transmission)Right Flange Shaft, Seal With Sleeve (One-Piece).
=> [ Right Flange Shaft, Seal and Sleeve (Two-Piece) ] Right Flange Shaft, Seal and Sleeve (Two-Piece).
• Assembling, refer to => [ Differential ] Service and Repair.
3 TORX(R) Bolt
• 25 Nm
• Always replace.
• Self-locking.
• For the reverse shaft support.
4 TORX(R) Bolt
• 30 Nm
• Always replace.
• Self-locking.
• For the reverse shaft support.
5 O-ring
• Always replace.
6 Support Pin
7 Bolt
• 25 Nm
8 Bolt
• 25 Nm
9 Sealing Cap
10 Bolt
• 25 Nm
• Always replace.
• For the reverse shaft support.
11 Bolt
• 5 Nm
12 Transmission Neutral Position Sensor (G701)
• Not available in the US/Canadian market.
• For vehicles with the Start/Stop System.
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 => [ Gear Shift Unit ] Gear Shift Unit.
17 Bolt
• 25 Nm
Input Shaft, Output Shafts, Differential and Shift Forks
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 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, Seal with Sleeve (One-Piece) ] Final Drive, Differential (0A4 Manual Transmission)Right Flange Shaft, Seal With Sleeve (One-Piece).
=> [ Right Flange Shaft, Seal and Sleeve (Two-Piece) ] Right Flange Shaft, Seal and Sleeve (Two-Piece).
• Assembling, refer to => [ Differential ] Service and Repair.
13 Bolt
• 25 Nm