Transmission Component Overviews
Transmission Component Overviews
I - => [ Transmission Housing and 5th Gear Cover ]
II - => [ Clutch Housing ]
III - => [ Input Shaft, Output Shaft, Differential, Shift Mechanism and Shift Forks ]
Transmission Housing and 5th Gear Cover
1 Transmission Housing
2 5th Gear
• Installed position, refer to => [ Installed Position
of the 5th Gear: ] Transmission.
3 Lock Ring
• Determining thickness, refer to => [ Select a new lock ring. ] Transmission.
4 Seal
5 Transmission Housing Cover
• If the transmission housing cover is installed when the transmission is installed, check the fluid level. Refer to => [ Transmission Fluid, Checking ] Service and Repair.
6 Bolt
• 5 Nm + 90° (1/4) additional turn.
• Always replace.
7 Lock Ring
• Determining thickness, refer to => [ Select a new lock ring. ] Transmission.
8 Synchronizer Hub with Locking Collar and Stop Ring for 5th Gear
• Disassembling and assembling, refer to => [ Input Shaft ] Input Shaft.
9 5th Gear Synchronizer Ring
10 5th Gear
11 Needle Bearing
• For 5th gear.
12 5th Gear Shift Fork
• Disassembling and assembling, refer to => [ Shift Forks ] Shift Forks.
13 Pin
• For the 5th gear shift fork.
Clutch Housing
1 Bolt
• 25 Nm
2 Flange Shaft with Pressure Spring
• Removing and installing, refer to => [ Transmission ] Transmission.
• Assembling, refer to => [ Differential ] Service and Repair.
3 Bolt
• 5 Nm + 90° (1/4) additional turn.
• Always replace.
4 Clutch Housing
• Disassembling and assembling, refer to => [ Transmission Housing and Clutch Housing ] Transmission Housing and Clutch Housing.
5 Transmission Housing
• Disassembling and assembling, refer to => [ Transmission Housing and Clutch Housing ] Transmission Housing and Clutch Housing.
6 Clutch Release Lever
• With the guide sleeve and release bearing.
• Removing and installing, refer to => [ Clutch Release Lever with Release Bearing and Guide Sleeve ] Service and Repair.
7 Bolt
• Information and tightening specification, see - item 2 -=> [ Bolt ] Clutch Release Mechanism Overview.
Input Shaft, Output Shaft, Differential, Shift Mechanism and Shift Forks
1 Differential
• Disassembling and assembling, refer to => [ Differential ] Service and Repair.
2 Transmission Housing
• Disassembling and assembling, refer to => [ Transmission Housing and Clutch Housing ] Transmission Housing and Clutch Housing.
• Shim S1 for the differential outer race/tapered roller bearing if deleted from transmission build date 04 December 2006. Refer to => [ Shim S for
the Outer Race/Tapered Roller Bearing is Deleted as of Production
date 04 December 2006 ] Adjustments.
• Outer race/tapered roller bearing seat adapted in transmission housing.
3 Drain Plug
• Tightening specification, refer to => [ Different versions of
the Fill and Drain Plugs ] Service and Repair.
4 Flange Shaft with Pressure Spring
• Removing and installing, refer to => [ Transmission ] Transmission.
• Assembling, refer to => [ Differential ] Service and Repair.
5 Bolt
• 25 Nm
6 Self Locking Bolt
• 5 Nm + 90° (1/4) additional turn.
• Always replace
• For securing the bearing mount with grooved ball bearing for the input and output shaft - item 16 -.
7 Self Locking Bolt
• 23 Nm
• Always replace
• For the shift forks - item 15 -.
8 O-ring
• Always replace
9 Pivot Pin
10 Bolt
• 5 Nm + 90° (1/4) additional turn.
• Always replace.
11 Shift Unit
• Disassembling and assembling, refer to => [ Shift Unit ] Shift Unit.
12 Bolt
• 5 Nm + 90° (1/4) additional turn.
• Always replace.
13 Backup Lamp Switch (F4)
• 20 Nm
• Short after series introduction of transmission with permanent seal.
14 Seal
• Always replace, if equipped.
• Not on all transmissions.
15 Shift Forks
• Disassembling and assembling, refer to => [ Shift Forks ] Shift Forks.
16 Input Shaft with Output Shaft and Bearing Mount/Grooved Ball Bearing
• If the bearing mount is removed from the transmission housing, it must always be replaced.
• Bearing mount removing and installing, see - item 8 -=> [ Bearing Mount with Grooved Ball
Bearing ] Input Shaft.
• Input shaft, disassembling and assembling. Refer to => [ Input Shaft ] Input Shaft.
• Output shaft, disassembling and assembling. Refer to => [ Output Shaft ] Output Shaft.
17 Reverse Gear Axle
18 Reverse Gear
19 Bolt
• 25 Nm + 45° (1/8) additional turn.
• Always replace.
• For securing the reverse gear axle.