Overhaul (Disassembly & Assembly)

Input shaft ball bearing and multi-function sensor, removing and installing





1 - Transmission housing
^ With differential and flange shafts
^ Removing and installing flange shafts
^ Removing and installing differential
^ Removing and installing speedometer sensor and drive wheel
^ Breather installation position

2 - Torx socket head bolt
^ Self-locking
^ Always replace
3 - Guide sleeve
^ With O-ring and seal for input shaft
^ Installation position: Oil drain hole points downward
4 - Dished washer
^ Smaller diameter (convex side) to guide sleeve
5 - Circlip
^ Determining thickness adjusting input shaft
6 - Ball bearing
^ Removing and installing
7 - Circlip
^ Determining thickness adjusting input shaft
8 - Input shaft
^ Removing and installing
^ Disassembling and assembling
^ Adjusting
^ Servicing input shaft bearings
9 - Bolt
10 - Tab washer
^ For multi-function sensor
11 - Multi-function sensor
12 - Connector for multi-function sensor
13 - Bolt - 10 Nm
14 - Cover for selector shaft
^ Removing and installing
15 - Locking module for 5th gear and reverse gear
^ Removing and installing

Fig. 1 Installation position of breather:

The breather must project 21 mm out of housing, after being pressed in.

Input shaft, drive pinion, selector rods and transmission cover, removing and installing





1 - Selector rod with selector fork for 3rd and 4th gear
^ Disassembling and assembling
^ Replacing mounting bushings

2 - Input shaft
^ Disassembling and assembling
^ Adjusting
^ Servicing input shaft bearings
3 - Left stop bolt - 40 Nm
4 - Washer
5 - Relay shaft
^ Installation position
6 - Washer
7 - Right stop bolt - 40 Nm
8 - Selector shaft
^ Installation position
^ Replace selector shaft sealing ring
9 - Detent segment
^ Installation position
10 - Torx bolt - 25 Nm
^ With collar to secure the detent segment spring
11 - Selector rod with selector fork for 1st/2nd/5th and reverse gear
^ Disassembling and assembling
^ Removing and installing ball sleeves
12 - Drive pinion
^ Disassembling and assembling
^ Adjusting
^ Servicing drive pinion bearings
13 - Transmission cover
^ Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces
^ Removing and installing oil collector
14 - Transmission housing
^ Match components according to transmission code letters found in parts catalog

15 - Torx bolt - 22 Nm

Fig. 1 Removing and installing oil collector:

Removing
- Turn the oil collector arrow- and then pull out.

Installing
- Push oil collector into transmission cover until it snaps in place.
^ Installation position: Oil collector faces upward in transmission cover