Drive Pinion and Hollow Shaft Assembly Overview
Drive Pinion and Hollow Shaft Assembly Overview
Drive pinion disassembling and assembling, refer to => [ Drive Pinion ] Drive Pinion.
Hollow shaft disassembling and assembling, refer to => [ Hollow Shaft ] Hollow Shaft.
• When installing new gears or gear set, note technical data.
• If drive pinion (gear set) => [ (Item 3) Drive pinion ] is replaced, then always replace double angular contact ball bearing => [ (Item 5) Double angular contact ball bearing ] too.
• Insert all needle bearings and synchronizer rings with transmission fluid.
• When replacing synchronizer rings, the intermediate ring and synchronizer ring for the respective gear must be replaced together.
• If the synchronizer rings are not to be replaced, make sure they are reallocated to their original gear. Do not interchange reverse gear synchronizer rings with 1st and 2nd gear synchronizer rings, refer to => [ Differentiation of reverse gear synchronization
rings and 1st/2nd gear ] Transmission
• Items - 22 through 29 -, - 32 and 49 - were changed in the version with selector rod for 1st/2nd gear with spring loaded shift fork, refer to => [ 1st/2nd Gear Selector Rod with Spring Loaded Shift Fork ] First, Second and Reverse Gear Assembly Overview Allocate components via the.
• Adjustments are required when replacing components marked with 1). List of adjustments, refer to => [ Adjustment Overview ] Adjustment Overview.
1 Transmission housing 1)
2 Adjustment shim "S3"
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.
3 Drive pinion1)
• Is mated with ring gear, always replace together as a set.
• Disassembling and assembling, refer to => [ Drive Pinion ] Drive Pinion.
• Drive pinion and ring gear, adjusting, refer to => [ Pinion and Ring Gear ] Pinion and Ring Gear.
4 Needle bearing
• For flange shaft mounting in drive pinion.
• Pulling out, refer to => [ Flange shaft mounting needle bearing, removing from drive pinion ] Drive Pinion
• Driving in, refer to => [ Flange shaft mounting needle bearing, driving in flush in drive pinion ] Drive Pinion
5 Double angular contact ball bearing
• No adjustment is needed if only this bearing is replaced.
• Pressing off, refer to => [ Double angular contact ball bearing, pressing off ] Drive Pinion
• Pressing on, refer to => [ Double angular contact ball bearing, pressing on ] Drive Pinion
• Installation position: shoulder on outer race faces toward pinion face.
6 Adjustment shim "S5"
• For positioning inner race/tapered roller bearing => [ (Item 7) Tapered roller bearing inner race ]
• Determine thickness, refer to => [ Redetermining Shim S5 for Positioning Inner Race/Tapered Ball Bearing ] Redetermining Shim S5 for Positioning Inner Race/Tapered Ball Bearing.
7 Tapered roller bearing inner race
• Pressing off, refer to => [ Pressing off inner race/tapered roller bearing ] Drive Pinion
• Pressing on, Refer to => [ Pressing on inner race/tapered roller bearing ] Drive Pinion
8 Washer
9 Circlip
• Determine thickness, refer to => [ Circlip , determining ] Drive Pinion
10 Needle bearing
• For drive pinion in hollow shaft.
• Coat with transmission fluid.
11 Adjustment shim "S4"
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.
12 Holding plate
• Installation position: sanded side faces toward transmission housing, fits only in one position.
13 Bolt, 30 Nm
• Quantity: 6
• Insert with locking fluid (AMV 185 101 A1).
14 Hollow shaft
• With 3rd and 4th gears.
• Disassembling and assembling, refer to => [ Hollow Shaft ] Hollow Shaft.
15 Drive gear for 6th gear
• Pressing off, Refer to => [ 6th gear selector gear, pressing off ] Hollow Shaft
• Pressing on, refer to => [ 6th gear drive gear, pressing on ] Hollow Shaft
• Installation position: High inner collar faces 5th gear drive gear.
16 Drive gear for 5th gear
• Pressing off, refer to => [ Pressing off 5th gear, gear wheel ] Hollow Shaft
• Pressing on, refer to => [ Pressing on 5th gear, gear wheel ] Hollow Shaft
• Installation position: High inner collar faces 6th gear drive gear.
17 Roller bearing
• For hollow shaft.
• Do not exchange with input shaft roller bearing.
• Press off together with drive gear for 5th gear, refer to => [ Pressing off 5th gear, gear wheel ] Hollow Shaft
• Pressing on, refer to => [ Hollow shaft roller bearing, pressing on ] Hollow Shaft
18 Bearing bracket
• Roller bearing outer race => [ (Item 17) Roller bearing ] cannot be replaced individually, replace bearing bracket if worn.
• Roller bearing outer race must not have any radial play in bearing bracket.
19 Adjustment shim "S6"
• For positioning 2nd gear selector gear.
• Determine thickness, refer to => [ Redetermining Shim S6 for Positioning 2nd Gear Selector Gear ] Redetermining Shim S6 for Positioning 2nd Gear Selector Gear.
20 Inner race/needle bearing
• For selector gear of 2nd gear.
• Press off together with drive gear for 5th gear, refer to => [ Pressing off 5th gear, gear wheel ] Hollow Shaft
• Pressing on, refer to => [ Inner race/needle bearing for 2nd gear selector gear, pressing on ] Hollow Shaft
21 Needle bearing
• For 2nd gear.
22 Selector gear for 2nd gear
23 Inner race for 2nd gear
• Installed location, refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Checking for wear, refer to => [ Synchronizer rings for 1st, 2nd and reverse gears, checking for wear ] Transmission
• Replace if grooved or scored.
24 Intermediate ring for 2nd gear
• Installed location, refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Checking for wear, refer to => [ Synchronizer rings for 1st, 2nd and reverse gears, checking for wear ] Transmission
25 Synchronizer ring for 2nd gear
• Installed location, refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Checking for wear, refer to => [ Synchronizer rings for 1st, 2nd and reverse gears, checking for wear ] Transmission
• Replace if grooved or scored.
26 Locking sleeve with synchronizer hub for 1st and 2nd gears
• Removing and installing, refer to => [ Transmission ] Transmission.
• Assembling locking collar/synchronizer hub, refer to => [ Assembly of locking collar/synchronizer hub for 1st and 2nd gear ] Transmission.
27 Synchronizer ring for 1st gear
• Installed location, refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Checking for wear, refer to => [ Synchronizer rings for 1st, 2nd and reverse gears, checking for wear ] Transmission
• Replace if grooved or scored.
28 Intermediate ring for 1st gear
• Installed location, refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Checking for wear, refer to => [ Synchronizer rings for 1st, 2nd and reverse gears, checking for wear ] Transmission
29 Inner race for 1st gear
• Installed location, Refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Checking for wear, refer to => [ Synchronizer rings for 1st, 2nd and reverse gears, checking for wear ] Transmission
• Replace if grooved or scored.
30 Inner race/needle bearing
• For 1st gear selector gear.
31 Needle bearing
• For 1st gear.
32 Drive gear for 1st gear
33 Thrust washer
• For 1st gear and reverse gear selector gears.
34 Gear wheel for reverse gear
• With reverse gear locking collar.
• Removing and installing, refer to => [ Transmission ] Transmission.
• Locking collar and reverse gear selector gear, disassembling and assembling, refer to => [ Assemble locking collar and reverse gear selector gear ] Transmission
35 Synchronizer ring for reverse gear
• Installed location, refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Checking for wear, refer to => [ Synchronizer rings for 1st, 2nd and reverse gears, checking for wear ] Transmission
• Replace if grooved or scored.
36 Reverse gear intermediate ring
• Installed location, refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Checking for wear, refer to => [ Synchronizer rings for 1st, 2nd and reverse gears, checking for wear ] Transmission
37 Reverse gear inner race
• Installed location, Refer to => [ Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear ] Transmission
• Replace if grooved or scored.
38 Needle bearing
• For reverse gear selector gear.
39 Clutch hub
• Removing and installing, refer to => [ Transmission ] Transmission.
40 Transmission cover
41 Twelve point nut, 75 Nm
42 Spacer ring
• Secures twelve-point nut => [ (Item 41) Twelve point nut, 75 Nm ] on hollow shaft against loosening on its own.
43 Tapered roller bearing outer race
• Can be installed and removed by hand.
44 Tapered roller bearing inner race
• Can be installed and removed by hand.
45 Washer
• Note thickness.
• Determine thickness, refer to => [ Determine thickness of circlip and shim(s) as follows: ] Transmission.
46 Circlip
• Note thickness.
• Determine thickness, refer to => [ Determine thickness of circlip and shim(s) as follows: ] Transmission.
47 Synchronizer hub for 1st and 2nd gear
48 Thrust plate
• Installing thrust pieces (3x), refer to => [ Assembly of locking collar/synchronizer hub for 1st and 2nd gear ] Transmission.
49 Locking collar for 1st and 2nd gear
50 Thrust plate
• Installing thrust pieces (3x), refer to => [ Assemble locking collar and reverse gear selector gear ] Transmission
51 Gear wheel for reverse gear
52 Reverse gear selector gear locking collar