Output Shaft

Output Shaft





Special Tools

Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

1. General note
^ See "Description and Operation" for a general view of the output shaft.
^ If there any replacement of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.

2. CAUTION: Only loosely attach the special tool to avoid damaging the synchronizer ring.





Using the special tool, remove the taper roller bearing together with the reverse gear wheel.





3. Remove the needle roller bearing and the synchronizer ring.
1. Needle roller bearing.
2. Synchronizer ring.





4. Remove the fifth/reverse gear synchronizer assembly.
1. Remove the snap-ring.
2. Remove the synchronizer assembly.





5. Remove the fifth gear.
1. Remove the synchronizer ring.
2. Remove the fifth gear.
3. Remove the bearing.

6. CAUTION: The taper roller bearing is damaged when it is pressed off using the special tool and cannot be reused.





Using the special tool, press the taper roller bearing off the output shaft.

7. CAUTION: Note the marks on the output pinion for reinstallation. The output shaft and output pinion belong together and can only be replaced as a pair.

CAUTION: Only loosely attach the special tool to avoid damaging the synchronizer ring.





Using the special tool, remove the output pinion and first gear.
1. Remove the snap-ring.
2. Remove the output pinion and first gear together.





8. Remove the double synchronizer with the first gear wheel.
1. Needle roller bearing
2. Inner synchronizer ring
3. Synchronizer cone
4. Outer synchronizer ring





9. Remove the first/second gear synchronizer assembly.
1. Remove the snap-ring.
2. Remove the synchronizer assembly.





10. Remove the double synchronizer together with the second gear wheel.
1. Outer synchronizer ring
2. Synchronizer cone
3. Inner synchronizer ring
4. Gear wheel (second gear)
5. Needle roller bearing

NOTE: Mark the location of the selector ring.

11. CAUTION: Take care when pulling the selector ring off the synchronizer hub. The detent balls are spring-loaded.





Dismantle the synchronizer assembly.
1. Pull off the selector ring.
2. Synchronizer hub
3. Compression spring
4. Blocker bar
5. Detent bar

Assembly

CAUTION: Immerse the double synchronizer units in a bath of Manual transmission fluid before installation.

1. Carefully clean and check all sliding parts and lubricate them with Manual transmission fluid before installation.

2. NOTE: Do not oil taper roller bearings which are to be used again.





Install the second gear wheel with the double synchronizer and needle roller bearing.
1. Needle roller bearing
2. Gear wheel (second gear)
3. Inner synchronizer ring
4. Synchronizer cone
5. Outer synchronizer ring

3. NOTE: Marking.





Assemble the first/second gear synchronizer.
1. Insert the compression springs.
2. Insert the blocker bar with detent balls against the spring pressure.
3. Install the selector ring the right way round and slide it on.

4. NOTE: Install the synchronizer ring hub with the small collar and the annular groove of the selector ring facing outwards.





Installation position of the synchronizer assembly.

5. NOTE: Installation position.





Install the first/second gear synchronizer assembly.
1. Install the first/second gear synchronizer assembly.
2. Install a new snap-ring.

6. NOTE: Do not oil taper roller bearings which are to be used again.





Install the double synchronizer together with the first gear wheel.
1. Outer synchronizer ring
2. Synchronizer cone
3. Inner synchronizer ring
4. Gear wheel (first gear)
5. Needle roller bearing

7. CAUTION: The output pinion can only be installed on the shaft splines in one position.

NOTE: Install the output pinion with the mark facing upwards.





Install the output pinion on.
1. Using a suitable length or tube, install the output pinion.
2. Install a new snap-ring.





8. Install the bearing.
^ Using a suitable length or tube, install the bearing.





9. Install the fifth gear.
1. Install the bearing.
2. Install fifth gear.
3. Install the synchronizer ring.

10. NOTE: Install the synchronizer hub with the small collar and the annular groove running round it facing outwards.





Installation position of the synchronizer assembly.





11. Install fifth/reverse gear synchronizer assembly
1. Install the synchronizer assembly.
2. Install a new snap-ring.





12. Install reverse gear.
1. Install the synchronizer ring.
2. Install the bearing.
3. Install reverse gear.





13. Using a suitable length or tube, install the bearing.