Pinion Shaft, Assembly Overview

Pinion shaft, assembly overview, 01X, 6-Speed Front-wheel Drive M/T

Note:
^ Refer to technical data when installing new gear wheels
^ Lubricate all needle bearings on output shaft with gear oil before installing.
^ Adjustment work is required when replacing the parts marked with 1)





1 - Transmission housing 1)

2 - Shim "S3"

3 - Tapered roller bearing outer race 1)
^ Pulling out
^ Pressing in and

4 - Pinion shaft (output shaft) 1)
^ Is mated with crown wheel, always replace together as a set

5 - Tapered roller bearing inner race 1)
^ Will be damaged during removal
^ Replace
^ Pressing off
^ Pressing on

6 - Circlip
^ Re-determine thickness if taper roller bearing is replaced

7 - Needle bearing
^ For 1st gear

8 - 1st speed selector gear
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

9 - Inner ring for 1st gear
^ Installation position
^ Checking for wear
^ Replace if scored or if there are visible traces of wear

10 - Intermediate ring for 1st gear
^ Installation position
^ Checking for wear

11 - Synchro-ring for 1st gear
^ Installation position
^ Checking for wear
^ Replace if scored or if there are visible traces of wear

12 - Locking collar for 1st and 2nd gear
^ Mark position in relation to synchronizing hub prior to removing
^ Assembling locking collar/synchronizing hub

13 - Locking piece
^ Install locking pieces (3 Qty.)

14 - Synchronizing hub for 1st and 2nd gear
^ Installation position: high inside collar faces 2nd speed selector gear
^ Pressing off
^ Pressing on
^ Assembling locking collar/synchronizing hub

15 - Circlip
^ Mark
^ Installation position - item 1 -
^ Re-determine thickness when replacing 1st and 2nd gear synchronizing hub or pinion shaft

16 - Needle bearing
^ For 2nd gear

17 - Synchro-ring for 2nd gear
^ Installation position
^ Checking for wear
^ Replace if scored or if there are visible traces of wear

18 - Intermediate ring for 2nd gear
^ Installation position
^ Checking for wear

19 - Inner ring for 2nd gear
^ Installation position
^ Checking for wear
^ Replace if scored or if there are visible traces of wear

20 - 2nd speed selector gear
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

21 - Circlip
^ Mark
^ Installation position - item 2 -

22 - Tapered roller bearing inner race 1)
^ Pressing off
^ Pressing on

23 - Circlip
^ Mark
^ Installation position - item 3 -

24 - Thrust washer
^ For reverse selector gear
^ Pressing off
^ Pressing on

25 - Tapered roller bearing outer race 1)
^ Pulling out
^ Pressing in

26 - Shim "S4"

27 - Bearing housing 1)

28 - Needle bearing
^ For reverse selector gear

29 - Reverse selector gear
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

30 - Spring
^ Insert into reverse selector gear

31 - Synchronizing ring for reverse gear
^ Checking for wear

32 - Reverse gear synchronizing hub
^ Installation position: high inside collar faces 3rd gearwheel

33 - Reverse gear locking collar
^ Mark position in relation to synchronizing hub prior to removing
^ Installation position: taper faces reverse gear synchro-ring

34 - 3rd gear wheel
^ Installation position: machined side faces reverse gear synchronizing hub

35 - Circlip
^ Mark
^ Installation position - item 4 -
^ Re-determine thickness when replacing 3rd gear wheel, reverse gear synchronizing hub or pinion shaft

36 - 4th gear wheel
^ Installation position: high inside collar faces 5th gearwheel

37 - 5th gear wheel
^ Installation position: high inside collar faces 4th gearwheel

38 - Spacer sleeve

39 - 6th gear wheel

40 - Circlip
^ Mark
^ Installation position - item 5 -
^ Re-determine thickness when replacing gear wheels for 4th to 6th gear, the spacer sleeve or pinion shaft

41 - Needle bearing
^ Bearing for pinion shaft in transmission cover

42 - Multi-point socket head bolt, 24 Nm

43 - Retaining plate

44 - Transmission cover





Inserting spring in selector gear
The bent end of spring - arrow - must be hooked into hole in selector gear.





Checking synchro-ring for wear
- Press synchro-ring into locking collar and measure gap - a - at positions - A -, - B - and - C - using feeler gauge.
- Add measured values and divide by 3.

The determined value should not exceed 0.45 mm.