Pinion Shaft and Hollow Shaft, Assembly Overview

Pinion shaft and hollow shaft, assembly overview, 02X, 6-Speed Four-Wheel Drive M/T

Note:
^ When installing new gear wheels or the final drive set consult technical data.
^ Observe technical data when installing new gear wheels
^ Lubricate all needle bearings on hollow 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 - Double tapered roller bearing outer race 1)
^ Pulling out
^ Pressing in and

4 - Pinion shaft 1)
^ Is mated with ring gear, always replace together as a set

5 - Double tapered roller bearing inner race
^ Will be damaged during removal
^ Replace
^ Pressing off
^ Pressing on

6 - Circlip
^ Redetermine thickness if double tapered roller bearing is replaced

7 - Large needle bearing
^ For pinion shaft in hollow shaft
^ Lubricate with gear oil

8 - Hollow shaft
^ Disassembling and assembling

9 - Small needle bearing
^ For pinion shaft in hollow shaft
^ Lubricate with gear oil

10 - Large needle bearing for 1st gear

11 - Small needle bearing for 1st gear

12 - 1st speed selector gear
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

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

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

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

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

17 - Locking piece
^ Install locking pieces (3x)

18 - 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

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

20 - Needle bearing
^ For 2nd gear

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

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

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

24 - 2nd speed selector gear
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

25 - Circlip
^ Mark
^ Installation position item 2

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

27 - Circlip
^ Mark
^ Installation position item 3

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

29 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in

30 - Shim "S4"

31 - Bearing housing

32 - Needle bearing
^ For reverse selector gear

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

34 - Spring
^ Insert into reverse selector gear

35 - Synchronizing ring for reverse gear
^ Checking for wear

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

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

38 - 3rd gear wheel
^ Installation position: machined side faces reverse gear synchronizing hub

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

40 - 4th gear wheel
^ Installation position: high inside collar faces 5th gearwheel

41 - 5th gear wheel
^ Installation position: high inside collar faces 4th gearwheel

42 - Spacer sleeve

43 - 6th gear wheel

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

45 - Needle bearing
^ Bearing for hollow shaft in transmission cover

46 - Multi-point socket head bolt, 24 Nm

47 - Retaining plate

48 - 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.