Pinion Shaft, Assembly Overview
Pinion shaft, assembly overview - 6 Spd. M/T 01X Front Wheel Drive
Note:
^ Refer to technical data when installing new gear wheels or the final drive gear set.
^ 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"
^ Table of adjustments
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
^ Adjusting crown wheel and pinion shaft
5 - Tapered roller bearing inner race1)
^ 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"
^ Table of adjustments
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
^ Allocation of spring to selector gear
31 - Synchronizing ring for reverse gear
^ Checking for wear
32 - Reverse gear synchronizing hub
^ Installation position: high inside collar faces 3rd gear wheel
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 gear wheel
37 - 5th gear wheel
^ Installation position: high inside collar faces 4th gear wheel
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.