Output Shaft: Service and Repair
Disassembly/Assembly
NOTE:
Tapered roller bearings are only to be replaced as a set. After replacement, adjust the output shaft.
The following have been modified for vehicles with the 2.0 liter 85kW(1l5 hp) engine:
- Increased hub spline diameter for 4Th gear
- Additional groove and circlip for 4th gear, on 3rd gear side
1 Transmission housing cover
2 Needle bearing
- Removal/installation - Case
3 Attachment bolt
4 Circlip for 5th gear (always replace)
- Must seat firmly in groove
5 Thrust washer
- Not installed on vehicles with 2.0 liter, 85kW (115 hp) engine
6 Retainer plate for 5th gear
- Installed only on vehicles with 2.0 liter, 85 kW (115 hp) engine
7 5th gear
- Installing - 020 Transmission Assembly
- Vehicles with 2.0 liter, 85 kW (115 hp) engine: additional circlip on 3rd gear side
8 Transmission housing
9 Needle bearing
- Removal/installation - Transmission Housing
10 Circlip for 4th gear (always replace)
- Must seat firmly in groove
11 4th gear
- Vehicles with 2.0 liter, 85 kW (115 hp) engine: additional circlip on 3rd gear side
- Larger internal diameter for modified output shaft
- Removal/installation - Transmission Housing
12 Circlip for 4th gear
- Additional on vehicles with 2.0 liter, 85 kW (115 hp) engine
13 Circlip for 3rd gear (always replace)
- Must seat firmly in groove
- Recheck for thickness - 020 Transmission Assembly
- Increased diameter on vehicles with 2.0 liter, 85 kW (115 hp) engine
14 3rd gear
- Installation position/adjusting axial clearance - 020 Transmission Assembly
15 2nd gear
16 Needle bearing for 2nd gear
- Removal/installation - 020 Transmission Assembly
17 2nd gear synchronizer ring
- Checking synchronizer rings
^ Friction surface coated with molybdenum
^ Press synchronizer rings onto gear cones and measure gap -a- with feeler gauge
^ a = New: 1.1-1.7 mm (0.043A).067 in)
^ a = Wear limit: 0.5 mm (0.020 in)
CAUTION: Synchronizer rings that are being reused must not be interchanged.
18 Operating sleeve/synchronizer hub for lst/2nd gear
- Removal/installation - 020 Transmission Disassembly - 020 Transmission Assembly
- Assembling operating sleeve and hub
^ Installation position of synchronizer hub: identification groove on end face (arrow) is toward outer teeth on operating sleeve
^ Slide operating sleeve over synchronizer hub
^ Recesses for locking keys on synchronizer hub and operating sleeve must be aligned
- Assembling synchronizer hub and sleeve
^ Insert locking keys and install springs at - 120° offset, angled ends of each spring must engage in hollow keys
19 Spring
20 Operating sleeve
21 Synchronizer hub
22 Locking key
23 1st gear synchronizer ring
- Checking synchronizer rings
^ Press synchronizer rings onto gear cones and measure gap -a- with feeler gauge
^ a = New: 1.1-1.7 mm (0.043A).067 in)
^ a = Wear limit: 0.5 mm (0.020 in)
- Marking of synchronizer with 110° tooth angle
CAUTION: Synchronizer rings that are being reused must not be interchanged.
24 1st gear
25 Thrust washer
26 Shim S3
27 Outer race of small tapered roller bearing
- Removing outer race of small tapered roller bearing from clutch housing
^ A = Internal extractor 37-46 mm, e.g. Kukko 21/6
^ B = Counter support, e.g. Kukko 22/2
- Installing outer race of small tapered roller bearing into clutch housing
28 Inner race of small tapered roller bearing
- Removing inner race of small tapered roller bearing
^ A = Separator, 22-115 mm, e.g. Kukko 17/22
- Installing inner races of small and large tapered roller bearings
^ Heat to approx. 100°C (212°F)
29 Clutch housing
30 Output shaft
- Matched to final drive gear
- Vehicles with 2.0 liter, 85 kW (115 hp) engine: have an additional groove for 4th gear circlip
- Adjust when replacing - Output Shaft
31 Inner race of large tapered roller bearing
- Removal of inner race of large tapered roller bearing
^ A = Separator, 22-115 mm, e.g. Kukko 17/22
NOTE: The bearing is destroyed during removal.
- Installing inner races of small and large tapered roller bearings
^ Heat to approx. 100°C (212°F)
32 Bearing cover
- With outer race of large tapered roller bearing and stop for reverse idler gear
- Bearing cover and outer race are single unit
- Do not press out outer race
33 Hex-head bolt
- Tightening torque: 25 Nm (18 ft lb) plus additional 1/4 turn (90°)