Part 2

Output shaft, disassembling and assembling, 02J, 5 Spd. M/T





Fig. 4 Pressing on small tapered roller bearing inner race





Fig. 5 Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gears with transmission housing needle roller bearing sleeve
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
B - Hex bolt 17 mm AF - M10 0 x 20

Note: Support separating appliance so that the 1st and 2nd gear locking collar is not pulled off at the same time.





Fig. 6 Pulling off locking collar with synchro-hub via bearing support
A - Two-arm puller, e.g. Kukko 20/10 with 250 mm reach hooks
B - Hex bolt 17 mm AF - M10 0 x 20

Note: Remove circlip before puffing off individual components.





Fig. 7 Pulling off large tapered roller bearing inner race
A - Protective jaws
- Before fitting puller insert an M10 x 20 hex bolt in output shaft drilling.





Fig. 8 Pressing on large tapered roller bearing inner race
A - Thrust washer
- Fit thrust washer before pressing on inner race. Shoulder faces inner race.





Fig. 9 Checking synchro-ring for wear
- Press synchro-ring onto gear cone and measure gap a with feeler gauge.








Fig. 10 Disassembling and assembling 1st and 2nd gear locking collar and synchro-hub
1 - Spring
2 - Locking collar
3 - Synchro-hub
4 - Locking piece
- Slide locking collar over synchro-hub.
The wide shoulder of the synchro-hub (arrow -A-) and the outer splines of the locking collar (arrow -B-) face opposite directions after assembly. Recesses for locking pieces on synchro-hub and locking collar must align.





Fig. 11 Assembling 1st and 2nd gear locking collar/synchro-hub
^ Locking collar is pushed over synchro-hub.

- Insert locking pieces and install springs 120° off-set. Angled end of spring must locate in hollow locking piece





Fig. 12 Installation position 1st and 2nd gear locking collar/synchro-hub
The locking collar splines (arrow -1-) point to splines for 3rd/4th gear synchro-hub -A-.
The wide shoulder of the synchro-hub (arrow -2-) then faces to 1st gear -B-.





Fig. 13 Pressing on 1st and 2nd gear locking collar/synchro-hub

Note: Before pressing on, place 1st gear synchro-ring on 1st gear.





Fig. 14 Identifying 1st and 2nd gear synchro-rings
^ 1st gear synchro-ring- 3 ground-down half teeth (arrow)
^ 2nd gear synchro-ring- 3 ground down half teeth (arrow) or 2 ground-down half teeth
Only the version with 2 ground-down half teeth is available as a spare part for the 2nd gear synchro-ring.





Fig. 15 Distinguishing 1st and 2nd gear synchro-rings
^ 1st gear synchro-ring- no recesses
^ 2nd gear synchro-ring- three recesses (arrows)





Fig. 16 Checking 2nd gear synchro-ring for wear
- Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap a with feeler gauge.








Fig. 17 Installation position outer-ring
The lugs (arrows) face to 1st gear -A-





Fig. 18 Checking inner ring for wear
- Press inner ring onto 2nd selector gear cone and measure gap a with a feeler gauge.








Fig. 19 Installation position synchro-ring (inner-ring) -A-
The lugs (arrow -1-) locate in the recesses (arrow -2-) in the synchro-ring -B-.





Fig. 20 Installation position 2nd gear
The higher shoulder -A- faces to 1st gear -B-. The recesses in the shoulder (arrows) locate with the lugs of the outer-ring (arrow go to Fig. 17)





Fig. 21 Pressing on needle roller bearing sleeve for 3rd gear





Fig. 22 Disassembling and assembling 3rd and 4th gear locking collar and synchro-hub
1 - Spring
2 - Locking piece
3 -Locking collar
4 - Synchro-hub
- Slide locking collar over synchro-hub.

The recesses for locking pieces in synchro-hub and locking collar must align.





Fig. 23 Assembling 3rd and 4th gear locking collar/synchro-hub
The locking collar has been pushed over the synchro-hub.
- Insert locking pieces and install springs 120° off-set. Angled end of spring must locate in hollow locking piece.





Fig. 24 Installation position 3rd and 4th gear locking collar/synchro-hub
Chamfer (arrow) faces to 4th gear.





Fig. 25 Pressing on 3rd and 4th gear synchro-hub with locking collar





Fig. 26 Pressing on sleeve for 4th gear needle roller bearing





Fig. 27 Pressing on sleeve for output shaft needle roller bearing