Transmission Components Overview
Transmission Components Overview
I - => [ Transmission Housing and Shift Unit ]
II - => [ Input Shaft, Output Shafts, Differential, and Shift Rods ]
Transmission Housing and Shift Unit
1 Bolt
• 35 Nm
• Always replace
2 Left Stub Shaft with Spring
• Removing and installing, refer to => [ Left Stub Shaft and Seal ] Left Stub Shaft and Seal.
• Differential overview, refer to => [ Differential Overview ] Removal and Replacement.
3 Locking Ring
• For the grooved ball bearing/input shaft.
4 Sealing Cap
5 Screw
• 5 Nm
6 Retainer Plate
• Secure the sealing cap either with the retainer plate or with the retaining bracket - 7 -. Refer to => [ Securing the Retainer Plate: ] Transmission, Assembly.
7 Retaining Bracket
• Secure the sealing cap either with the retaining bracket or with the retainer plate - 6 -. Refer to => [ Securing the Retainer Plate: ] Transmission, Assembly.
8 Stud Bolt
• 20 Nm
9 Nut
• 20 Nm + 90° (1/4) additional turn.
10 Bolt
• Not available on US/Canadian vehicles.
11 Transmission Neutral Position Sensor (G701)
• Not available on US/Canadian vehicles.
12 Back-Up Lamp Switch (F4)
• 20 Nm
• Shortly after series introduction of transmission, with a permanent seal
13 Seal
• Not on all transmissions.
14 Bolt
• Always replace, for the correct allocation refer to the Parts Catalog.
• There are different bolts and tightening specifications:
• Internal hex round head = through build date August 08 2000, aluminum M8 bolt = 8 Nm + 180° (1/2) additional turn.
• Internal hex round head = through build date August 08 2000, aluminum M9 bolt = 15 Nm + 180° (1/2) additional turn.
• Outer hex head = steel bolt = 15 Nm + 90° (1/40 additional turn.
• Only on aluminum transmissions with M8 aluminum bolts = use steel bolts as a replacement part.
• Aluminum transmission identification, refer to => [ Aluminum Transmission Identification ].
• Replacement steel bolt allocation. Refer to => [ Only on Aluminum Transmissions with
M8 Aluminum Bolts = Allocation of Steel Bolts as a Replacement Part: ].
15 O-ring
• Always replace
16 Shift Unit
• Disassembly and assembly, refer to => [ Shift Unit ] Shift Unit.
17 Bolt
• 25 Nm
• Always replace.
18 Clutch Housing
• Aluminum (shiny), may be installed only on with a aluminum transmission housing.
• Magnesium (dull gray), may be installed only with a magnesium transmission housing.
• Clutch and transmission housing identification. Refer to => [ Aluminum Transmission Identification ].
• Disassembly and assembly, refer to => [ Clutch Housing ] Clutch Housing.
19 Transmission Housing
• Aluminum (shiny), may be installed only with a aluminum clutch housing.
• Magnesium (dull gray), may be installed only with a magnesium clutch housing.
• Clutch and transmission housings identification. Refer to => [ Aluminum Transmission Identification ].
• Disassembly and assembly, refer to => [ Transmission Housing ] Transmission Housing.
20 Seal
• Always replace
21 Oil Drain Plug
• 45 Nm
Aluminum Transmission Identification
An aluminum transmission has a plate - arrows 1 and 2 - with "AL Si 9Cu 31 (Fe)-D" written on it.
"AL = Aluminum"; additional data depends on the manufacturing.
Only on Aluminum Transmissions with M8 Aluminum Bolts = Allocation of Steel Bolts as a Replacement Part:
The steel bolts have a different length.
• Only the longer steel bolt can be installed near both alignment sleeves.
Input Shaft, Output Shafts, Differential, and Shift Rods
1 Reverse Gear Output Shaft
• Overview, refer to => [ Reverse Gear Output Shaft Overview ] Reverse Gear Output Shaft Overview.
• Installed position, refer to => [ Installed Location of Shafts and Selector
Forks in Transmission ].
2 Reverse Gear Selector Fork
• Installed position, refer to => [ Installed Location of Shafts and Selector
Forks in Transmission ].
3 O-ring
• Installed in some transmissions.
• Discontinued shortly after the start of production.
4 1st and 2nd Gear Output Shaft
• Overview, refer to => [ 1st and 2nd Gear Output Shaft Overview ] 1st and 2nd Gear Output Shaft Overview.
• Installed position, refer to => [ Installed Location of Shafts and Selector
Forks in Transmission ].
5 Selector Shaft with Selector Fork for 1st and 2nd Gear
• Installed position, refer to => [ Installed Location of Shafts and Selector
Forks in Transmission ].
6 3rd and 4th Gear Output Shaft
• Overview, => [ 3rd and 4th Gear Output Shaft Overview ] 3rd and 4th Gear Output Shaft Overview.
• Installed position, refer to => [ Installed Location of Shafts and Selector
Forks in Transmission ].
7 Selector Shaft with Selector Fork for 3rd and 4th Gear
• Pay attention to the installed position, refer to => [ 3rd and 4th Gear Selector Shaft with
Selector Rod Installed Position () ] Transmission, Assembly.
8 Input Shaft
• Overview, refer to => [ Input Shaft Overview ] Input Shaft Overview.
• With selector gears for 5th and 6th gear.
• Installed position, refer to => [ Installed Location of Shafts and Selector
Forks in Transmission ].
• Always replace the grooved ball bearing - item 16 - in => [ Input Shaft Overview ] Input Shaft Overview on the input shaft.
9 Selector Shaft and Selector Fork for 5th and 6th Gear
• Installed position, refer to => [ Installed Location of Shafts and Selector
Forks in Transmission ].
10 Breather Assembly
• Attaches to the clutch slave cylinder - 14 -.
11 Clutch Housing
• Disassembly and assembly, refer to => [ Clutch Housing ] Clutch Housing.
12 O-ring
• Installed on the line connection.
• Lubricate with brake fluid before installing.
13 Bolt
• Quantity: 3
• Removing and installing, see - item 4 - in => [ Clutch Release Mechanism Overview ] Clutch Release Mechanism Overview.
14 Clutch Slave Cylinder with Release Bearing
• Removing and installing, refer to => [ Clutch Release Mechanism Overview ] Clutch Release Mechanism Overview.
15 Input Shaft Seal
• Removing and installing, refer to => [ Input Shaft Seal ] Input Shaft Seal.
16 Bolt
• 35 Nm
17 Right Stub Shaft with Spring
• Not available in the US/Canadian market. Only for vehicles with All Wheel Drive (AWD).
18 Bevel Box
• Not available in the US/Canadian market. Only for vehicles with AWD.
19 Bolt
• See - item 23 - in => [ Differential Overview ] Removal and Replacement.
• Quantity: 4
• Always replace
20 Bolt
• 12 Nm
21 Trip Recorder Sensor (G75)
• May be installed in some transmissions.
22 O-ring
23 Differential
• Overview, refer to => [ Differential Overview ] Removal and Replacement.
Installed Location of Shafts and Selector Forks in Transmission
1 Reverse gear output shaft
2 1st and 2nd gear output shaft
3 Input shaft
4 3rd and 4th gear output shaft
A Selector rod with selector fork, reverse gear
B Selector rod with selector fork for 1st/2nd gear
C Selector rod with selector fork for 5th/6th gear
D Selector rod with selector fork for 3rd/4th gear