Transmission Component Overviews
Transmission Component Overviews
l - => [ Transmission Housing and Shift Unit ]
II - => [ Input Shaft, Output Shaft, Differential, Bevel Box and Selector Rods ]
Assembly sequence, transmission with locking ring - A - for the locking cover/input shaft, refer to => [ Transmission, with a Sealing Cap Circlip for the Input Shaft ] Transmission, With a Sealing Cap Circlip For the Input Shaft
Transmission Housing and Shift Unit
1 Countersunk Bolt
2 Flange Shaft with Pressure Spring
• For FWD
3 Locking Ring
• For the sealing cap - item 4 - => [ (Item 4) Cover ]
• Installed from transmission build date 01.21.2008
4 Cover
• Secured with circlip from transmission build date 01.21.2008
• Refer to the Parts Catalog
5 Locking Ring
• For the grooved ball bearing/input shaft - item 1 - => [ (Item 1) Countersunk Bolt ]
6 Back-Up Lamp Switch (F4)
• 20 Nm
• Short after series introduction of transmission with permanent seal
7 Seal
• Not installed on all transmissions
8 Oil Drain Plug
• Tightening specification, refer to => [ Different Versions of the Oil Fill
and Drain Plugs ] Service and Repair
9 Seal
• Always replace
10 Bolt
• 6 Nm
11 Transmission Neutral Position Sensor (G701)
• For vehicles with the Start/Stop System
12 Locking Bolt
• 45 Nm
• For the gearshift shaft
13 Bolt
• 15 Nm + 90° additional turn
• Use the bolt with permanent washer only as a replacement part.
• Always replace, refer to the Parts Catalog
• Replacement bolts allocation, refer to => [ Replacement Bolts Allocation ]
14 Bolt
• 15 Nm + 90° additional turn
• Without a washer
• Always replace, refer to the Parts Catalog
• Replacement bolts allocation, refer to => [ Replacement Bolts Allocation ]
15 Gear Shift Unit
• For servicing, refer to => [ Shift Unit Overview ] Shift Unit Overview
• Removing with the transmission installed:
• Remove the battery and the battery tray.
• The lock elbow - item 6 - => [ (Item 6) Locking Pin ] Transmission Housing, Servicing for adjusting the shift mechanism must not be engaged
• Remove cables and transmission shift lever, refer to => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview
• Remove the locking bolt - item 12 - => [ (Item 12) Locking Bolt ] and remove the shift mechanism.
16 Bolt
• 20 Nm
• Always replace
17 Seal
• Always replace
18 Clutch Housing
• Servicing, refer to => [ Clutch Housing ] Clutch Housing
19 Transmission Housing
• For servicing, refer to => [ Transmission Housing, Servicing ] Transmission Housing, Servicing
Replacement Bolts Allocation
A Bolt with permanent washer
B Bolt without washer
C Bolt with permanent washer
Input Shaft, Output Shaft, Differential, Bevel Box and Selector Rods
1 Output Shaft, 1st to 4th Gears
• Installed position, refer to => [ Selector Shafts and Forks, Installed Position ] Selector Shafts and Forks, Installed Position
• Disassembling and assembling, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears
2 Gearshift Rod and Shift Fork for 1st and 2nd Gear
• Installed position, refer to => [ Selector Shafts and Forks, Installed Position ] Selector Shafts and Forks, Installed Position
• For servicing, refer to => [ Shift Forks ] Shift Forks
3 Gearshift Rod and Shift Fork for 3rd and 4th Gear
• Installed position, refer to => [ Selector Shafts and Forks, Installed Position ] Selector Shafts and Forks, Installed Position
• For servicing, refer to => [ Shift Forks ] Shift Forks
4 5th/6th and Reverse Gear Output Shaft
• Installed position, refer to => [ Selector Shafts and Forks, Installed Position ] Selector Shafts and Forks, Installed Position
• Disassembling and assembling. Refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears
5 Gearshift Rod and Shift Fork for 5th and 6th Gear
• Installed position, refer to => [ Selector Shafts and Forks, Installed Position ] Selector Shafts and Forks, Installed Position
6 Reverse Gear Shift Fork
• Installed position, refer to => [ Selector Shafts and Forks, Installed Position ] Selector Shafts and Forks, Installed Position
• Difference, refer to => [ Reverse Gear Selector Fork Differentiation ] Shift Forks
• For servicing, refer to => [ Shift Forks ] Shift Forks
7 Input Shaft
• Installed position, refer to => [ Selector Shafts and Forks, Installed Position ] Selector Shafts and Forks, Installed Position
• Disassembling and assembling, refer to => [ Input Shaft ] Input Shaft
• Always replace the grooved ball bearing on the input shaft - item 6 - => [ (Item 6) Grooved Ball Bearing ] Input Shaft Overview
8 Reverse Shaft
• With a thrust washer
9 Thrust Washer
10 Bleeder
• Connect with slave cylinder
11 Clutch Housing
• For servicing, refer to => [ Clutch Housing ] Clutch Housing
12 Input Shaft Seal
13 Seal
• Install on the line connection
• Coat with brake fluid before installing
14 Clutch Slave Cylinder with Release Bearing
15 Bolt
• Quantity: 3
• Always replace
16 Countersunk Bolt
17 Bolt
• 40 Nm + 90° turn
• Quantity: 4
• Always replace
18 Bevel Box
• Removing and installing, refer to => [ Bevel Box ] Removal and Replacement
19 Differential
• Disassembling and assembling, refer to => [ Differential ] Service and Repair
Installation Location of Shafts and Gearshift Rods in Transmission
1 Input Shaft
2 Output Shaft, 1st to 4th Gears
3 Output shaft 5th/6th and reverse gear
4 Reverse Shaft
A 3rd and 4th gear gearshift rod
B 1st and 2nd gear gearshift rod
C 5th and 6th gear gearshift rod
D Reverse gear shift fork 1)
1) On some transmissions, the bearing on the reverse gear shift fork on the shift rod for 5th and 6th gear shift fork - C -. Difference, reverse gear shift forks, refer to => [ Reverse Gear Selector Fork Differentiation ] Shift Forks