Output Shaft Overview
Output Shaft Overview
• Disassemble the output shaft as follows: place the separating device under the 2nd gear (- item 21 -) and remove it as described. Refer to => [ Removing the Synchronizer and 3rd and 4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft. Remove the lock ring (- item 17 -), refer to => [ Removing the Locking Collar with the Synchronizer Hub and Bearing Mount ] Output Shaft.
• Refer to the Parts Catalog and to the technical data (=> [ Transmission-Engine Allocation ] Transmission-Engine Allocation), when installing new gears or a new input shaft.
• Replace both tapered roller bearings together.
• Wearing safety gloves, heat the bearing inner race/tapered roller bearing, the gears and the synchronizer hubs to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414) or equivalent before installing them.
1 Nut
• 25 Nm + an additional 90° (1/4) turn.
• Always replace.
• Quantity: 4
• For the output shaft taper roller bearing support.
2 Clutch Housing
3 Adjusting Shim
• For the output shaft.
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.
4 Small Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Remove the Small Outer Race/Tapered Roller Bearing ] Output Shaft.
• Installing, refer to => [ Installing the Small Outer Race/Tapered Roller Bearing ] Output Shaft.
5 Bearing Inner Race/Small Tapered Roller Bearing
• Removing, refer to => [ Removing the Bearing Inner Race/Small Tapered Roller Bearing ] Output Shaft.
• Installing, refer to => [ Installing the Bearing Inner Race/Small Tapered Roller Bearing ] Output Shaft.
6 Output Shaft
• Adjusting, refer to => [ Output Shaft, Adjusting ] Output Shaft, Adjusting.
7 Bearing Inner Race/Large Tapered Roller Bearing
• Removing, refer to => [ Removing the Bearing Inner Race/Large Tapered Roller Bearing ] Output Shaft.
• Installing, refer to => [ Installing the Bearing Inner Race/Large Tapered Roller Bearing ] Output Shaft.
8 Seal
• Place the four seals on the bearing support studs.
• Always replace.
9 Output Shaft Taper Roller Bearing Support
• With the large outer race/tapered roller bearing and bolts.
• Replace the outer race only together with the large tapered roller bearing and support.
10 Thrust Washer
• The collar on the thrust washer faces the tapered roller bearing.
11 1st Gear
12 Needle Bearing
• For 1st gear.
13 Synchronizer Ring
• (Inner race for 1st gear)
• Installed position, refer to => [ Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring ] Output Shaft.
• Checking for wear, refer to => [ Checking the Inner Race for 1st and 2nd Gears for Wear ] Output Shaft.
• Check for scoring.
14 1st Gear Outer Race
• Installed position, refer to => [ Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring ] Output Shaft.
• Checking for wear, refer to => [ Checking the 1st and 2nd Gear Synchronizer Rings for Wear ] Output Shaft.
• Replace if there are grooves or scoring.
15 1st Gear Synchronizer Ring
• Installed position, refer to => [ Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring ] Output Shaft.
• Checking for wear, refer to => [ Checking the 1st and 2nd Gear Synchronizer Rings for Wear ] Output Shaft.
16 Locking Collar with Synchronizer Hub for 1st and 2nd Gears
• After removing the lock ring (- item 17 -), remove with the bearing mount => [ Removing the Locking Collar with the Synchronizer Hub and Bearing Mount ] Output Shaft.
• Disassembling, refer to => [ Disassembling and Assembling the Locking Collar and Synchronizer Hub for 1st and 2nd Gears ] Output Shaft.
• Assembling the operating sleeve/synchronizer hub, refer to => [ Disassembling and Assembling the Locking Collar and Synchronizer Hub for 1st and 2nd Gears ] Output Shaft, => [ Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears together with Locking Pieces that are Hollow on the Inside ] Output Shaft and to => [ Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears together with Locking Pieces that are not Hollow ] Output Shaft.
• Installed position, refer to => [ Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears ] Output Shaft.
• Installing, refer to => [ Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears ] Output Shaft.
17 Lock Ring
18 2nd Gear Synchronizer Ring
• Checking for wear, refer to => [ Checking the 1st and 2nd Gear Synchronizer Rings for Wear ] Output Shaft.
• Insert it so that the holes engage into the engagement pieces of the locking collar (- item 16 -).
19 2nd Gear Outer Race
• Insert into the synchronizer ring (- item 18) -.
• Installed position, refer to => [ Installed Position of the 2nd Gear Outer Race ] Output Shaft.
• Replace if there are grooves or scoring.
20 Synchronizer Ring
• (Inner race for 2nd gear)
• Checking for wear, refer to => [ Checking the 1st and 2nd Gear Synchronizer Rings for Wear ] Output Shaft.
• Check for scoring.
• Installed position, refer to => [ Installed Position: Synchronizer Ring (2nd Gear Inner Race) ] Output Shaft.
21 2nd Gear
• Installed position, refer to => [ Installed Position: 2nd Gear ] Output Shaft.
22 Needle Bearing
• For 2nd gear.
23 Thrust Washer
24 Sleeve
• For the 3rd gear needle bearing.
• Removing with the 2nd gear, refer to => [ Removing the Synchronizer and 3rd and 4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft.
• Installing, refer to => [ Installing the Sleeve for the 3rd Gear Needle Bearing ] Output Shaft.
25 Needle Bearing
• For 3rd gear.
26 3rd Gear
27 3rd Gear Synchronizer Ring
• Checking for wear, refer to => [ Checking the 3rd and 4th Gear Synchronizer Ring for Wear ] Output Shaft.
28 Locking Collar with Synchronizer Hub for 3rd and 4th Gears
• Remove with the 2nd gear (- item 21 -) and 3rd gear (- item 26 -). Refer to => [ Removing the Synchronizer and 3rd and 4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft.
• Disassembling, refer to => [ Disassembling and Assembling the Locking Collar and Synchronizer Hub for 3rd and 4th Gears ] Output Shaft.
• Assembling the operating sleeve/synchronizer hub, refer to => [ Disassembling and Assembling the Locking Collar and Synchronizer Hub for 3rd and 4th Gears ] Output Shaft, => [ Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears together with Locking Pieces that are Hollow on the Inside ] Output Shaft and to => [ Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears together with Locking Pieces that are not Hollow ] Output Shaft.
• Installed position: locking collar/synchronizer hub, refer to => [ Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears ] Output Shaft.
• Installing, refer to => [ Heating and Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears ] Output Shaft.
29 Sleeve
• For the 4th gear needle bearing.
• Removing with the locking collar and the 3rd/4th gear synchronizer hub (- item 28 -). Refer to => [ Removing the Synchronizer and 3rd and 4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft.
• Installing, refer to => [ Installing the Sleeve for the 4th Gear Needle Bearing ] Output Shaft.
30 Needle Bearing
• For 4th gear.
31 4th Gear Synchronizer Ring
• Checking for wear, refer to => [ Checking the 3rd and 4th Gear Synchronizer Ring for Wear ] Output Shaft.
32 4th Gear
33 Thrust Washer
34 Needle Bearing
• For the output shaft.
• Removing and installing, see - item 2 - in the => [ Transmission Housing and Clutch Housing Overview ] Transmission Housing and Clutch Housing Overview.
35 Transmission Housing
36 Sleeve
• For the needle bearing/output shaft.
• Removing, refer to => [ Removing the Synchronizer and 3rd and 4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft ] Output Shaft.
• Installing, refer to => [ Installing the Sleeve for the Needle Bearing/Output Shaft ] Output Shaft.
37 5th Gear
• Removing individually, refer to => [ Transmission Cover and 5th Gear ] Transmission Cover and 5th Gear.
• Remove with the transmission housing. Refer to => [ Transmission ] Transmission.
38 Plate Spring
• Installed position, refer to => [ Installed Position of the Concave Washers for the 5th Gear Synchronizer Hub and Drive Gear Bolts ] Transmission.
39 Bolt
• Tightening specification, see - item 4 - in the => [ Transmission Cover and 5th Gear Overview ] Transmission Cover and 5th Gear Overview.
• Always replace.
• Removing and installing, refer to => [ Transmission ] Transmission.