Transmission Components Overviews
Transmission Components Overviews
I - => [ Transmission Housing and Shift Unit ]
II - => [ Input Shaft, Output Shafts, Differential and Shift Rods ]
Transmission Housing and Shift Unit
1 Countersunk Bolt
• 33 Nm
2 Flange Shaft with Pressure Spring
• Removing and installing, refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
• Assembling, refer to => [ Differential Overview ] Description and Operation.
3 Circlip
• For the metal sealing cap. Refer to => [ The circlip has been discontinued together with the plastic sealing cap for the input shaft. ] Transmission.
• Not used with the plastic sealing cap.
4 Sealing Cap
• Made of metal or plastic. Refer to => [ The circlip has been discontinued together with the plastic sealing cap for the input shaft. ] Transmission.
• Made of metal: Secured with a circlip - item 3 -.
• Made of plastic: The circlip - item 3 - is not used.
• Refer to the Parts Catalog.
5 Locking Ring
• For the grooved ball bearing/input shaft.
6 Backup Lamp Switch (F4)
• 20 Nm
• With a permanent seal.
7 Seal
• Not installed on all transmissions.
• Always replace, if equipped.
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)
• Not available in the US/Canadian market.
12 Locking Screw
• 45 Nm
• For the gear shift shaft.
13 Bolt
• M9 aluminum bolt = 15 Nm and 180° (1/2) additional turn.
• Always replace.
14 Bolt
• M9 aluminum bolt = 15 Nm and 180° (1/2) additional turn.
• Always replace.
15 Gear Shift Unit
• (Gear shift shaft with gear shift cover)
• Overview, refer to => [ Gear Shift Unit Overview ] Gear Shift Unit Overview.
• Removing with the transmission installed:
• Remove the battery and the battery tray.
• The locking pin - item 6 - in => [ Transmission Housing Overview ] Transmission Housing Overview for adjusting the shift mechanism must not be engaged.
• Remove the cables and transmission shift lever. Refer to => [ Shift and Selector Cables ] Shift Mechanism Overviews.
• Remove the locking screw - item 12 - and remove the shift mechanism.
16 Bolt
• 20 Nm
• Always replace.
17 O-ring
• Always replace.
18 Clutch Housing
• Disassembly and assembly, refer to => [ Clutch Housing ] Clutch Housing.
19 Transmission Housing
• Disassembly and assembly, refer to => [ Transmission Housing ] Transmission Housing.
Input Shaft, Output Shafts, Differential and Shift Rods
1 Output Shaft, 1st to 4th Gears
• Disassembling and assembling, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
• Installed position, refer to => [ Selector Shaft with Selector Fork, Installed Positions ].
2 Selector Shaft with Selector Fork, for 1st and 2nd Gear
• Installed position, refer to => [ Selector Shaft with Selector Fork, Installed Positions ].
3 Selector Shaft with Selector Fork, for 3rd and 4th Gear
• Installed position, refer to => [ Selector Shaft with Selector Fork, Installed Positions ].
4 Output Shaft, 5th, 6th and Reverse Gears
• Disassembling and assembling, refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.
• Installed position, refer to => [ Selector Shaft with Selector Fork, Installed Positions ].
5 Selector Shaft with Selector Fork, for 5th and 6th Gears
• Installed position, refer to => [ Selector Shaft with Selector Fork, Installed Positions ].
6 Selector Fork, Reverse Gear
• Installed position, refer to => [ Selector Shaft with Selector Fork, Installed Positions ].
7 Input Shaft
• Disassembling and assembling, refer to => [ Input Shaft Overview ] Input Shaft Overview.
• Always replace the grooved ball bearing - item 4 - in => [ Input Shaft Overview ] Input Shaft Overview on the input shaft.
8 Thrust Washer
• Place on the reverse shaft - item 9 -.
9 Reverse Shaft
10 Thrust Washer
11 Breather Assembly
• Connects to the clutch slave cylinder - item 15 -.
12 Clutch Housing
• Disassembly and assembly, refer to => [ Clutch Housing ] Clutch Housing.
13 Input Shaft Seal
• Removing and installing, refer to => [ Input Shaft Seal ] Input Shaft Seal.
14 O-ring
• Installed on the line connection.
• Coat with brake fluid before installing.
15 Clutch Slave Cylinder with Release Bearing
16 Bolt
• Quantity: 3
• Always replace.
• Without locking fluid 12 Nm (clutch slave cylinder with a metal housing only).
• With locking fluid 15 Nm (clutch slave cylinder with a plastic housing only).
• Carefully tighten diagonally and in small stages so that clutch slave cylinder bolt tabs do not break off.
• Pay attention to the thread pitch on the bolt when cleaning the threaded hole in the clutch housing.
17 Countersunk Bolt
• 33 Nm
18 Flange Shaft with Pressure Spring
• Removing and installing, refer to => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
• Assembling, refer to => [ Differential Overview ] Description and Operation.
19 Differential
• Disassembling and assembling, refer to => [ Differential ] Service and Repair.
Selector Shaft with Selector Fork, Installed Positions
1 Input shaft
2 Output shaft, 1st to 4th gears
3 Output shaft, 5th, 6th and reverse gears
4 Reverse shaft
A 3rd and 4th gear selector shaft with selector fork
B 1st and 2nd gear selector shaft with selector fork
C 5th and 6th gear selector shaft with selector fork
D Reverse gear selector fork
• The reverse gear selector fork - D - is mounted on the 5th and 6th gear selector shaft with selector fork - C -.