Dismantling and assembling drive pinion

No.

Designation

Removal

Installation

1

Snap ring

1

Note thickness for reinstallation

Redetermine thickness if required (refer to page 34-17)

2

Tapered roller bearing inner race

1

Press off across 1st gear loose gearwheel (No. 3) using a suitable sep. tool (e.g. Kukko 15-17 size 2)

Heat to approx. 100'C and press on

3

1 st gear loose gearwheel

1

Insert spring before fitting the gearwheel

4

Needle roller bearing

1

Mark for reinstallation

Fit with the same gearwheel as before. Oil with transmission oil before fitting

5

Bearing inner race

1

Press off across 2nd gear loose gearwheel (No. 10) using a suitable separating tool (e.g. Kukko 15-17 size 2). Mark for reinstall.

Heat to approx. 100*C and press on

6

1st gear synchronizing ring

1

Mark for reinstallation

Check for wear. Fit with the same gearwheel as bef. (Ref. to page 35 - 5)

7

Sliding sleeve

1

Install in correct position. Groove for shift fork faces 1st gear

8

Synchronizer hub

1

Press off across 2nd gear loose gearwheel (No. 10)

Heat to approx. 100'C and press on, observing correct position

9

2nd gear synchronizing ring (molybdenium-coated)

1

Mark for reinstallation

Check for wear. Fit with the same gearwheel as before (Refer to page 35-5)

10

2nd gear loose gearwheel

1

Insert spring before fitting gearwheel

11

Needle roller bearing

1

Mark for reinstallation

Fit with the same gearwheel as before. Oil with transmission oil before fitting

12

Bearing inner race

1

Press off across 3rd gear fixed gearwheel (No. 13), using a suitable sep. dev. (e.g. Kukko 15-17, size 2).

Heat to approx. 100°C and press on, making sure the collar faces 3rd gear fixed gearwheel

No.

Designation

Removal

Installation

13

3rd gear fixed gearwheel

1

Press off as for bearing inner race (No. 12)

Heat to approx. 100°C and press on, making sure the collar faces the gearwheel for 4th gear

14

Spacer sleeve

1

15

4th gear fixed gearwheel

1

Press off with separating device (e.g. Kukko 15-17, size 2)

Heat to approx. 100°C and press on, making sure the collar faces the gearwheel for 3rd gear

16

Tapered roller bearing inner race

1

Press off with suitable separating device (e.g. Kukko 15-17, size 2)

Heat to approx. 100°C and press on

17

Drive pinion

1

Supplied in matched pairs with ring gear (drive set). When repl. the pinion, adjust drive pinion/ring gear (Refer to page 39-13)

18

End cover

1

Page 34-10

19

Snap ring

1

Page 34-10

20

5th gear fixed gearwheel

1

Page 34-10

21

Snap ring

1

Page 34 - 21

22

6th gear fixed gearwheel

1

Page 34 - 21

23

End shield

1

Page 34 - 21

24

Adjusting shim "S4"

X

Page 34 - 32

25

Tapered roller bearing outer race

1

Page 34 - 32

26

Tapered roller bearing outer race

1

Page 34 - 38

27

Adjusting shim "S3'"

X

Page 34 - 38

28

Transmission housing

1

Page 34 - 38

If components No. 4, 5, 8, 11, 12, 13, 14 and 15 have been replaced, the thickness of shim "S4" must be recalculated (Refer to page 34 - 29)

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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