Servicing 6-speed manual gearbox 0A3 Exploded View
| Pinion shaft and hollow shaft - exploded view |
| Dismantling and assembling pinion shaft → Chapter |
| Dismantling and assembling hollow shaft → Chapter |
Note| t | Refer to technical data when installing new gears or final drive gear set → 6-speed manual gearbox 0A3, four-wheel drive; Rep. Gr.00. |
| t | Always renew the double angular contact ball bearing → Item when renewing the pinion shaft (final drive gear set) → Item. |
| t | Lubricate all needle bearings and synchro-rings with gear oil before installing. |
| t | When renewing synchro-rings, renew inner ring, intermediate ring and synchro-ring for the corresponding gear together. |
| t | If synchro-rings are not being renewed, make sure they are re-installed on the same gear. Do not interchange synchro-rings for reverse gear with synchro-rings for 1st and 2nd gear → Fig.. |
| t | Items 22 to 29, 32 and 49 were modified on 1st and 2nd gear selector rod version with spring-loaded selector fork → Fig.. Refer to → Electronic parts catalogue “(ETKA)” to allocate components. |
| t | Adjustment work is required when renewing the parts marked with 1). Table of adjustments → Chapter. |
| 1 - | Gearbox housing 1) |
| 2 - | Shim “S3” |
| q | Table of adjustments → Chapter |
| 3 - | Pinion shaft 1) |
| q | Is mated with crown wheel, always renew together as a set |
| q | Dismantling and assembling → Chapter |
| q | Adjusting crown wheel and pinion shaft → Chapter |
| 4 - | Needle bearing |
| q | Bearing for flange shaft in pinion shaft |
| q | Pulling out → Fig. |
| q | Driving in → Fig. |
| 5 - | Double angular contact ball bearing |
| q | If only this bearing is renewed, re-adjustment is not necessary |
| q | Pressing off → Fig. |
| q | Pressing on → Fig. |
| q | Installation position: shoulder on outer race faces towards pinion gear |
| 6 - | Shim “S5” |
| q | To position tapered roller bearing inner race → Item |
| q | Re-determining thickness → Chapter |
| 7 - | Tapered roller bearing inner race |
| q | Pressing off → Fig. |
| q | Pressing on → Fig. |
| 8 - | Washer |
| 9 - | Circlip |
| q | Re-determining thickness → Fig. |
| 10 - | Needle bearing |
| q | For pinion shaft in hollow shaft |
| q | Lubricate with gear oil |
| 11 - | Shim “S4” |
| q | Table of adjustments → Chapter |
| 12 - | Retaining plate |
| q | Installation position: machined side faces towards gearbox housing (can only be installed in one position). |
| 13 - | Bolt, 30 Nm |
| q | 6 x |
| q | Apply locking fluid -AMV 185 101 A1- when fitting |
| 14 - | Hollow shaft |
| q | With 3rd and 4th gear wheels |
| q | Dismantling and assembling → Chapter |
| 15 - | 6th gear wheel |
| q | Pressing off → Fig. |
| q | Pressing on → Fig. |
| q | Installation position: high inside collar faces 5th gear wheel |
| 16 - | 5th gear wheel |
| q | Pressing off → Fig. |
| q | Pressing on → Fig. |
| q | Installation position: high inside collar faces towards 6th gear wheel |
| 17 - | Roller bearing |
| q | For hollow shaft |
| q | Do not interchange with roller bearing for input shaft |
| q | Pressing off with 5th gear wheel → Fig. |
| q | Pressing on → Fig. |
| 18 - | Bearing mounting |
| q | The roller bearing outer race → Item cannot be renewed individually; renew bearing mounting if signs of wear are found. |
| q | The roller bearing outer race must not have any radial clearance in the bearing mounting. |
| 19 - | Shim “S6” |
| q | To position 2nd speed selector gear |
| q | Re-determining thickness → Chapter |
| 20 - | Needle bearing inner race |
| q | For 2nd speed selector gear |
| q | Pressing off with 5th gear wheel → Fig. |
| q | Pressing on → Fig. |
| 21 - | Needle bearing |
| q | For 2nd gear |
| 22 - | 2nd speed selector gear |
| 23 - | Inner ring for 2nd gear |
| q | Installation position → Fig. |
| q | Checking for wear → Fig. |
| q | Renew if scored or if there are visible traces of wear |
| 24 - | Intermediate ring for 2nd gear |
| q | Installation position → Fig. |
| q | Checking for wear → Fig. |
| 25 - | Synchro-ring for 2nd gear |
| q | Installation position → Fig. |
| q | Checking for wear → Fig. |
| q | Renew if scored or if there are visible traces of wear |
| 26 - | Locking collar with synchronising hub for 1st and 2nd gear |
| q | Removing and installing → Chapter |
| q | Assembling locking collar/synchronising hub → Anchor |
| 27 - | Synchro-ring for 1st gear |
| q | Installation position → Fig. |
| q | Checking for wear → Fig. |
| q | Renew if scored or if there are visible traces of wear |
| 28 - | Intermediate ring for 1st gear |
| q | Installation position → Fig. |
| q | Checking for wear → Fig. |
| 29 - | Inner ring for 1st gear |
| q | Installation position → Fig. |
| q | Checking for wear → Fig. |
| q | Renew if scored or if there are visible traces of wear |
| 30 - | Needle bearing inner race |
| q | For 1st speed selector gear |
| 31 - | Needle bearing |
| q | For 1st gear |
| 32 - | 1st speed selector gear |
| 33 - | Thrust washer |
| q | For 1st speed selector gear and reverse gear |
| 34 - | Reverse selector gear |
| q | With locking collar for reverse gear |
| q | Removing and installing → Chapter |
| q | Dismantling and assembling locking collar and reverse selector gear → Fig. |
| 35 - | Synchro-ring for reverse gear |
| q | Installation position → Fig. |
| q | Checking for wear → Fig. |
| q | Renew if scored or if there are visible traces of wear |
| 36 - | Intermediate ring for reverse gear |
| q | Installation position → Fig. |
| q | Checking for wear → Fig. |
| 37 - | Inner ring for reverse gear |
| q | Installation position → Fig. |
| q | Renew if scored or if there are visible traces of wear |
| 38 - | Needle bearing |
| q | For reverse selector gear |
| 39 - | Clutch unit |
| q | Removing and installing → Chapter |
| 40 - | Gearbox cover |
| 41 - | 12-point nut, 75 Nm |
| 42 - | Spacer ring |
| q | Secures 12-point nut → Item on hollow shaft to prevent it from working loose |
| 43 - | Tapered roller bearing outer race |
| q | Can be removed and installed by hand |
| 44 - | Tapered roller bearing inner race |
| q | Can be removed and installed by hand |
| 45 - | Washer |
| q | Note thickness |
| q | Re-determining thickness → Anchor |
| 46 - | Circlip |
| q | Note thickness |
| q | Re-determining thickness → Anchor |
| 47 - | Synchronising hub for 1st and 2nd gear |
| 48 - | Thrust block |
| q | Installing thrust blocks (3x) → Anchor |
| 49 - | Locking collar for 1st and 2nd gear |
| 50 - | Thrust block |
| q | Installing thrust blocks (3x) → Fig. |
| 51 - | Reverse selector gear |
| 52 - | Locking collar for reverse selector gear |
