4
-
1st/2nd gear synchronizer clutch
7
-
3rd/4th gear synchronizer clutch
9
-
Output shaft 1st/4th gear
11
-
Output shaft 5th/6th/reverse gear
13
-
5th/6th gear synchronizer clutch
15
-
Reverse gear synchronizer clutch
17
-
Output pinion – 5th/6th/reverse gear output shaft
Construction features on the differential side
All gears have helical teeth and are permanently engaged.
5th, 6th and reverse gear have simple synchronisation. 1st to 4th gears are double synchronised.
Construction features on the input shaft side.
1
-
Output shaft 5th/6th/reverse gear
3
-
Output shaft 1st/4th gear
4
-
3rd/4th gear synchronizer clutch selector fork
5
-
1st/2nd gear synchronizer clutch selector fork
10
-
Reverse gear synchronizer clutch selector fork
12
-
5th/6th gear synchronizer clutch selector fork
All driving gear wheels of the transmission are located on the input shaft.
The input shaft is a solid shaft and runs on one ball bearing and one roller bearing.
Because of this mounting the input shafts runs without preload and therefore needs no adjusting shims.
The input shaft seal nearest the clutch is pressed into the clutch housing.
Input shaft
1
-
Clutch housing roller bearing
6
-
Input shaft ball bearing holder
Input shaft
The gear wheels for 1st and 2nd gear are an integral part of the input shaft. The gearwheels for 3rd and 5th gears and the gearwheel for 4th/6th gear are pressed on.
Because of the high force used to press on the components, the gear wheels cannot be pressed off in service. A faulty input shaft can only be replaced as a complete unit.
Defective bearings can be pressed off and changed.
Output shaft 1st/4th gear
The 1st/4th gear output shaft runs on tapered roller bearings.
This bearing arrangement requires the shaft to be preloaded. Please refer to the service literature for further information on how to measure the pre-load.
The output pinion of the 1st/4th gear output shaft is an integral part of the shaft.
The synchroniser assemblies of the 1st/2nd and the 3rd/4th gears are located on the output shaft.
The 1st to 4th gear output shaft is a hollow shaft; the oil is supplied to the internal oilways via oil funnels.
Internal oilways provide lubrication to the needle roller bearings and the synchroniser assemblies.
1
-
Transmission housing taper roller bearing
4
-
Inner synchroniser ring
5
-
4th gear synchronizer cone
6
-
Outer synchronizer ring (4th gear)
8
-
3rd/4th gear synchronizer
9
-
Outer synchronizer ring (3rd gear)
10
-
3rd gear synchronizer cone
11
-
Inner synchroniser ring
17
-
Inner synchroniser ring
18
-
2nd gear synchronizer cone
19
-
Outer synchronizer ring (2nd gear)
21
-
1st/2nd gear synchronizer
22
-
Outer synchronizer ring (1st gear)
23
-
1st gear synchronizer cone
24
-
Inner synchroniser ring
27
-
Output shaft 1st/4th gear
28
-
Oil storage ring (until 10/2005)
29
-
Clutch housing taper roller bearing
30
-
Bearing retaining bolt (left-hand thread)
Output shaft 5th/6th/reverse gear
The 5th/6th/reverse gear output shaft runs on tapered roller bearings.
This bearing arrangement requires the shaft to be preloaded. Please refer to the service literature for further information on how to measure the pre-load.
The output pinion is an integral part of the shaft.
The 5th/6th and reverse gear synchronizer assemblies are located on the shaft.
The 5th/6th/reverse gear output shaft is a hollow shaft; the oil is supplied to the internal oilways via oil funnels.
Internal oil passages provide lubrication to the needle roller bearings and the synchronizer assemblies.
The (MMT6) synchroniser assemblies have been reworked for the 6-speed manual transmission.
The detent balls, springs and sliding blocks form one unit.
This arrangement makes it easier to service the synchroniser assembly.
Differential
Because the Vehicle Speed Sensor (VSS) is discontinued, so is the sender wheel.
The ABS wheel speed sensors send the current wheel speed to the powertrain control module (PCM).
The differential has taper roller bearings.
This bearing arrangement requires the shaft to be preloaded. Please refer to the service literature for further information on how to measure the pre-load.
1
-
Transmission housing taper roller bearing
3
-
Clutch housing taper roller bearing
Power transmission in the individual gears
The following diagrams show a schematic representation of the power flow.
Power is transmitted via the non-positive gear pair to the output pinion of the output shaft(s) and thus to the differential ring gear.
NOTE:The three shafts are shown away from their real positions for clarity.
Power transmission route in 1st gear
Internal shift mechanism
The internal shift mechanism has been newly developed for this transmission.
The reverse gear switch is located on the housing cover of the internal shift mechanism.
The counterbalance improves the smoothness of the gear shifting. Due to its mass, the synchronization shift resistances that can be felt during shifting are reduced. The gear shifting process becomes smoother.
The internal shift mechanism can only be changed as a complete unit in service.