F23 gearbox overhaul: shafts and bearings (NA)

This is workshop-level gearbox work that needs special tools. For taking the gearbox out of the car and changing the clutch see F23 gearbox removal and clutch replacement.

Drive shaft bearing in the clutch housing

NA (Z22SE) only.

Procedure

1. Illustration of drive shaft
2. Remove transmission from vehicle- see "Transmission, Remove and Install"
3. Disassemble transmission - see "Transmission, Seal Completely"
4. Remove drive shaft bearing and spacer sleeve from clutch housing with KM-248-2 and KM-248-4
5. Clean all removed parts and check for wear and damage; replace if necessary
6. Install drive shaft bearing into clutch housing with KM-6120 in conjunction with KM-523-1. Rounded-off side (arrows) of drive shaft bearing points to spacer sleeve
7. Install spacer sleeve into clutch housing with KM-6112 in conjunction with KM-523-1
8. Assemble transmission - see "Transmission, Seal Completely"
9. Install transmission into vehicle- see "Transmission, Remove and Install"

Intermediate shaft bearing in the clutch housing

NA (Z22SE) only.

Procedure

1. Illustration of Intermediate shaft bearing
2. Remove transmission from vehicle - see "Transmission, Remove and Install"
3. Disassemble transmission - see "Transmission, Seal Completely"
4. Remove retaining ring with retaining ring pliers
5. Drive intermediate shaft bearing out of clutch housing with KM-248
6. Clean all removed parts and check for wear and damage; replace if necessary
7. Install intermediate shaft bearing into clutch housing with KM-6119 in conjunction with KM-523-1
8. Install new retaining ring with retaining ring pliers
   • Ensure correct seating of retaining ring in clutch housing
9. Assemble transmission - see "Transmission, Seal Completely"
10. Install transmission into vehicle - see "Transmission, Remove and Install"

Main shaft and drive shaft bearings in the gearbox housing

NA (Z22SE) only.

Procedure

1. Illustration of main shaft and drive shaft in transmission housing
2. Remove transmission from vehicle- see "Transmission, Remove and Install"
3. Disassemble transmission - see "Transmission, Seal Completely"
4. If required, remove and install new, or old, main shaft bearings using KM-6122 in conjunction with KM-523-1
5. Remove drive shaft bearing from transmission housing using KM-6123 in conjunction with KM-523-1
6. Clean all parts
7. Check all parts; replace if necessary
8. When replacing main shaft bearing in transmission housing, pressure collar adjustment must be determined and adjusted if necessary. For this, seat of bearing inner race for main shaft relative to sealing surface of transmission housing must be determined. This is described in following steps
9. Support transmission housing using wooden block so that main shaft bearing inner ring is unobstructed
10. Position KM-621-23 on transmission housing
11. Determine dimension (bearing inner ring to transmission housing sealing surface) using commercially available digital depth gauge with measuring range of at least 250 mm and graduation of 0.01 mm
    • Perform this measurement at three evenly-spaced measurement
    • Add measured values and divide sum by number of measurements.
12. Purpose of following tables is to explain pressure comb adjustment using example calculation
13. After installation, this measurement must be performed in same way for new main shaft bearing. If a value deviates by more than 0.08 mm from other values of a particular measurement, measurement must be repeated as measurement error has occurred
14. Mean value for new main shaft bearing is then subtracted from mean value for old main shaft bearing. If dimension difference between old and new main shafts is greater than + 0.02-0.06 mm, pressure comb must be adjusted. For this purpose, tapered roller bearings must be removed from differential - see "Tapered Roller Bearings - Differential, Remove and Install" (± Difference; ± Difference)
15. Select shim
    • If difference is positive (+), then the shim (transmission
    • If difference is negative (-), then the shim (transmission
    • If the shim (transmission housing side) is thicker, the
    • If the shim (transmission housing side) is thinner, the
    • In other words, total thickness of two shims remains same since
    • Corresponding shims can be obtained from "Aftersales" division.
16. Examples for selection of available shims are listed in following table
17. Shims must be selected so that smallest possible tolerance is achieved during adjustment Note: Used shims can be re-used in subsequent adjustment operations provided that shims are not damaged
18. Install differential tapered roller bearings - see "Tapered Roller Bearings - Differential, Remove and Install"
19. Install drive shaft bearing and main shaft bearing in transmission housing - see "Transmission, Seal Completely"
20. Assemble transmission - see "Transmission, Seal Completely"
21. Install transmission - see "Transmission, Remove and Install"

Main shaft: strip and rebuild

NA (Z22SE) only.

Procedure

1. Illustration of main shaft
2. Remove main shaft - see "Main Shaft, Remove and Install"
3. Press 4th gear from main shaft using KM-6220, KM-6223-1, and KM-6223-2
4. Press 3rd gear from main shaft using KM-6220, KM-6223-1, and KM-6224
5. Check wearing parts for damage and replace as necessary
6. Remove 5th gear and 5th gear synchroniser ring from main shaft
7. Remove 2x needle roller bearing (4, 5) from bushing
8. Check wearing parts for damage and replace as necessary Note: Ball, slider are under spring tension. When removing shift sleeve, ensure that ball, slider, and spring are not lost
9. Press reverse gear with pressure comb, needle roller bearing, reverse synchroniser ring, synchromesh body for 5th-/reverse gear and bushing from main shaft using KM-6220 and KM-6221
10. Check all parts for damage and replace damaged parts as necessary.
11. Assemble syncromesh
    • Spring
    • Clamp main shaft in vice - use protective jaws. Slide
    • Push slider slightly upwards. Press ball against spring
12. Install pressure comb, reverse gear and needle roller bearing to main shaft
    • Ensure that needle roller bearing is not damaged
13. Install reverse gear synchroniser ring, 5th /reverse gear synchromesh body and 5th gear synchroniser ring on main shaft
14. Install 5th gear and needle roller bearing to main shaft
    • Ensure that needle roller bearing is not damaged
15. Press 3rd gear onto main shaft using KM-514
16. Press 4th gear onto main shaft using KM-6219
17. Install main shaft - see "Main Shaft, Remove and Install"

Intermediate shaft: strip and rebuild

NA (Z22SE) only.

Procedure

1. Illustration of intermediate shaft
2. Remove intermediate shaft from transmission - see "Intermediate Shaft, Remove and Install"
3. Press intermediate shaft out of 1st / 2nd gear synchromesh body using KM-523-1, KM-6126 and KM-6223
4. Remove needle roller bearings from intermediate shaft
5. Disassemble 1st gear
   • Remove thrust washer from 1st gear
   • Remove front roller bearing from 1st gear
   • Remove bushing for roller bearing from 1st gear
   • Remove rear roller bearing from 1st gear
6. Check wearing parts for damage and replace as necessary
7. Disassemble synchromesh
   • Remove 1st gear from synchromesh body
   • Remove spacer from synchromesh body
   • Remove inner synchroniser ring for 1st gear from
   • Remove intermediate synchroniser ring for 1st gear
   • Remove outer synchroniser ring for 1st gear from
8. Check wearing parts for damage and replace as necessary
9. Disassemble synchromesh
   • Remove synchromesh body from 2nd gear
   • Remove outer synchroniser ring for 2nd gear from 2nd
   • Remove intermediate synchroniser ring for 2nd gear
   • Remove inner synchroniser ring for 2nd gear from 2nd
10. Check wearing parts for damage and replace as necessary
11. Assemble synchromesh
    • Remove inner synchroniser ring for 2nd gear from 2nd
    • Install intermediate synchroniser ring for 2nd gear to
    • Install outer synchroniser ring for 2nd gear to 2nd
    • Install synchromesh body to 2nd gear
12. Assemble synchromesh
    • Install outer synchroniser ring for 1st gear to
    • Install intermediate synchroniser ring for 1st gear to
    • Install inner synchroniser ring for 1st gear to
    • Install spacer to synchromesh body
13. Assemble synchromesh
    • Install 1st gear to 1st/2nd gear synchromesh body
    • Install rear roller bearing to 1st gear - narrow collar
    • Install front roller bearing to 1st gear - wide collar
    • Install bushing for roller bearing
14. 1. Press thrust washer and 1st/2nd gear assembly with synchromesh body onto intermediate shaft using KM-6219
15. Install intermediate shaft - see "Intermediate Shaft, Remove and Install"

Intermediate shaft: removal and refitting

NA (Z22SE) only.

Procedure

1. Illustration of intermediate shaft
2. Remove transmission - see "Transmission, Remove and Install"
3. Disassemble transmission - see "Transmission, Seal Completely"
4. Inspect intermediate shaft for wear and damage; replace if necessary
5. Assemble transmission - see "Transmission, Seal Completely"
6. Install transmission - see "Transmission, Remove and Install"

Intermediate shaft cover

NA (Z22SE) only.

Procedure

1. Illustration of cover, intermediate shaft
2. Remove transmission from vehicle - see "Transmission, Remove and Install"
3. Install KM-6115 to transmission
4. Install KM-6115 with transmission to KM-113-2
5. Drive a hole through the centre of intermediate shaft cover using suitable drift
6. Drive KM-6101 in conjunction with KM-328-B flush with intermediate shaft cover
7. Drive intermediate shaft cover from transmission
8. Remove fluid spout from transmission
9. Clean all parts
10. Check condition of fluid spout, replace if necessary
11. Install fluid spout to transmission
12. Drive intermediate shaft cover flush with transmission using KM-6102 in conjunction with KM-523-1
13. Remove KM-6115 with transmission from KM-113-2
14. Remove KM-6115 from transmission
15. Install transmission - see "Transmission, Remove and Install"