02T 5-speed gearbox

Kapitelübersicht

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Identification code, assembly allocation, ratios, capacities
  2
• 2 Power transmission diagram
  4
• 2.1 Power transmission diagram
  4
• 3 Calculating the demultiplication ratio "i"
  6
• 3.1 Calculating the demultiplication ratio "i"
  6
• 4 General notes on the repair
  6
• 4.1 General notes on the repair
  6
• Clutch
  9
• 1 Clutch mechanism: repairing
  9
• 1.1 Clutch mechanism: repairing
  9
• 1.2 General assembly diagram- pedal gear
  10
• 1.3 Removing and installing neutral retaining spring
  14
• 1.4 Clutch pedal: removing and installing
  16
• 1.5 Assembly overview - hydraulics
  18
• 1.6 Clutch pump: Removal and installation
  21
• 1.7 Clutch pump: removal and installation
  25
• 1.8 Pipe unit and hose: removal and installation
  27
• 1.9 Bleed clutch system:
  29
• 2 Declutching unit: repairing
  30
• 2.1 Declutching unit: repairing
  30
• 3 Repairing clutch
  33
• 3.1 Repairing clutch
  33
• Controls, Housing
  38
• 1 Servicing gear drive mechanism
  38
• 1.1 Servicing gear drive mechanism
  38
• 1.2 Gear drive mechanism mounting position
  38
• 1.3 Gear lever dust cover and knob: removal and installation
  41
• 1.4 Gear lever and protective cover: repairing
  43
• 1.6 Removing and installing gear selector mechanism
  50
• 1.7 Gear drive mechanism: adjustment
  54
• 2 Gearbox: removal and installation
  58
• 2.1 Gearbox: removal and installation
  58
• 2.2 Modifying support rail VW 457/1
  60
• 3 Gear oil level: checking
  73
• 3.1 Gear oil level: checking
  73
• 4 Dismantling and assembling gearbox
  75
• 4.1 Dismantling and assembling gearbox
  75
• 4.2 Gearbox assembly overview
  75
• 4.3 The installation and removal of the gearbox housing and 5th gear
  78
• 4.4 Clutch housing: removing and installing
  81
• 4.6 Installation sequence
  87
• 4.7 Gearbox support 3221: modify
  89
• 5 Repairing gearbox housing and clutch housing
  97
• 5.1 Repairing gearbox housing and clutch housing
  97
• 6 Gear drive mechanism: dismantling and assembling
  105
• 6.1 Gear drive mechanism: dismantling and assembling
  105
• 7 Dismantling and assembling selector forks
  108
• 7.1 Dismantling and assembling selector forks
  108
• 7.2 Dismantling and assembling selector forks: Gearbox codes FNT, FLU, GEQ, GAH, GEW
  109
• 7.3 Dismantling and assembling selector forks: Gearbox codes GSE, GSG
  115
• Gears, Shafts
  124
• 1 Dismantling and assembling input shaft
  124
• 1.1 Dismantling and assembling input shaft
  124
• 2 Dismantling and assembling output shaft
  141
• 2.1 Dismantling and assembling output shaft
  141
• Final drive, Differential
  155
• 1 Oil seal for flanged shaft: renew
  155
• 1.1 Oil seal for flanged shaft: renew
  155
• 1.2 Renewing oil seal for left flanged shaft: Gearbox codes FNT, FLU, GAH
  155
• 1.3 Renewing oil seal for left flanged shaft: Gearbox codes GEQ, GSE, GEW, GSG
  158
• 1.4 Renewing oil seal for right flanged shaft: Gearbox codes FNT, FLU, GAH
  161
• 1.5 Renewing oil seal for right flanged shaft: Gearbox codes GEQ, GSE, GEW, GSG
  164
• 2 Dismantling and assembling differential
  166
• 2.1 Dismantling and assembling differential
  166
• 2.2 Dismantling and assembling differential: Gearbox codes: FNT, FLU, GAH
  166
• 3 Adjusting differential
  192
• 3.1 Adjusting differential
  192
• 3.2 Adjusting differential: Gearbox codes FNT, FLU, GAH
  192
• 3.3 Adjusting differential: Gearbox codes GEQ, GSE, GEW, GSG
  197