5-Speed manual gearbox 02J

Kapitelübersicht

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, gearbox allocation, ratios, capacities
  2
• 2 Transmission layout
  3
• 2.1 Transmission layout
  3
• 3 Calculating overall ratio "i"
  5
• 3.1 Calculating overall ratio "i"
  5
• 4 General repair instructions
  5
• 4.1 General repair instructions
  5
• Clutch
  8
• 1 Servicing clutch control
  8
• 1.1 Servicing clutch control
  8
• 1.2 Assembly overview - Pedal cluster
  9
• 1.3 Removing and installing clutch pedal
  13
• 1.4 Removing and installing over-centre spring
  16
• 1.5 Assembly overview - Hydraulic system
  18
• 1.6 Removing and installing master cylinder
  21
• 1.7 Bleeding clutch system
  25
• 2 Servicing clutch release mechanism
  26
• 2.1 Servicing clutch release mechanism
  26
• 3 Servicing clutch
  29
• 3.1 Servicing clutch
  29
• Controls, Housing
  34
• 1 Servicing gear selector mechanism
  34
• 1.1 Servicing gear selector mechanism
  34
• 1.2 Installation position of gear selector mechanism
  34
• 1.3 Removing and installing selector lever knob and gaiter
  37
• 1.4 Servicing gear stick and gear stick housing
  39
• 1.5 Assembly overview - removing and installing selector cables
  43
• 1.6 Removing and installing gear selector mechanism
  46
• 1.7 Adjusting gear selector mechanism
  48
• 2 Removing and installing gearbox
  52
• 2.1 Removing and installing gearbox
  52
• 3 Checking gear oil
  67
• 3.1 Checking gear oil
  67
• 4 Dismantling and assembling gearbox
  68
• 4.1 Dismantling and assembling gearbox
  68
• 4.2 Overview
  68
• 4.3 Assembly overview
  70
• 4.4 Removing and installing cover for gearbox housing and 5th gear
  71
• 4.5 Removing and installing gearbox housing and selector mechanism
  74
• 4.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  76
• 4.7 Assembly sequence
  79
• 5 Servicing gearbox housing and clutch housing
  97
• 5.1 Servicing gearbox housing and clutch housing
  97
• 6 Dismantling and assembling gearbox selector mechanism
  107
• 6.1 Dismantling and assembling gearbox selector mechanism
  107
• 7 Dismantling and assembling selector forks
  113
• 7.1 Dismantling and assembling selector forks
  113
• Gears, Shafts
  120
• 1 Dismantling and assembling input shaft
  120
• 1.1 Dismantling and assembling input shaft
  120
• 2 Adjusting input shaft
  133
• 2.1 Adjusting input shaft
  133
• 2.2 Table of adjustment shims
  135
• 2.3 Performing measurement check
  137
• 3 Dismantling and assembling output shaft
  138
• 3.1 Dismantling and assembling output shaft
  138
• 4 Adjusting output shaft
  168
• 4.1 Adjusting output shaft
  168
• 5 Dismantling and assembling reverse shaft
  171
• 5.1 Dismantling and assembling reverse shaft
  171
• Final drive, Differential rear
  176
• 1 Renewing oil seals for flanged shafts
  176
• 1.1 Renewing oil seals for flanged shafts
  176
• 1.2 Renewing oil seal for left flanged shaft
  176
• 1.3 Renewing oil seal for right flanged shaft
  179
• 2 Dismantling and assembling differential
  182
• 2.1 Dismantling and assembling differential
  182
• 3 Adjustment overview
  195
• 3.1 Adjustment overview
  195
• 4 Adjusting differential
  196
• 4.1 Adjusting differential
  196