5-speed manual gearbox 01A, all-wheel drive

Kapitelübersicht

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Identification code, assembly allocation, ratios, capacities
  1
• 2 Identifying rear final drive
  6
• 2.1 Identification code, assembly allocation, capacities
  6
• 3 Overview - power transmission
  8
• 4 Calculating overall gear ratio „i“
  10
• 5 General repair notes
  11
• 5.1 Components
  11
• Clutch
  14
• 1 Functional check of clutch master and slave cylinders
  14
• 2 Distinguishing clutch control mechanisms
  16
• 3 Repairing clutch control mechanism (master cylinder secured to clutch pedal with a pin)
  17
• 3.1 Overview
  17
• 3.2 Assembly overview - pedal cluster (LHD vehicles)
  18
• 3.3 Removing and installing clutch pedal and over-centre spring
  19
• 3.4 Assembly overview - pedal cluster (RHD vehicles)
  20
• 3.5 Assembly overview - hydraulic system
  22
• 3.6 Removing and installing master cylinder
  23
• 4.1 Overview
  27
• 4.2 Assembly overview - pedal cluster (LHD vehicles)
  28
• 4.3 Removing and installing clutch pedal and over-centre spring
  29
• 4.4 Assembly overview - pedal cluster (RHD vehicles)
  30
• 4.5 Assembly overview - hydraulic system
  32
• 4.6 Removing and installing master cylinder
  34
• 5 Clutch pedal switch
  39
• 5.2 Checking and adjusting clutch pedal switch F36
  39
• 6 Bleeding clutch system
  42
• 7 Repairing clutch release mechanism
  43
• 7.1 Removing and installing slave cylinder
  45
• 8 Repairing clutch
  49
• Controls, housing
  52
• 1 Repairing selector mechanism (gear lever must be pressed down to engage reverse gear)
  52
• 1.1 Installation position of selector mechanism
  52
• 1.2 Repairing gear lever, gear lever mounting, push rod and selector rod
  52
• 1.3 Removing and installing selector mechanism
  55
• 1.4 Adjusting selector mechanism
  56
• 2.1 Installation position of selector mechanism
  59
• 2.2 Repairing gear lever and gear lever mounting
  61
• 2.3 Repairing selector rod and push rod
  62
• 2.4 Removing and installing gear lever with gear lever mounting
  64
• 2.5 Removing and installing selector mechanism
  64
• 2.6 Adjusting selector mechanism
  66
• 3 Removing and installing gearbox
  68
• 3.1 Removing gearbox
  69
• 3.2 Transporting gearbox
  74
• 3.3 Installing gearbox
  74
• 4 Removing and installing cover with Torsen differential
  80
• 5 Checking gearbox oil
  82
• 6 Dismantling and assembling gearbox
  83
• 6.1 Overview - gearbox
  83
• 6.2 Assembly overview
  84
• 6.3 Removing and installing input shaft ball bearing and multifunction sender
  85
• 6.5 Dismantling and assembling procedure
  88
• 7 Repairing cover for Torsen differential, removing and installing Torsen differential
  96
• 8 Dismantling and assembling selector mechanism on gearbox side
  103
• 8.1 Checking and renewing locking unit for 5th gear and reverse gear
  107
• Gears, shafts
  109
• 1 Input shaft
  109
• 1.1 Dismantling and assembling input shaft
  109
• 1.2 Modified synchronisation of 3rd and 4th gear from gearbox date 23 06 3
  119
• 1.3 Adjusting input shaft
  119
• 2 Dismantling and assembling pinion shaft and hollow shaft through gearbox date 22 06 3
  123
• 2.1 Reinforcement from gearbox date 17 08 8 in vicinity of for 4th gear wheel
  136
• 4 Removing and installing reverse gear wheel
  153
• Final drive - rear differential
  154
• 1 Repairing propshaft
  154
• 1.1 Removing and installing propshaft
  155
• 1.2 Measuring and marking radial run-out at propshaft flange on rear final drive
  157
• 1.3 Adjusting propshaft
  159
• 2 Renewing oil seals for flange shafts
  162
• 3 Renewing oil seal for propshaft flange
  163
• 3.1 Removing oil seal
  163
• 3.2 Installing oil seal
  165
• 4 Removing and installing rear final drive
  168
• 4.1 Removing rear final drive
  168
• 4.2 Installing final drive
  169
• 4.3 Securing rear final drive to repair stand
  170
• 5 Checking oil level in rear final drive
  172
• 6 Dismantling and assembling rear final drive
  173
• 7 Removing and installing differential
  174
• 7.1 Removing and installing differential
  175
• 8 Dismantling and assembling differential
  177
• 9 Removing and installing pinion shaft and dismantling and assembling
  185
• 10 Adjusting drive pinion and crown wheel
  195
• 10.1 Adjustment and marking of final drive gear sets
  195
• 10.2 Recommended sequence for readjusting final drive gear set
  196
• 10.3 Adjustment overview
  197
• 10.4 Position of shims
  197
• 10.5 Adjusting drive pinion
  198
• 10.6 Adjusting crown wheel
  203
• Final drive - front differential
  210
• 1 Renewing flange shaft oil seals with gearbox installed
  210
• 2 Renewing propshaft flange shaft oil seal
  213
• 3 Renewing speedometer sender and drive wheel
  215
• 3.1 Replacing speedometer sender
  215
• 3.2 Renewing speedometer drive wheel
  215
• 4 Removing and installing differential
  217
• 5 Dismantling and assembling differential
  221
• 6 Adjusting drive pinion and crown wheel
  229
• 6.1 Adjustment and marking of final drive gear sets
  229
• 6.2 Position of shims
  230
• 6.3 Adjustment overview
  231
• 6.4 Recommended sequence for readjusting final drive gear set
  232
• 6.5 Adjusting drive pinion
  232
• 6.6 Determining shim „S4“ thickness when replacing gearbox cover
  241
• 6.7 Adjusting crown wheel
  242