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
  17
• 2.1 Transmission layout
  17
• 3 Calculating overall ratio "i"
  19
• 3.1 Calculating overall ratio "i"
  19
• 4 General repair instructions
  19
• 4.1 General repair instructions
  19
• Clutch
  22
• 1 Servicing clutch control
  22
• 1.1 Servicing clutch control
  22
• 1.2 Assembly overview - Pedal cluster
  23
• 1.3 Removing and installing over-centre spring
  26
• 1.4 Removing and installing clutch pedal
  28
• 1.5 Assembly overview - Hydraulic system
  30
• 1.6 Removing and installing master cylinder
  33
• 1.7 Bleeding clutch system
  37
• 2 Servicing clutch release mechanism
  38
• 2.1 Servicing clutch release mechanism
  38
• 3 Servicing clutch
  43
• 3.1 Servicing clutch
  43
• Controls, Housing
  48
• 1 Servicing gear selector mechanism up to 05.99
  48
• 1.1 Servicing gear selector mechanism up to 05.99
  48
• 1.2 Installation position of gear selector mechanism
  48
• 1.3 Assembly overview - removing and installing selector cables
  50
• 1.4 Removing and installing gear selector mechanism
  55
• 1.5 Servicing gear stick housing
  59
• 1.6 Servicing gear stick
  62
• 1.7 Adjusting gear selector mechanism up to 05.99
  66
• 2 Servicing gear selector mechanism from 05.99
  71
• 2.1 Servicing gear selector mechanism from 05.99
  71
• 2.2 Installation position of gear selector mechanism
  71
• 2.3 Removing and installing selector lever knob and gaiter
  74
• 2.4 Servicing gear stick and gear stick housing
  76
• 2.5 Assembly overview - Removing and installing selector cables
  80
• 2.6 Removing and installing selector mechanism
  84
• 2.7 Adjusting gear selector mechanism from 05.99
  88
• 3 Removing and installing gearbox
  93
• 3.1 Removing and installing gearbox
  93
• 4 Checking gear oil
  113
• 4.1 Checking gear oil
  113
• 5 Dismantling and assembling gearbox
  115
• 5.1 Dismantling and assembling gearbox
  115
• 5.2 Overview
  115
• 5.3 Assembly overview
  117
• 5.4 Removing and installing cover for gearbox housing and 5th gear
  118
• 5.5 Removing and installing gearbox housing and selector mechanism
  121
• 5.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  123
• 5.7 Assembly sequence
  126
• 6 Servicing gearbox housing and clutch housing
  144
• 6.1 Servicing gearbox housing and clutch housing
  144
• 7 Dismantling and assembling gearbox selector mechanism up to 05.99
  156
• 7.1 Dismantling and assembling gearbox selector mechanism up to 05.99
  156
• 8 Dismantling and assembling gearbox selector mechanism from 05.99
  161
• 8.1 Dismantling and assembling gearbox selector mechanism from 05.99
  161
• 9 Dismantling and assembling selector forks
  167
• 9.1 Dismantling and assembling selector forks
  167
• Gears, Shafts
  176
• 1 Dismantling and assembling input shaft
  176
• 1.1 Dismantling and assembling input shaft
  176
• 1.2 From gearbox build date 05 11 1 circlips for 5th gear synchronisation have been modified
  189
• 2 Adjusting input shaft
  191
• 2.1 Adjusting input shaft
  191
• 2.2 Table of adjustment shims
  193
• 2.3 Performing measurement check
  195
• 3 Dismantling and assembling output shaft
  196
• 3.1 Dismantling and assembling output shaft
  196
• 4 Adjusting output shaft
  226
• 4.1 Adjusting output shaft
  226
• 5 Dismantling and assembling reverse shaft
  229
• 5.1 Dismantling and assembling reverse shaft
  229
• Final drive, Differential rear
  234
• 1 Renewing oil seals for flanged shafts with gearbox installed
  234
• 1.1 Renewing oil seals for flanged shafts with gearbox installed
  234
• 1.2 Renewing oil seal for left flanged shaft
  234
• 1.3 Renew right flange shaft oil seal
  236
• 2 Dismantling and assembling differential
  240
• 2.1 Dismantling and assembling differential
  240
• 3 Adjustment overview
  255
• 3.1 Adjustment overview
  255
• 4 Adjusting differential
  256
• 4.1 Adjusting differential
  256