6-speed manual gearbox 02Q, 0BB

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Repair notes
  6
• 3.1 General repair instructions
  6
• 4 Technical data
  10
• 4.1 Capacities
  10
• 4.2 Allocation gearbox - engine
  10
• 4.3 Calculation of gear ratios
  11
• 5 Overview - power transmission
  12
• 5.1 Overview - power transmission - front-wheel drive
  12
• 6 Electrical components
  14
• 6.1 Overview of fitting locations - electrical components
  14
• Clutch
  16
• 1 Clutch mechanism
  16
• 1.1 Assembly overview - pedal cluster
  16
• 1.2 Assembly overview - clutch hydraulics
  18
• 1.3 Assembly overview - clutch release mechanism
  23
• 1.4 Removing and installing clutch pedal
  24
• 1.5 Removing and installing over-centre spring
  26
• 1.6 Removing and installing return spring
  30
• 1.7 Removing and installing mounting bracket
  33
• 1.8 Removing and installing bearing bush
  39
• 1.9 Removing and installing clutch master cylinder
  40
• 1.10 Removing and installing clutch slave cylinder together with release bearing
  41
• 1.11 Removing and installing lines for clutch mechanism
  42
• 1.12 Removing and installing bleeder
  46
• 1.13 Bleeding clutch mechanism
  48
• 1.14 Checking clutch master cylinder and clutch slave cylinder
  49
• 1.15 Removing and installing clutch position sender G476
  49
• 1.16 Repairing clutch release mechanism
  50
• 2 Clutch
  53
• 2.1 Determining make of clutch
  53
• 2.2 Assembly overview - clutch
  54
• 2.3 Removing and installing clutch
  57
• Controls, housing
  74
• 1 Bevel box
  74
• 1.1 Assembly overview - bevel box
  74
• 1.2 Removing bevel box
  76
• 1.3 Installing bevel box
  85
• 2 Selector mechanism
  91
• 2.1 Installation position - selector mechanism
  91
• 2.2 Assembly overview – gear knob and cover
  91
• 2.3 Assembly overview - selector mechanism
  92
• 2.4 Removing and installing gear knob
  94
• 2.5 Removing and installing selector mechanism
  96
• 2.6 Adjusting selector mechanism
  106
• 2.7 Checking selector mechanism
  110
• 2.8 Renewing selector shaft seal
  110
• 3 Removing and installing gearbox
  113
• 3.1 Specified torques for gearbox
  113
• 3.2 Removing gearbox
  113
• 3.3 Installing gearbox
  143
• 4 Assembly mountings
  159
• 4.1 Assembly overview - assembly mountings
  159
• 5 Front differential lock
  163
• 5.1 Assembly overview - front differential lock
  163
• 5.2 Allocation of front differential lock
  163
• 5.3 Removing front differential lock
  163
• 5.4 Installing front differential lock
  167
• 6 Transporting gearbox
  171
• 6.1 Transporting gearbox
  171
• 6.2 Transporting front differential lock
  172
• 7 Dismantling and assembling gearbox
  173
• 7.1 Schematic overview - gearbox
  173
• 7.2 Assembly overview - gearbox
  175
• 7.3 Assembly overview - gearbox housing and selector mechanism
  177
• 7.4 Assembly overview - selector unit
  179
• 7.5 Assembly overview - input shaft, output shafts, differential, selector rods
  180
• 7.6 Assembly overview - selector forks
  184
• 7.7 Renewing selector shaft seal
  185
• 7.8 Dismantling and assembling gearbox
  187
• 8 Gearbox housing, clutch housing
  208
• 8.1 Assembly overview - gearbox housing
  208
• 8.2 Assembly overview - clutch housing
  210
• 8.3 Repairing gearbox housing
  212
• 8.4 Repairing clutch housing
  221
• 9 Securing to engine and gearbox support
  224
• 9.1 Installing manual gearbox to engine and gearbox support
  224
• 9.2 Installing bevel box or front differential lock to engine and gearbox support
  225
• 10 Gear oil
  227
• 10.1 Distinguishing between different manual gearbox types when filling oil
  227
• 10.2 Checking gear oil level
  227
• Gears, shafts
  232
• 1 Input shaft
  232
• 1.1 Assembly overview - input shaft
  232
• 1.2 Dismantling and assembling input shaft
  233
• 1.3 Renewing input shaft seal
  239
• 2 Output shaft
  241
• 2.1 Assembly overview - output shaft
  241
• 2.2 Dismantling and assembling output shaft
  248
• 2.3 Adjusting output shaft
  277
• Final drive - differential
  289
• 1 Gear oil
  289
• 1.1 Checking gear oil level
  289
• 2 Seals
  296
• 2.1 Overview of fitting locations - oil seals
  296
• 2.2 Renewing left seal
  298
• 2.3 Renewing right seal
  301
• 3 Differential
  316
• 3.1 Assembly overview - differential
  316
• 3.2 Dismantling and assembling differential
  321
• 3.3 Adjusting differential
  335
• 4 Adjustment overview
  340
• 5 Components of bevel box
  341
• 5.1 Assembly overview - components of bevel box
  341
• 5.2 Renewing output flange and redetermining thickness of shim
  343
• 5.3 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  344
• 5.4 Renewing bevel box seals
  348
• 6 Components of front differential lock
  361
• 6.1 Assembly overview - components of front differential lock
  361
• 6.2 Checking function
  363
• 6.3 Removing and installing pump V181
  363
• 6.4 Removing and installing coupling for front differential lock
  365
• 6.5 Removing and installing differential lock control unit J647
  365
• 6.6 Renewing seals for front differential lock
  366
• 6.7 Renewing ball bearing for flange shaft
  370
• 7 Oil for front differential lock
  373
• 7.1 Checking oil level for front differential lock
  373
• 7.2 Draining and filling oil for front differential lock
  374