6-speed manual gearbox 02S

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Repair notes
  4
• 3.1 General repair instructions
  4
• 4 Technical data
  8
• 4.1 Capacities
  8
• 4.2 Allocation gearbox - engine
  8
• 4.3 Calculation of gear ratios
  9
• 5 Overview - power transmission
  10
• 5.1 Overview - power transmission - front-wheel drive
  10
• Clutch
  12
• 1 Clutch operation
  12
• 1.1 Assembly overview - pedal cluster
  12
• 1.2 Assembly overview - clutch hydraulics
  15
• 1.3 Assembly overview - clutch release mechanism
  19
• 1.4 Removing and installing clutch pedal
  20
• 1.5 Removing and installing over-centre spring
  25
• 1.6 Removing and installing mounting bracket
  30
• 1.7 Removing and installing clutch master cylinder
  37
• 1.8 Removing and installing clutch slave cylinder
  39
• 1.9 Bleeding clutch mechanism
  42
• 1.10 Checking clutch master cylinder and clutch slave cylinder
  43
• 1.11 Removing and installing clutch position sender G476
  44
• 1.12 Repairing clutch release mechanism
  46
• 2 Clutch
  48
• 2.1 Assembly overview - clutch
  48
• 2.2 Removing and installing clutch
  49
• Controls, housing
  52
• 1 Selector mechanism
  52
• 1.1 Installation position - selector mechanism
  52
• 1.2 Assembly overview - gear knob and cover
  54
• 1.3 Assembly overview - Gear lever and selector housing
  55
• 1.4 Assembly overview - Selector cables
  57
• 1.5 Removing and installing gear knob
  61
• 1.6 Removing and installing selector mechanism
  63
• 1.7 Adjusting selector mechanism
  69
• 1.8 Checking selector mechanism
  73
• 1.9 Removing and installing gear selector cable and gate selector cable
  73
• 1.10 Renewing selector shaft seal
  74
• 1.11 Dismantling and assembling selector mechanism
  75
• 2 Removing and installing gearbox
  82
• 2.1 Specified torques for gearbox
  82
• 2.2 Removing gearbox
  82
• 2.3 Installing gearbox
  96
• 3 Assembly mountings
  105
• 3.1 Assembly overview - assembly mountings
  105
• 4 Transporting gearbox
  107
• 5 Dismantling and assembling gearbox
  108
• 5.1 Schematic overview - gearbox
  108
• 5.2 Assembly overview - cover for gearbox housing and 5th/6th gear
  109
• 5.3 Assembly overview - gearbox housing and selector mechanism
  111
• 5.4 Assembly overview - selector unit
  112
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  113
• 5.6 Assembly overview - selector forks
  114
• 5.7 Repairing selector unit
  117
• 5.8 Repairing selector forks
  118
• 5.9 Dismantling and assembling gearbox
  122
• 6 Gearbox housing, clutch housing
  154
• 6.1 Assembly overview - gearbox housing
  154
• 6.2 Assembly overview - clutch housing
  156
• 6.3 Assembly overview - gearbox housing cover
  157
• 6.4 Repairing gearbox housing
  158
• 6.5 Repairing clutch housing
  165
• 6.6 Repairing gearbox housing cover
  170
• 7 Securing to engine and gearbox support
  172
• 8 Gear oil
  173
• 8.1 Checking gear oil level
  173
• 8.2 Draining and filling gear oil
  173
• Gears, shafts
  176
• 1 Input shaft
  176
• 1.1 Assembly overview - input shaft
  176
• 1.2 Dismantling and assembling input shaft
  179
• 1.3 Adjusting input shaft
  183
• 2 Output shaft
  189
• 2.1 Assembly overview - output shaft
  189
• 2.2 Dismantling and assembling output shaft
  192
• 2.3 Adjusting output shaft
  202
• 3 Reverse shaft
  209
• 3.1 Assembly overview - reverse shaft
  209
• 3.2 Dismantling and assembling reverse shaft
  212
• Final drive - differential
  215
• 1 Oil seals
  215
• 1.1 Overview of fitting locations - seals
  215
• 1.2 Renewing left seal
  216
• 1.3 Renewing right oil seal
  218
• 1.4 Renewing input shaft seal
  221
• 2 Differential
  224
• 2.1 Assembly overview - differential
  224
• 2.2 Dismantling and assembling differential
  226
• 2.3 Adjusting differential
  232
• 3 Adjustment overview
  237