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 instructions
  5
• 3.1 General repair instructions
  5
• 4 Technical data
  10
• 4.1 Capacities
  10
• 4.2 Allocation gearbox - engine
  10
• 4.3 Calculation of gear ratios
  10
• 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
  22
• 1.4 Removing and installing clutch pedal
  24
• 1.5 Removing and installing over-centre spring
  25
• 1.6 Removing and installing return spring
  29
• 1.7 Removing and installing mounting bracket
  32
• 1.8 Removing and installing bearing bush
  37
• 1.9 Removing and installing clutch master cylinder
  39
• 1.10 Removing and installing clutch slave cylinder
  39
• 1.11 Removing and installing lines for clutch mechanism
  41
• 1.12 Bleeding clutch mechanism
  44
• 1.13 Checking clutch master cylinder and clutch slave cylinder
  46
• 1.14 Removing and installing clutch position sender G476
  46
• 1.15 Repairing clutch release mechanism
  47
• 2 Clutch
  49
• 2.1 Determining make of clutch
  49
• 2.2 Assembly overview - clutch
  50
• 2.3 Removing and installing clutch
  53
• Controls, housing
  69
• 1 Selector mechanism
  69
• 1.1 Installation position - selector mechanism
  69
• 1.2 Assembly overview – gear knob and cover
  70
• 1.3 Assembly overview - selector mechanism
  70
• 1.4 Removing and installing gear knob
  72
• 1.5 Removing and installing selector mechanism
  74
• 1.6 Adjusting selector mechanism
  82
• 1.7 Checking selector mechanism
  86
• 1.8 Renewing selector shaft seal
  86
• 2 Removing and installing gearbox
  88
• 2.1 Specified torques for gearbox
  88
• 2.2 Removing gearbox
  88
• 2.3 Installing gearbox
  105
• 3 Assembly mountings
  115
• 3.1 Assembly overview - assembly mountings
  115
• 4 Transporting gearbox
  119
• 5 Dismantling and assembling gearbox
  121
• 5.1 Schematic overview - gearbox
  121
• 5.2 Assembly overview - cover for gearbox housing and 5th/6th gear
  122
• 5.3 Assembly overview - gearbox housing and selector mechanism
  124
• 5.4 Assembly overview - selector unit
  126
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  126
• 5.6 Assembly overview - selector forks
  128
• 5.7 Repairing selector unit
  131
• 5.8 Repairing selector forks
  133
• 5.9 Removing cover for gearbox housing and 5th and 6th gears
  138
• 5.10 Dismantling and assembling gearbox
  146
• 5.11 Installing cover for gearbox housing and 5th and 6th gears
  163
• 6 Gearbox housing, clutch housing
  170
• 6.1 Assembly overview - gearbox housing
  170
• 6.2 Assembly overview - clutch housing
  173
• 6.3 Assembly overview - gearbox housing cover
  175
• 6.4 Repairing gearbox housing
  176
• 6.5 Repairing clutch housing
  183
• 6.6 Repairing gearbox housing cover
  188
• 7 Securing to engine and gearbox support
  192
• 8 Gear oil
  193
• 8.1 Checking gear oil level
  193
• 8.2 Draining and filling gear oil
  193
• Gears, shafts
  197
• 1 Input shaft
  197
• 1.1 Assembly overview - input shaft
  197
• 1.2 Dismantling and assembling input shaft
  199
• 1.3 Adjusting input shaft
  205
• 2 Output shaft
  211
• 2.1 Assembly overview - output shaft
  211
• 2.2 Dismantling and assembling output shaft
  214
• 2.3 Adjusting output shaft
  228
• 3 Reverse shaft
  234
• 3.1 Assembly overview - reverse shaft
  234
• 3.2 Dismantling and assembling reverse shaft
  236
• Final drive - differential
  240
• 1 Oil seals
  240
• 1.1 Overview of fitting locations - seals
  240
• 1.2 Renewing left seal
  240
• 1.3 Renewing right seal
  243
• 1.4 Renewing input shaft seal
  248
• 2 Differential
  251
• 2.1 Assembly overview - differential
  251
• 2.2 Dismantling and assembling differential
  253
• 2.3 Adjusting differential
  260
• 3 Adjustment overview
  264