6-speed manual gearbox 08D

Kapitelübersicht

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation, capacities
  1
• 2 Overview - power transmission
  3
• 3 Calculating overall gear ratio “i”
  4
• 4 Repair instructions
  5
• 4.1 General repair instructions
  5
• Clutch
  8
• 1 Repairing clutch mechanism
  8
• 1.1 Overview
  8
• 1.2 Assembly overview - pedal cluster
  10
• 1.3 Removing, installing and adjusting clutch pedal switch F36
  12
• 1.4 Removing and installing clutch pedal switch F194 (interlock switch)
  13
• 1.5 Removing and installing over-centre spring
  14
• 1.6 Removing and installing clutch pedal
  15
• 1.7 Assembly overview - hydraulics (LHD)
  16
• 1.8 Assembly overview - hydraulics (RHD)
  19
• 1.9 Removing and installing master cylinder
  21
• 1.10 Bleeding clutch mechanism
  22
• 2 Repairing clutch release mechanism
  24
• 2.1 Removing and installing slave cylinder
  25
• 3 Repairing clutch
  28
• Controls, housing
  35
• 1 Repairing selector mechanism
  35
• 1.1 Installation position of selector mechanism
  35
• 1.2 I - Removing and installing gear knob and cover
  37
• 1.3 II - Repairing gear lever and selector housing
  39
• 1.4 III - Assembly overview - removing and installing selector cables
  40
• 1.5 Removing and installing selector mechanism
  42
• 1.6 Adjusting selector mechanism
  46
• 2 Removing and installing gearbox
  52
• 2.1 Removing and installing gearbox, vehicles with 5-cylinder diesel engines
  52
• 2.2 Removing and installing gearbox, vehicles with 6-cylinder diesel engines
  59
• 2.3 Removing and installing gearbox, vehicles with 6-cylinder petrol engine
  66
• 2.4 Transporting gearbox
  77
• 3 Checking gear oil
  78
• 4 Gearbox
  79
• 4.1 Assembly overview - components on gearbox
  79
• 4.2 Installing to engine and gearbox support
  81
• 4.3 Renewing locking pin
  82
• 5 Renewing seals and sealing covers
  83
• 5.1 Renewing input shaft seal
  83
• 5.2 Renewing output shaft seal
  84
• 5.3 Renewing seals for rotary gear and gate selector shafts
  86
• 5.4 Renewing layshaft cap
  88
• 6 Selector unit
  90
• 6.1 Removing and installing selector unit
  90