4 Speed Manual Gearbox 091/I

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 2 Code letters, allocation, gearbox ratios, oil capacity
  2
• 2.1 Code letters, allocation, gearbox ratios, oil capacity
  2
• 3 Transmission layout
  5
• 3.1 Transmission layout
  5
• 4 Calculating ratios "i" and speed "V"
  6
• 4.1 Calculating ratios "i" and speed "V"
  6
• Clutch
  8
• 1 Clutch control
  8
• 1.1 Clutch control
  8
• 1.2 Repairs to the hydraulic clutch control
  8
• 1.3 Bleeding clutch
  13
• 1.4 Rubber buffer for clutch cable
  13
• 2 Clutch repairs
  14
• 2.1 Clutch repairs
  14
• 2.2 Removing, installing and checking clutch
  14
• Controls, Housing
  18
• 1 Repairing gearshift mechanism
  18
• 1.1 Repairing gearshift mechanism
  18
• 1.2 Modified rear shift rod mounting
  22
• 1.3 Repairing gearshift linkage
  24
• 1.4 Adjusting gearshift linkage
  25
• 1.5 Modified gear lever bearing
  26
• 1.6 Amendments
  27
• 2 Removing and installing gearbox
  27
• 2.1 Removing and installing gearbox
  27
• 3 Dismantling and assembling gearbox
  30
• 3.1 Dismantling and assembling gearbox
  30
• 3.2 Removing and installing clutch housing/differential
  30
• 3.3 Dismantling and assembling gearbox
  37
• 3.4 Dismantling and assembling gearbox
  42
• 3.5 Determining thickness of thrust washer for reverse gear
  46
• 3.6 Determining thrust washer from table
  46
• 3.7 Dismantling and assembling gearbox
  48
• 3.8 Dismantling and assembling gearbox
  52
• Gears, Shafts
  57
• 1 General view
  57
• 1.1 General view
  57
• 2 Dismantling and assembling input shaft
  58
• 2.1 Dismantling and assembling input shaft
  58
• 2.2 Dismantling and assembling pinion
  66
• Final drive, Differential
  78
• 1 Renewing drive flange oil seal
  78
• 1.1 Renewing drive flange oil seal
  78
• 2 Dismantling and assembling differential
  80
• 2.1 Dismantling and assembling differential
  80
• 2.2 Adjusting axial play of differential gears
  88
• 3 Dismantling and assembling limited slip differential
  90
• 3.1 Dismantling and assembling limited slip differential
  90
• 4 Adjusting crown wheel and pinion
  96
• 4.1 Adjusting crown wheel and pinion
  96
• 4.2 General instructions
  96
• 4.3 Differential with four pinions
  96
• 4.4 Crown wheel and pinion marks
  96
• 4.5 Adjustment table
  98
• 4.6 Finding position of pinion (actual dimension)
  98
• 4.7 Adjusting pinion
  99
• 4.8 Adjusting crown wheel
  102