4 and 5 speed manual gearbox 020/02K

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, assembly allocation, ratios, capacities
  2
• 2 Calculating overall ratio "i"
  5
• 2.1 Calculating overall ratio "i"
  5
• 3 Transmission layout
  6
• 3.1 Transmission layout
  6
• 4 General repair instructions
  8
• 4.1 General repair instructions
  8
• Clutch
  10
• 1 Servicing clutch control
  10
• 1.1 Servicing clutch control
  10
• 1.2 Assembly overview - Pedal cluster mechanical clutch control
  12
• 1.3 Removing and installing over-centre spring
  15
• 1.4 Removing and installing clutch pedal
  17
• 1.5 Assembly overview - Mechanics
  19
• 1.6 Checking function of clutch cable
  22
• 1.7 Removing and installing clutch cable
  24
• 1.8 Assembly overview - Pedal cluster for hydraulically operated clutch
  27
• 1.9 Removing and installing clutch pedal
  31
• 1.10 Assembly overview - Hydraulic system
  34
• 1.11 Removing and installing master cylinder
  38
• 1.12 Bleeding clutch system
  41
• 2 Servicing clutch
  42
• 2.1 Servicing clutch
  42
• 2.2 Removing and installing clutch
  45
• Controls, Housing
  48
• 1 Servicing gear selector mechanism
  48
• 1.1 Servicing gear selector mechanism
  48
• 1.2 Installation position of gear selector mechanism
  48
• 1.3 Assembly overview - Gearstick housing/gearstick
  50
• 1.4 Installing gear stick gaiter to gear stick knob
  57
• 1.5 Assembly overview - gear selector relay points at gearbox
  58
• 1.6 Removing and installing gearstick/selector rod
  63
• 1.7 Adjusting gear selector mechanism
  65
• 2 Servicing gearbox housing cover
  69
• 2.1 Servicing gearbox housing cover
  69
• 3 Removing and installing gearbox
  75
• 3.1 Removing and installing gearbox
  75
• 4 Dismantling and assembling gearbox
  92
• 4.1 Dismantling and assembling gearbox
  92
• 4.2 Overview
  92
• 4.3 Assembly overview
  94
• 4.4 Removing and installing gearbox housing cover and 5th gear
  95
• 4.5 Removing and installing gearbox housing and selector mechanism
  98
• 4.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  101
• 4.7 Dismantling and assembling sequence
  107
• 5 Servicing gearbox housing and selector shaft
  127
• 5.1 Servicing gearbox housing and selector shaft
  127
• 6 Checking gearbox oil
  133
• 6.1 Checking gearbox oil
  133
• 7 Servicing clutch housing
  134
• 7.1 Servicing clutch housing
  134
• Gears, Shafts
  143
• 1 Dismantling and assembling input shaft
  143
• 1.1 Dismantling and assembling input shaft
  143
• 2 Dismantling and assembling output shaft
  156
• 2.1 Dismantling and assembling output shaft
  156
• 2.2 Allocating output shafts
  169
• 3 Adjusting output shaft
  170
• 3.1 Adjusting output shaft
  170
• Final drive, Differential
  174
• 1 Removing and installing drive flange oil seal
  174
• 1.1 Removing and installing drive flange oil seal
  174
• 2 Dismantling and assembling differential
  177
• 2.1 Dismantling and assembling differential
  177
• 3 Adjusting differential
  190
• 3.1 Adjusting differential
  190
• 4 Adjustment overview
  193
• 4.1 Adjustment overview
  193