5-Speed manual gearbox 02A

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, gearbox allocation, ratios, capacities
  2
• 2 Transmission layout
  3
• 2.1 Transmission layout
  3
• 3 Calculating overall ratio (i)
  5
• 3.1 Calculating overall ratio (i)
  5
• 4 General repair instructions
  5
• 4.1 General repair instructions
  5
• Clutch
  7
• 1 Servicing clutch control
  7
• 1.1 Servicing clutch control
  7
• 1.2 Assembly overview - Pedal cluster
  8
• 1.3 Removing and installing over-centre spring
  11
• 1.4 Removing and installing clutch pedal
  13
• 1.5 Assembly overview - Hydraulic system
  14
• 1.6 Removing and installing master cylinder
  17
• 1.7 Bleeding clutch system
  18
• 2 Servicing clutch release mechanism
  19
• 2.1 Servicing clutch release mechanism
  19
• 3 Servicing clutch
  22
• 3.1 Servicing clutch
  22
• Controls, Housing
  26
• 1 Servicing gear selector mechanism
  26
• 1.1 Servicing gear selector mechanism
  26
• 1.2 Installation position of gear selector mechanism
  26
• 1.3 Removing and installing gear selector cables
  29
• 1.4 Removing and installing gear stick housing
  35
• 1.5 Installing gear stick gaiter to gear stick knob
  38
• 1.6 Removing and installing gear stick
  39
• 1.7 Adjusting gear selector mechanism
  43
• 2 Removing and installing gearbox
  46
• 2.1 Removing and installing gearbox
  46
• 3 Checking gearbox oil
  58
• 3.1 Checking gearbox oil
  58
• 4 Dismantling and assembling gearbox
  60
• 4.1 Dismantling and assembling gearbox
  60
• 4.2 Removing and installing cover for gearbox housing and 5th gear
  61
• 4.3 Removing and installing gearbox housing and selector mechanism
  64
• 4.4 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  67
• 4.5 Dismantling and assembling sequence
  70
• 5 Servicing gearbox housing and clutch housing
  87
• 5.1 Servicing gearbox housing and clutch housing
  87
• 6 Dismantling and assembling gearbox selector mechanism
  96
• 6.1 Dismantling and assembling gearbox selector mechanism
  96
• 7 Dismantling and assembling selector forks
  101
• 7.1 Dismantling and assembling selector forks
  101
• Gears, Shafts
  107
• 1 Dismantling and assembling input shaft
  107
• 1.1 Dismantling and assembling input shaft
  107
• 2 Adjusting input shaft
  118
• 2.1 Adjusting input shaft
  118
• 2.2 Table of adjustment shims
  119
• 2.3 Carrying out check measurement
  121
• 3 Dismantling and assembling output shaft (pinion shaft)
  122
• 3.1 Dismantling and assembling output shaft (pinion shaft)
  122
• 4 Adjusting output shaft
  146
• 4.1 Adjusting output shaft
  146
• 5 Dismantling and assembling reverse shaft
  149
• 5.1 Dismantling and assembling reverse shaft
  149
• Final drive, Differential
  153
• 1 Renewing flanged shaft oil seals (gearbox installed)
  153
• 1.1 Renewing flanged shaft oil seals (gearbox installed)
  153
• 1.2 Renewing oil seals on gearboxes without springs behind flanges
  153
• 1.3 Renewing oil seal on gearboxes with springs behind flanges
  154
• 2 Dismantling and assembling differential
  157
• 2.1 Dismantling and assembling differential
  157
• 3 Adjustment overview
  173
• 3.1 Adjustment overview
  173
• 4 Adjusting differential
  173
• 4.1 Adjusting differential
  173