5-Speed manual gearbox 02G

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
  4
• 2.1 Transmission layout
  4
• 3 Calculating overall ratio "i"
  6
• 3.1 Calculating overall ratio "i"
  6
• 4 General repair instructions
  6
• 4.1 General repair instructions
  6
• Clutch
  9
• 1 Servicing clutch control
  9
• 1.1 Servicing clutch control
  9
• 1.2 Assembly overview - Pedal cluster
  11
• 1.3 Removing and installing clutch pedal
  13
• 1.4 Assembly overview - Hydraulics and clutch release
  14
• 1.5 Removing and installing over-centre spring
  19
• 1.6 Bleeding clutch system
  21
• 2 Servicing clutch
  23
• 2.1 Servicing clutch
  23
• Controls, Housing
  29
• 1 Servicing gear selector mechanism
  29
• 1.1 Servicing gear selector mechanism
  29
• 1.3 Removing and installing gear stick housing
  34
• 1.4 Removing and installing selector rods and gate rod
  37
• 1.5 Removing and installing gear stick
  45
• 1.6 Removing and installing cover for gear stick housing
  50
• 1.7 Removing and installing selector mechanism
  51
• 1.8 Adjusting gear selector mechanism
  53
• 1.10 Removing and installing gear stick housing
  58
• 1.11 Removing and installing selector rods and gate rod
  60
• 1.12 Removing and installing gear stick
  64
• 1.13 Removing and installing selector mechanism
  68
• 1.14 Adjusting gear selector mechanism
  70
• 2 Removing and installing gearbox
  73
• 2.1 Removing and installing gearbox
  73
• 2.3 Removing and installing gearbox (Transporter with short front end)
  76
• 2.4 Removing and installing gearbox (Transporter with long front end)
  88
• 3 Checking gearbox oil
  102
• 3.1 Checking gearbox oil
  102
• 4 Dismantling and assembling gearbox
  103
• 4.1 Dismantling and assembling gearbox
  103
• 4.2 Assembly overview
  103
• 4.3 Removing and installing gearbox housing and selector mechanism
  108
• 4.5 Assembly sequence
  114
• 5 Servicing gearbox housing
  121
• 5.1 Servicing gearbox housing
  121
• 5.2 Servicing gearbox housing for vehicles with engines up to 103 kW
  121
• 5.3 Servicing gearbox housing for vehicles of 111 kW and above
  128
• 6 Servicing clutch housing
  134
• 6.1 Servicing clutch housing
  134
• 6.2 Servicing clutch housing for vehicles with engines up to 103 kW
  134
• 6.3 Servicing clutch housing for vehicles with engines of 111 kW and above
  141
• 7 Dismantling and assembling selector mechanism on gearbox side
  148
• 7.1 Dismantling and assembling selector mechanism on gearbox side
  148
• Gears, Shafts
  151
• 1 Dismantling and assembling input shaft
  151
• 1.1 Dismantling and assembling input shaft
  151
• 2 Adjusting input shaft
  163
• 2.1 Adjusting input shaft
  163
• 2.2 Performing measurement check
  165
• 3 Dismantling and assembling output shaft
  166
• 3.1 Dismantling and assembling output shaft
  166
• 4 Adjusting output shaft
  192
• 4.1 Adjusting output shaft
  192
• 4.2 Determining shim S1
  193
• 4.3 Determining shim S2
  194
• 5 Removing and installing reverse gear wheel
  197
• 5.1 Removing and installing reverse gear wheel
  197
• Final drive, Differential rear
  200
• 1 Removing and installing seal for intermediate shaft or flange shaft
  200
• 1.1 Removing and installing seal for intermediate shaft or flange shaft
  200
• 4 Adjustment overview
  238
• 4.1 Adjustment overview
  238
• 5 Adjusting differential
  239
• 5.1 Adjusting differential
  239
• 5.2 Adjusting differential for vehicles with engines up to 103 kW
  239
• 5.3 Adjusting differential on vehicles with engines of 111 kW and above
  243