5-speed manual g/box 085 DS Lupo 3 L, Lupo FSI

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
  5
• 2.1 Transmission layout
  5
• 3 Calculating overall ratio "i"
  7
• 3.1 Calculating overall ratio "i"
  7
• 4 General repair instructions
  7
• 4.1 General repair instructions
  7
• Clutch
  10
• 1 Servicing clutch control
  10
• 1.1 Servicing clutch control
  10
• 1.2 Assembly overview
  11
• 1.3 Removing and installing slave cylinder
  14
• 1.4 Adjusting clutch play
  16
• 2 Servicing clutch release mechanism
  17
• 2.1 Servicing clutch release mechanism
  17
• 3 Servicing clutch
  23
• 3.1 Servicing clutch
  23
• Controls, Housing
  29
• 1 Locations of electrical/electronic components
  29
• 1.1 Locations of electrical/electronic components
  29
• 1.2 Electrical/electronic components in vehicle
  29
• 1.3 Electrical/electronic components on gearbox
  37
• 1.4 Electrical/electronic components on hydraulic control unit
  40
• 1.5 Connecting vehicle diagnosis, testing and information system VAS 5051
  42
• 2 Servicing gear change mechanism
  43
• 2.1 Servicing gear change mechanism
  43
• 2.2 Allocating gear change mechanism
  43
• 2.3 Checking gear change mechanism
  43
• 2.6 Removing and installing gear change mechanism
  46
• 2.7 Dismantling and assembling gear change mechanism
  49
• 2.8 Removing and installing selector lever knob and gaiter
  50
• 2.13 Servicing selector lever
  77
• 2.15 Removing and installing locking cable
  80
• 2.16 Adjusting locking cable - gear change mechanism with "STOP position forward"
  83
• 2.17 Adjusting locking cable - gear change mechanism with "STOP position forward left"
  84
• 3 Removing and installing gear actuator
  85
• 3.1 Removing and installing gear actuator
  85
• 3.4 Servicing gear actuator
  99
• 3.5 Control/adjustment of gear adjuster
  106
• 4 Removing and installing hydraulic control unit
  107
• 4.1 Removing and installing hydraulic control unit
  107
• 4.2 Removing and installing hydraulic control unit - vehicles with battery in engine compartment
  108
• 4.3 Removing and installing hydraulic control unit \- vehicles with battery in luggage compartment
  110
• 4.4 Servicing hydraulic control unit
  112
• 5 Removing and installing pipe/hose assembly
  118
• 5.1 Removing and installing pipe/hose assembly
  118
• 6 Checking oil level in reservoir for clutch control and selector mechanism
  123
• 6.1 Checking oil level in reservoir for clutch control and selector mechanism
  123
• 6.2 Checking oil level
  123
• 6.3 Correcting oil level
  124
• 7 Removing and installing gearbox - Lupo 3 L
  127
• 7.1 Removing and installing gearbox - Lupo 3 L
  127
• 8 Removing and installing gearbox - Lupo FSI
  139
• 8.1 Removing and installing gearbox - Lupo FSI
  139
• 9 Checking gear oil
  150
• 9.1 Checking gear oil
  150
• 10 Dismantling and assembling gearbox
  152
• 10.1 Dismantling and assembling gearbox
  152
• 10.2 Dismantling and assembling sequence
  161
• 11 Servicing clutch housing
  180
• 11.1 Servicing clutch housing
  180
• 12 Adjusting selector finger and selector sleeve
  191
• 12.1 Adjusting selector finger and selector sleeve
  191
• Gears, Shafts
  194
• 1 Dismantling and assembling input shaft
  194
• 1.1 Dismantling and assembling input shaft
  194
• 2 Adjusting input shaft
  206
• 2.1 Adjusting input shaft
  206
• 3 Dismantling and assembling output shaft
  211
• 3.1 Dismantling and assembling output shaft
  211
• 4 Adjusting output shaft
  227
• 4.1 Adjusting output shaft
  227
• Final drive, Differential
  231
• 1 Renewing selector shaft seal with gearbox in situ
  231
• 1.1 Renewing selector shaft seal with gearbox in situ
  231
• 2 Renewing oil seals for flanged shafts with gearbox installed
  233
• 2.1 Renewing oil seals for flanged shafts with gearbox installed
  233
• 2.2 Renewing flanged shaft sealing rings - Lupo 3 L
  233
• 2.3 Renewing flanged shaft sealing rings - Lupo FSI
  237
• 3 Dismantling and assembling differential
  240
• 3.1 Dismantling and assembling differential
  240
• 3.2 Removing and installing gears for final drive
  248
• 4 Adjustment overview
  250
• 4.1 Adjustment overview
  250
• 5 Adjusting differential
  251
• 5.1 Adjusting differential
  251
• 6 Definitions
  255
• 6.1 Definitions
  255