5-speed manual gearbox 002

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, assembly 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 Checking clutch cable function
  12
• 1.3 Removing and installing clutch cable
  13
• 1.4 Removing and installing clutch pedal
  17
• 2 Servicing clutch release mechanism
  20
• 2.1 Servicing clutch release mechanism
  20
• 3 Servicing clutch
  24
• 3.1 Servicing clutch
  24
• Controls, Housing
  29
• 1 Servicing gear selector mechanism
  29
• 1.1 Servicing gear selector mechanism
  29
• 1.2 I - Servicing gear stick housing, selector rod and relay
  30
• 1.3 Installing gear stick gaiter to gear stick knob
  38
• 1.4 II - Servicing gear stick and cable
  39
• 1.5 Removing and installing selector mechanism
  43
• 1.6 Adjusting gear selector mechanism
  47
• 2 Removing and installing gearbox
  51
• 2.1 Removing and installing gearbox
  51
• 3 Checking gear oil
  64
• 3.1 Checking gear oil
  64
• 4 Dismantling and assembling gearbox
  65
• 4.1 Dismantling and assembling gearbox
  65
• 4.2 Assembly overview
  65
• 4.3 Removing and installing gearbox housing cover and 5th gear
  66
• 4.5 Dismantling and assembling sequence
  72
• 5 Servicing gearbox housing
  79
• 5.1 Servicing gearbox housing
  79
• 6 Servicing clutch housing
  84
• 6.1 Servicing clutch housing
  84
• 7 Dismantling and assembling selector rods with selector forks
  94
• 7.1 Dismantling and assembling selector rods with selector forks
  94
• Gears, Shafts
  96
• 1 Dismantling and assembling input shaft
  96
• 1.1 Dismantling and assembling input shaft
  96
• 2 Dismantling and assembling output shaft
  102
• 2.1 Dismantling and assembling output shaft
  102
• Final drive, Differential
  113
• 1 Renewing flange shaft oil seal (gearbox installed)
  113
• 1.1 Renewing flange shaft oil seal (gearbox installed)
  113
• 2 Dismantling and assembling differential
  116
• 2.1 Dismantling and assembling differential
  116
• 3 Adjusting differential
  127
• 3.1 Adjusting differential
  127