5-speed manual gearbox 006

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
  10
• 1.3 Removing and installing clutch pedal
  12
• 1.4 Assembly overview - Hydraulics and clutch release mechanism
  15
• 1.5 Removing and installing master cylinder
  20
• 1.6 Removing and installing pipe/hose assembly
  22
• 1.7 Bleeding clutch system
  24
• 2 Servicing clutch
  25
• 2.1 Servicing clutch
  25
• Controls, Housing
  30
• 1 Servicing gear selector mechanism
  30
• 1.1 Servicing gear selector mechanism
  30
• 1.2 Servicing gear stick and gear stick housing
  31
• 1.3 Removing and installing gear stick and gear stick housing
  35
• 1.4 Installing gear stick cover
  39
• 1.5 Assembly overview: Removing and installing operating cables
  40
• 1.6 Removing and installing operating cables
  42
• 1.7 Adjusting gear selector mechanism
  48
• 2 Removing and installing gearbox
  50
• 2.1 Removing and installing gearbox
  50
• 2.2 Removing and installing gearbox - Vehicles with 4 cylinder engine -
  50
• 2.3 Removing and installing gearbox - Vehicles with 6 cylinder fuel injection engine -
  68
• 3 Checking gearbox oil
  87
• 3.1 Checking gearbox oil
  87
• 4 Dismantling and assembling gearbox
  88
• 4.1 Dismantling and assembling gearbox
  88
• 4.2 Modifying gearbox holder 2004
  92
• 4.3 Dismantling and assembling sequence
  92
• 5 Servicing gearbox housing and clutch housing
  99
• 5.1 Servicing gearbox housing and clutch housing
  99
• 6 Dismantling and assembling gearbox selector mechanism
  107
• 6.1 Dismantling and assembling gearbox selector mechanism
  107
• 7 Dismantling and assembling internal selectors
  111
• 7.1 Dismantling and assembling internal selectors
  111
• Gears, Shafts
  112
• 1 Dismantling and assembling input shaft
  112
• 1.1 Dismantling and assembling input shaft
  112
• 2 Adjusting input shaft
  121
• 2.1 Adjusting input shaft
  121
• 3 Dismantling and assembling output shaft (pinion shaft)
  124
• 3.1 Dismantling and assembling output shaft (pinion shaft)
  124
• 4 Adjusting output shaft
  137
• 4.1 Adjusting output shaft
  137
• Final drive, Differential rear
  140
• 1 Removing and installing oil seals for drive shafts
  140
• 1.1 Removing and installing oil seals for drive shafts
  140
• 2 Dismantling and assembling differential
  145
• 2.1 Dismantling and assembling differential
  145
• 3 Adjustment overview
  154
• 3.1 Adjustment overview
  154
• 4 Adjusting differential
  154
• 4.1 Adjusting differential
  154