5-speed manual gearbox 02B

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
  14
• 2.1 Transmission layout
  14
• 3 Calculating overall ratio "i"
  16
• 3.1 Calculating overall ratio "i"
  16
• 4 General repair instructions
  16
• 4.1 General repair instructions
  16
• Clutch
  19
• 1 Servicing clutch control
  19
• 1.1 Servicing clutch control
  19
• 1.2 Assembly overview - Pedal cluster - Hydraulic clutch control
  21
• 1.3 Removing and installing clutch pedal - Hydraulic clutch control
  24
• 1.4 Assembly overview - Hydraulic system
  25
• 1.5 Removing and installing slave cylinder
  29
• 1.6 Bleeding clutch system
  32
• 1.7 Assembly overview - Pedal cluster - Mechanical clutch control
  33
• 1.8 Removing and installing over-centre spring
  36
• 1.9 Removing and installing clutch pedal - Mechanical clutch control
  36
• 1.10 Assembly overview - Mechanics
  37
• 1.11 Removing and installing clutch cable
  40
• 2 Servicing clutch release mechanism
  43
• 2.1 Servicing clutch release mechanism
  43
• 3 Servicing clutch
  46
• 3.1 Servicing clutch
  46
• Controls, Housing
  52
• 1 Servicing gear selector mechanism
  52
• 1.1 Servicing gear selector mechanism
  52
• 1.2 Installation position of gear selector mechanism
  52
• 1.3 Removing and installing gear stick housing
  54
• 1.4 Removing and installing gear stick
  57
• 1.5 Removing and installing selector and gate rods
  60
• 1.6 Removing and installing selector mechanism
  67
• 1.7 Adjusting gear selector mechanism
  69
• 2 Removing and installing gearbox
  71
• 2.1 Removing and installing gearbox
  71
• 2.3 Removing and installing bearing housing with right-hand output shaft/drive flange
  91
• 2.4 Checking gearbox oil
  94
• 3 Dismantling and assembling gearbox
  96
• 3.1 Dismantling and assembling gearbox
  96
• 3.2 Removing and installing cover for gearbox housing and 5th gear
  97
• 3.3 Removing and installing gearbox housing and selector mechanism
  101
• 3.4 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  104
• 3.5 Dismantling and assembling sequence
  107
• 4 Servicing gearbox housing
  125
• 4.1 Servicing gearbox housing
  125
• 5 Servicing clutch housing
  129
• 5.1 Servicing clutch housing
  129
• 6 Servicing bearing housing
  135
• 6.1 Servicing bearing housing
  135
• 7 Dismantling and assembling selector mechanism, gearbox side
  141
• 7.1 Dismantling and assembling selector mechanism, gearbox side
  141
• 8 Dismantling and assembling selector forks
  148
• 8.1 Dismantling and assembling selector forks
  148
• Gears, Shafts
  156
• 1 Dismantling and assembling input shaft
  156
• 1.1 Dismantling and assembling input shaft
  156
• 2 Adjusting input shaft
  167
• 2.1 Adjusting input shaft
  167
• 2.2 Table of adjustment shims
  169
• 2.3 Performing measurement check
  171
• 3 Dismantling and assembling output shaft (pinion shaft)
  172
• 3.1 Dismantling and assembling output shaft (pinion shaft)
  172
• 4 Adjusting output shaft
  200
• 4.1 Adjusting output shaft
  200
• 5 Dismantling and assembling reverse shaft
  202
• 5.1 Dismantling and assembling reverse shaft
  202
• Final drive, Differential
  209
• 1 Removing and installing oil seal for flange shaft or drive flange
  209
• 1.1 Removing and installing oil seal for flange shaft or drive flange
  209
• 2 Dismantling and assembling differential
  213
• 2.1 Dismantling and assembling differential
  213
• 3 Adjustment overview
  224
• 3.1 Adjustment overview
  224
• 4 Adjusting differential
  224
• 4.1 Adjusting differential
  224