5-speed manual gearbox 02C, four-wheel drive

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Codes and production dates of gearbox
  1
• 1.3 Identification code, assembly allocation, ratios, capacities
  1
• 2 Identifying rear final drive
  5
• 2.1 Location on rear final drive
  5
• 2.2 Codes and production dates of gearbox
  5
• 2.3 Identification code, assembly allocation, ratios, capacities
  5
• 3 Overview - power transmission
  8
• 4 Calculation of gear ratios
  10
• 4.1 Notes on performance test
  10
• 5 General repair notes
  11
• Clutch
  14
• 1 Repairing clutch mechanism
  14
• 1.1 Assembly overview - pedal cluster
  15
• 1.2 Distinguishing between clutch pedal switches F36
  16
• 1.3 Removing and installing clutch pedal switch F36 with rectangular housing
  16
• 1.4 Removing and installing clutch pedal switch F36 with round housing
  17
• 1.5 Removing and installing over-centre spring
  17
• 1.6 Removing and installing clutch pedal
  19
• 1.7 Assembly overview - hydraulic system
  20
• 1.8 Removing and installing master cylinder
  22
• 1.9 Bleeding clutch system
  25
• 2 Repairing clutch release mechanism
  26
• 2.1 Assembly overview clutch release mechanism
  26
• 3 Repairing clutch
  28
• 3.1 Assembly overview
  28
• Controls, housing
  31
• 1 Connecting VAS 5051 and selecting functions
  31
• 2 Electrical and electronic components and their locations
  33
• 2.1 Overview of electrical and electronic components and their locations
  33
• 2.2 Removing and installing all-wheel drive control unit J492
  35
• 2.3 Removing and installing Haldex coupling pump V181
  36
• 3 Electrical check of Haldex coupling
  38
• 4 Repairing selector mechanism
  43
• 4.1 Installation position of selector mechanism
  43
• 4.2 Removing and installing gear knob and cover
  45
• 4.3 Repairing gear lever and selector housing
  46
• 4.4 Assembly overview - removing and installing selector cables
  48
• 4.5 Removing and installing selector mechanism
  49
• 4.6 Adjusting selector mechanism
  53
• 5 Removing and installing gearbox
  57
• 5.1 Removing
  57
• 5.2 Transporting gearbox
  64
• 5.3 Installing
  64
• 5.4 Specified torques
  71
• 6 Removing and installing bevel box
  72
• 7 Checking gear oil in manual gearbox with bevel box
  75
• 8 Dismantling and assembling gearbox
  76
• 8.1 Overview - gearbox
  76
• 8.2 Assembly overview
  78
• 8.3 Removing and installing cover for gearbox housing and 5th gear
  79
• 8.4 Removing and installing gearbox housing and selector mechanism
  80
• 8.5 Removing and installing input shaft, output shaft, differential and selector forks
  81
• 9 Assembly overview - Repairing gearbox housing and clutch housing
  93
• 10 Dismantling and assembling selector mechanism on gearbox side
  99
• 10.1 Assembly overview - selector shaft
  99
• 11 Dismantling and assembling selector forks
  103
• Gears, shafts
  108
• 1 Dismantling and assembling input shaft
  108
• 1.1 Assembly overview - input shaft
  108
• 1.2 Modification in springs for 5th gear synchronisation from gearbox date 05 11 1
  115
• 2 Adjusting input shaft
  116
• 2.1 Adjusting input shaft
  116
• 2.2 Table of shims
  117
• 2.3 Carrying out check measurement
  119
• 3 Adjusting output shaft
  120
• 4 Dismantling and assembling output shaft
  123
• 4.1 Assembly overview - output shaft
  123
• 4.2 1st gear synchronisation changed from gearbox date 04 09 0
  136
• 5 Dismantling and assembling reverse shaft
  138
• Final drive - rear differential
  141
• 1 Propshaft
  141
• 1.1 Assembly overview - repairing propshaft
  141
• 1.2 Removing and installing propshaft
  146
• 1.3 Removing and installing front flexible coupling
  151
• 1.4 Removing and installing rear flexible coupling
  153
• 2 Haldex coupling
  158
• 2.1 Checking function of Haldex coupling
  158
• 2.2 Checking oil level or changing oil in Haldex coupling
  158
• 2.3 Changing oil filter for Haldex coupling
  161
• 3 Modifying gearbox support VW 353
  162
• 4 Checking gear oil in rear final drive and topping up
  163
• 5 Removing and installing rear final drive
  164
• 6 Renewing propshaft flange oil seal on rear final drive (final drive removed)
  168
• 7 Renewing flange shaft oil seals (final drive installed)
  171
• 9 Renewing O-rings for rear final drive housing cover (final drive installed)
  176
• 10 Dismantling and assembling rear final drive
  177
• 10.1 Assembly overviews - rear final drive
  177
• 10.2 Removing and installing cover for Haldex coupling and plates
  178
• 10.3 Removing and installing pinion housing
  179
• 10.4 Removing and installing differential and bevel gear with stub shaft
  181
• 10.5 Removing and installing cover for Haldex coupling from plate housing
  183
• 11 Dismantling and assembling differential
  198
• 11.1 Assembly overview - differential
  198
• 12 Repair shaft bevel gear mounting
  207
• 12.1 Assembly overview - bevel gear mounting
  207
• 12.2 Assembly sequence - bevel gear mounting
  208
• 13 Repairing bearings for bevel gear with stub shaft
  216
• 13.1 Assembly overview - bearings for bevel gear with stub shaft
  216
• 13.2 Assembly sequence - bearings for bevel gear with stub shaft
  218
• 14.1 General notes
  224
• 14.2 Adjustment and marking of final drive gear sets
  224
• 14.3 Position of shims
  225
• 14.4 Adjustment overview - rear final drive
  225
• 14.5 Recommended sequence for new adjustment of final drive gear set
  226
• 14.6 Adjusting shaft bevel gear
  226
• 14.7 Adjusting bevel gear (with stub shaft)
  231
• Final drive - front differential
  236
• 1.1 Renewing oil seal for left flange shaft
  236
• 1.2 Renewing oil seal for flange shaft or right drive flange
  237
• 2 Renewing bevel box output flange oil seal (bevel box removed)
  240
• 3 Dismantling and assembling differential
  242
• 3.1 Assembly overview - differential
  242
• 3.2 Assembly sequence - differential
  243
• 4 Adjustment overview
  247
• 5 Adjusting differential
  248
• 6 Dismantling and assembling bevel box
  250
• 6.1 Bevel box - assembly overview
  250
• 6.2 Assembly sequence - bevel box
  253
• 7 Renewing needle bearing (polygon bearing) for right output shaft or for right flange shaft
  265
• 8.1 General notes
  269
• 8.2 Adjustment and marking of final drive gear sets
  269
• 8.3 Position of shims
  270
• 8.4 Adjustment overview - bevel box
  270
• 8.5 Recommended sequence for new adjustment of final drive gear set
  271
• 8.6 Determining shim "S4" thickness when renewing output flange
  271
• 8.7 Adjusting shaft bevel gear
  272
• 8.8 Adjusting bevel gear (with stub shaft)
  277