5-speed manual gearbox 02C four-wheel drive

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, assembly allocation, ratios, capacities
  2
• 2 Rear final drive identification
  4
• 2.1 Rear final drive identification
  4
• 2.2 Code letters, assembly allocation, ratios, capacities
  5
• 3 Transmission layout
  7
• 3.1 Transmission layout
  7
• 4 Calculating overall ratio "i"
  9
• 4.1 Calculating overall ratio "i"
  9
• 4.2 Notes on brake and performance tests and towing
  9
• 5 General repair instructions
  9
• 5.1 General repair instructions
  9
• Clutch
  12
• 1 Servicing clutch control
  12
• 1.1 Servicing clutch control
  12
• 1.2 Assembly overview - Pedal cluster
  13
• 1.3 Removing and installing over-centre spring
  14
• 1.4 Removing and installing clutch pedal
  16
• 1.5 Assembly overview - Hydraulic system
  19
• 1.6 Removing and installing master cylinder
  22
• 1.7 Bleeding clutch system
  27
• 2 Servicing clutch release mechanism
  27
• 2.1 Servicing clutch release mechanism
  27
• 3 Servicing clutch
  31
• 3.1 Servicing clutch
  31
• Controls, Housing
  36
• 1 Connecting VAS 5051 and selecting functions
  36
• 1.1 Connecting VAS 5051 and selecting functions
  36
• 2 Locations of electrical/electronic components
  38
• 2.1 Locations of electrical/electronic components
  38
• 2.2 Removing and installing four-wheel drive control unit -J492
  42
• 2.3 Removing and installing Haldex coupling pump -V181-
  43
• 3 Electrical check of Haldex coupling
  46
• 3.1 Electrical check of Haldex coupling
  46
• 4 Servicing gear selector mechanism
  52
• 4.1 Servicing gear selector mechanism
  52
• 4.2 Installation position of gear selector mechanism
  52
• 4.3 Removing and installing selector lever knob and gaiter
  55
• 4.4 Servicing gear stick and gear stick housing
  57
• 4.5 Assembly overview - removing and installing selector cables
  61
• 4.6 Removing and installing gear selector mechanism
  65
• 4.7 Adjusting gear selector mechanism
  70
• 5 Removing and installing gearbox
  74
• 5.1 Removing and installing gearbox
  74
• 6 Removing and installing bevel box
  94
• 6.1 Removing and installing bevel box
  94
• 7 Checking oil in manual gearbox with bevel box
  97
• 7.1 Checking oil in manual gearbox with bevel box
  97
• 8 Dismantling and assembling gearbox
  99
• 8.1 Dismantling and assembling gearbox
  99
• 8.2 Overview
  99
• 8.3 Assembly overview
  102
• 8.4 Removing and installing cover for gearbox housing and 5th gear
  103
• 8.5 Removing and installing gearbox housing and selector mechanism
  105
• 8.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  107
• 8.7 Assembly sequence
  109
• 9 Servicing gearbox housing and clutch housing
  127
• 9.1 Servicing gearbox housing and clutch housing
  127
• 10 Dismantling and assembling gearbox selector mechanism
  137
• 10.1 Dismantling and assembling gearbox selector mechanism
  137
• 11 Dismantling and assembling selector forks
  144
• 11.1 Dismantling and assembling selector forks
  144
• Gears, Shafts
  153
• 1 Dismantling and assembling input shaft
  153
• 1.1 Dismantling and assembling input shaft
  153
• 1.2 From gearbox build date 05 11 1 circlips for 5th gear synchronisation have been modified
  166
• 2 Adjusting input shaft
  168
• 2.1 Adjusting input shaft
  168
• 2.2 Table of adjustment shims
  170
• 2.3 Performing measurement check
  172
• 3 Dismantling and assembling output shaft
  173
• 3.1 Dismantling and assembling output shaft
  173
• 4 Adjusting output shaft
  201
• 4.1 Adjusting output shaft
  201
• 5 Dismantling and assembling reverse shaft
  205
• 5.1 Dismantling and assembling reverse shaft
  205
• Final drive, Differential rear
  211
• 1 Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed)
  211
• 1.1 Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed)
  211
• 1.2 Renewing left-hand flange shaft oil seal
  211
• 1.3 Renewing oil seal for flange shaft or right-hand drive flange
  214
• 2 Replacing bevel box output flange oil seal (bevel box removed)
  216
• 2.1 Replacing bevel box output flange oil seal (bevel box removed)
  216
• 3 Dismantling and assembling differential
  218
• 3.1 Dismantling and assembling differential
  218
• 4 Adjustment overview
  233
• 4.1 Adjustment overview
  233
• 5 Adjusting differential
  234
• 5.1 Adjusting differential
  234
• 6 Dismantling and assembling bevel box
  237
• 6.1 Dismantling and assembling bevel box
  237
• 7 Renewing needle roller bearing (polygon bearing) for right output shaft or right flanged shaft
  260
• 7.1 Renewing needle roller bearing (polygon bearing) for right output shaft or right flanged shaft
  260
• 8 Adjusting shaft bevel gear and bevel gear (gear set)
  263
• 8.1 Adjusting shaft bevel gear and bevel gear (gear set)
  263
• 8.2 General notes
  263
• 8.3 Adjusting and marking of gear sets
  264
• 8.4 Position of shims
  266
• 8.5 Adjustment overview (bevel box)
  266
• 8.6 Recommended sequence for adjusting gear set
  267
• 8.7 Determining shim "S4" thickness when replacing output flange
  267
• 8.8 Adjusting shaft bevel gear
  268
• 8.9 Adjusting bevel gear
  275
• 9 Removing and installing propshaft
  279
• 9.1 Removing and installing propshaft
  279
• 9.2 Removing and installing front flexible coupling
  284
• 9.3 Removing and installing rear flexible coupling
  287
• 10 Servicing propshaft
  292
• 10.1 Servicing propshaft
  292
• 11 Checking function of Haldex coupling
  301
• 11.1 Checking function of Haldex coupling
  301
• 12 Renewing propshaft flange oil seal on rear final drive (final drive removed)
  302
• 12.1 Renewing propshaft flange oil seal on rear final drive (final drive removed)
  302
• 13 Renewing flange shaft oil seal (final drive installed)
  305
• 13.1 Renewing flange shaft oil seal (final drive installed)
  305
• 15 Renewing O-rings for rear axle housing cover (final drive installed)
  310
• 15.1 Renewing O-rings for rear axle housing cover (final drive installed)
  310
• 16 Removing and installing rear final drive
  312
• 16.1 Removing and installing rear final drive
  312
• 17 Checking rear final drive oil
  317
• 17.1 Checking rear final drive oil
  317
• 18 Checking oil level in Haldex coupling or changing oil
  317
• 18.1 Checking oil level in Haldex coupling or changing oil
  317
• 18.2 Checking Haldex coupling oil level
  317
• 18.3 Changing oil in Haldex coupling
  319
• 18.4 Changing Haldex coupling oil filter
  320
• 19 Dismantling and assembling rear final drive
  322
• 19.1 Dismantling and assembling rear final drive
  322
• 19.2 Removing and installing Haldex coupling cover and plates
  323
• 19.3 Removing and installing pinion housing
  327
• 19.4 Removing and installing differential and input shaft bevel gear
  331
• 19.5 Removing and installing Haldex coupling plate housing cover
  335
• 19.6 Assembly sequence
  340
• 20 Dismantling and assembling differential
  353
• 20.1 Dismantling and assembling differential
  353
• 21 Servicing shaft bevel gear bearings
  359
• 21.1 Servicing shaft bevel gear bearings
  359
• 22 Servicing input shaft bevel gear bearings
  371
• 22.1 Servicing input shaft bevel gear bearings
  371
• 23 Adjusting bevel gear and shaft bevel gear (gear set)
  381
• 23.1 Adjusting bevel gear and shaft bevel gear (gear set)
  381
• 23.2 General notes
  381
• 23.3 Adjusting and marking of gear sets
  382
• 23.4 Position of shims
  384
• 23.5 Adjustment overview (rear final drive)
  384
• 23.6 Recommended sequence for adjusting gear set
  385
• 23.7 Adjusting shaft bevel gear
  386
• 23.8 Adjusting bevel gear
  391