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

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Code letters, allocation, ratios, capacities
  1
• 2 Identifying rear final drive
  3
• 2.1 Location on final drive
  3
• 2.2 Code letters, allocation, ratios, capacities
  3
• 3 Overview - power transmission
  5
• 4 Calculating overall gear ratio “i”
  7
• 5 Notes on performance test
  8
• 6 General repair instructions
  9
• 6.1 Components
  9
• Clutch
  11
• 1 Repairing clutch mechanism
  11
• 1.1 Assembly overview - pedal cluster
  12
• 1.2 Removing and installing clutch pedal
  13
• 1.3 Assembly overview - hydraulics and clutch release mechanism
  13
• 1.4 Removing and installing over-centre spring
  15
• 1.5 Bleeding clutch system
  16
• 2 Repairing clutch
  18
• Controls, housing
  21
• 1 Repairing selector mechanism
  21
• 1.1 Installation position of selector mechanism
  21
• 1.2 Removing and installing selector housing
  23
• 1.3 Removing and installing gear selector rod and gate selector rod
  24
• 1.4 Removing and installing gear lever
  30
• 1.5 Removing and installing cover for selector housing
  32
• 1.6 Removing and installing selector mechanism
  33
• 1.7 Adjusting selector mechanism
  35
• 1.8 Installation position of selector mechanism
  37
• 1.9 Removing and installing selector housing
  39
• 1.10 Removing and installing gear selector rod and gate selector rod
  40
• 1.11 Removing and installing gear lever
  42
• 1.12 Removing and installing selector mechanism
  44
• 1.13 Adjusting selector mechanism
  46
• 2.2 Removing and installing control element for differential lock
  50
• 2.3 Adjusting differential lock
  51
• 2.4 Removing and installing control element for freewheel lock
  51
• 3.1 Routing diagram for vehicles with diesel engine
  54
• 4 Removing and installing gearbox and bevel box
  60
• 4.1 Removing
  62
• 4.2 Transporting gearbox
  67
• 4.3 Installing
  68
• 5 Removing and installing bevel box
  72
• 5.1 Removing
  72
• 5.2 Installing
  75
• 6 Checking oil in manual gearbox with bevel box
  77
• 7 Dismantling and assembling gearbox
  78
• 7.1 Assembly overview
  78
• 7.2 Dismantling and assembling gearbox housing and selector mechanism
  80
• 7.4 Assembly procedure
  82
• 8 Repairing gearbox housing
  88
• 9 Repairing clutch housing
  93
• 10 Dismantling and assembling selector mechanism in gearbox
  99
• Gears, shafts
  102
• 1 Input shaft
  102
• 1.1 Dismantling and assembling input shaft
  102
• 1.2 Adjusting input shaft
  109
• 2 Output shaft
  114
• 2.1 Dismantling and assembling output shaft
  114
• 2.2 Adjusting output shaft
  128
• 3 Removing and installing gear wheel for reverse gear
  133
• Final drive - rear differential
  136
• 1 Two-part propshaft
  136
• 1.1 Removing and installing two-part propshaft
  136
• 1.2 Removing and installing two-part propshaft support on underbody
  138
• 1.3 Repairing two-part propshaft
  138
• 2 Three-part propshaft
  146
• 2.1 Removing and installing three-part propshaft
  146
• 2.2 Removing and installing three-part propshaft supports on underbody
  148
• 2.3 Repairing three-part propshaft
  150
• 3 Checking function of viscous coupling
  159
• 4 Removing and installing viscous coupling
  160
• 4.1 Removing
  160
• 4.2 Installing
  161
• 5 Renewing viscous coupling seal in rear final drive (final drive installed)
  163
• 6 Renewing flange shaft or drive flange oil seals (final drive installed)
  164
• 6.1 Renewing seal for right flange shaft
  164
• 6.2 Renewing left drive flange oil seal
  165
• 7 Checking function of freewheel
  169
• 8 Checking function of freewheel lock
  170
• 9 Removing and installing rear final drive
  171
• 9.1 Removing
  171
• 9.2 Installing
  172
• 10 Checking gear oil in rear final drive
  174
• 11 Dismantling and assembling rear final drive
  175
• 11.1 Removing and installing viscous coupling and pinion housing
  176
• 11.2 Removing and installing differential and freewheel lock
  177
• 11.4 Assembly procedure
  180
• 12 Dismantling and assembling differential and freewheel
  189
• 12.1 Assembly overview
  189
• 12.2 Dismantling and assembling differential (procedure)
  191
• 12.3 Removing and installing freewheel (procedure)
  194
• 12.4 Dismantling and assembling freewheel (procedure)
  195
• 13 Repairing shaft bevel gear bearing
  197
• 13.1 Assembly overview
  197
• 13.2 Assembly procedure
  198
• 14 Repairing bearing for bevel gear with stub shaft
  203
• 14.1 Assembly overview
  203
• 14.2 Assembly procedure
  207
• 15 Dismantling and assembling differential lock control
  214
• 16.1 General information
  215
• 16.2 Adjustment and marking of final drive gear sets
  215
• 16.3 Position of shims
  216
• 16.4 Adjustment overview - rear final drive
  216
• 16.5 Determining fitting position of shaft bevel gear (actual values)
  217
• 16.6 Recommended sequence for new adjustment of final drive gear set
  217
• 16.7 Adjusting shaft bevel gear
  218
• 16.8 Adjusting bevel gear (with stub shaft)
  221
• Final drive - front differential
  227
• 1 Removing and installing oil seal for drive flange or flange shaft
  227
• 2 Renewing oil seal for drive flange and bevel box
  231
• 3 Adjustment overview
  236
• 4 Differential
  237
• 4.1 Dismantling and assembling differential
  237
• 4.2 Adjusting differential
  246
• 5 Dismantling and assembling bevel box
  251
• 5.1 Assembly overview
  251
• 5.2 Assembly procedure
  254
• 6.1 General information
  268
• 6.2 Adjustment and marking of final drive gear sets
  268
• 6.3 Position of shims
  269
• 6.4 Adjustment overview - bevel box
  269
• 6.5 Recommended sequence for new adjustment of final drive gear set
  270
• 6.6 Adjusting shaft bevel gear
  270
• 6.7 Adjusting bevel gear (with stub shaft)
  277