5-speed manual gearbox 02J

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
  8
• 1 Servicing clutch control
  8
• 1.1 Servicing clutch control
  8
• 1.2 Assembly overview - pedal cluster
  9
• 1.3 Removing and installing over-centre spring
  13
• 1.4 Removing and installing clutch pedal
  14
• 1.5 Assembly overview - Hydraulic system
  16
• 1.6 Removing and installing master cylinder
  19
• 1.7 Bleeding clutch system
  22
• 2 Servicing clutch release mechanism
  22
• 2.1 Servicing clutch release mechanism
  22
• 3 Servicing clutch
  25
• 3.1 Servicing clutch
  25
• Controls, Housing
  30
• 1 Servicing gear selector mechanism
  30
• 1.1 Servicing gear selector mechanism
  30
• 1.2 Installation position of gear selector mechanism
  30
• 1.3 Assembly overview - removing and installing selector cables
  32
• 1.4 Removing and installing gear selector mechanism
  37
• 1.5 Servicing gear stick housing
  39
• 1.6 Servicing gear stick
  42
• 1.7 Adjusting selector mechanism
  46
• 2 Removing and installing gearbox
  50
• 2.1 Removing and installing gearbox
  50
• 3 Checking gear oil
  64
• 3.1 Checking gear oil
  64
• 4 Dismantling and assembling gearbox
  66
• 4.1 Dismantling and assembling gearbox
  66
• 4.2 Overview
  66
• 4.3 Assembly overview
  68
• 4.4 Removing and installing cover for gearbox housing and 5th gear
  69
• 4.5 Removing and installing gearbox housing and selector mechanism
  72
• 4.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  74
• 4.7 Assembly sequence
  77
• 5 Servicing gearbox housing and clutch housing
  95
• 5.1 Servicing gearbox housing and clutch housing
  95
• 6 Dismantling and assembling gearbox selector mechanism
  105
• 6.1 Dismantling and assembling gearbox selector mechanism
  105
• 7 Dismantling and assembling selector forks
  110
• 7.1 Dismantling and assembling selector forks
  110
• Gears, Shafts
  117
• 1 Dismantling and assembling input shaft
  117
• 1.1 Dismantling and assembling input shaft
  117
• 2 Adjusting input shaft
  130
• 2.1 Adjusting input shaft
  130
• 2.2 Table of adjustment shims
  132
• 2.3 Performing measurement check
  134
• 3 Dismantling and assembling output shaft
  135
• 3.1 Dismantling and assembling output shaft
  135
• 4 Adjusting output shaft
  165
• 4.1 Adjusting output shaft
  165
• 5 Dismantling and assembling reverse shaft
  168
• 5.1 Dismantling and assembling reverse shaft
  168
• Final drive, Differential
  173
• 1 Renewing flanged shaft oil seals (gearbox installed)
  173
• 1.1 Renewing flanged shaft oil seals (gearbox installed)
  173
• 2 Dismantling and assembling differential
  176
• 2.1 Dismantling and assembling differential
  176
• 3 Adjustment overview
  189
• 3.1 Adjustment overview
  189
• 4 Adjusting differential
  190
• 4.1 Adjusting differential
  190