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
  3
• 2.1 Transmission layout
  3
• 3 Calculating overall ratio "i"
  5
• 3.1 Calculating overall ratio "i"
  5
• 4 General repair instructions
  5
• 4.1 General repair instructions
  5
• 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 clutch pedal
  13
• 1.4 Removing and installing over-centre spring
  16
• 1.5 Assembly overview - Hydraulic system
  18
• 1.6 Removing and installing master cylinder
  21
• 1.7 Bleeding clutch system
  24
• 2 Servicing clutch release mechanism
  25
• 2.1 Servicing clutch release mechanism
  25
• 3 Servicing clutch
  28
• 3.1 Servicing clutch
  28
• Controls, Housing
  33
• 1 Servicing gear selector mechanism
  33
• 1.1 Servicing gear selector mechanism
  33
• 1.2 Installation position of gear selector mechanism
  33
• 1.3 Removing and installing selector lever knob and gaiter
  36
• 1.4 Servicing gear stick and gear stick housing
  38
• 1.5 Assembly overview - removing and installing selector cables
  42
• 1.6 Removing and installing gear selector mechanism
  45
• 1.7 Adjusting gear selector mechanism
  47
• 2 Removing and installing gearbox
  51
• 2.1 Removing and installing gearbox
  51
• 3 Checking gear oil
  65
• 3.1 Checking gear oil
  65
• 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
  111
• 7.1 Dismantling and assembling selector forks
  111
• Gears, Shafts
  118
• 1 Dismantling and assembling input shaft
  118
• 1.1 Dismantling and assembling input shaft
  118
• 2 Adjusting input shaft
  131
• 2.1 Adjusting input shaft
  131
• 2.2 Table of adjustment shims
  133
• 2.3 Performing measurement check
  135
• 3 Dismantling and assembling output shaft
  136
• 3.1 Dismantling and assembling output shaft
  136
• 4 Adjusting output shaft
  166
• 4.1 Adjusting output shaft
  166
• 5 Dismantling and assembling reverse shaft
  169
• 5.1 Dismantling and assembling reverse shaft
  169
• Final drive, Differential rear
  174
• 1 Renewing oil seals for flanged shafts
  174
• 1.1 Renewing oil seals for flanged shafts
  174
• 1.2 Renewing oil seal for left flanged shaft
  174
• 1.3 Renewing oil seal for right flanged shaft
  177
• 2 Dismantling and assembling differential
  180
• 2.1 Dismantling and assembling differential
  180
• 3 Adjustment overview
  193
• 3.1 Adjustment overview
  193
• 4 Adjusting differential
  194
• 4.1 Adjusting differential
  194