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
  5
• 2.1 Transmission layout
  5
• 3 Calculating overall ratio "i"
  7
• 3.1 Calculating overall ratio "i"
  7
• 4 General repair instructions
  7
• 4.1 General repair instructions
  7
• Clutch
  10
• 1 Servicing clutch control
  10
• 1.1 Servicing clutch control
  10
• 1.2 Assembly overview - Pedal cluster
  11
• 1.3 Removing and installing over-centre spring
  14
• 1.4 Removing and installing clutch pedal
  15
• 1.5 Removing and installing mounting bracket
  17
• 1.6 Assembly overview - Hydraulic system
  21
• 1.7 Removing and installing master cylinder
  25
• 1.8 Bleeding clutch system
  27
• 2 Servicing clutch release mechanism
  28
• 2.1 Servicing clutch release mechanism
  28
• 3 Servicing clutch
  31
• 3.1 Servicing clutch
  31
• Controls, Housing
  36
• 1 Servicing gear selector mechanism up to 09.99
  36
• 1.1 Servicing gear selector mechanism up to 09.99
  36
• 1.2 Installation position of gear selector mechanism
  36
• 1.3 Removing and installing gear selector cables
  38
• 1.4 Removing and installing gear stick housing
  44
• 1.5 Installing gear stick gaiter to gear stick knob
  47
• 1.6 Removing and installing gear stick
  48
• 1.7 Adjusting gear selector mechanism up to 09.99
  52
• 2 Servicing gear selector mechanism from 10.99
  56
• 2.1 Servicing gear selector mechanism from 10.99
  56
• 2.2 Installation position of gear selector mechanism
  56
• 2.3 Removing and installing selector lever knob and gaiter
  59
• 2.4 Servicing gear stick and gear stick housing
  61
• 2.5 Assembly overview - Removing and installing selector cables
  65
• 2.6 Removing and installing selector mechanism
  68
• 2.7 Adjusting gear selector mechanism from 10.99
  70
• 3 Removing and installing gearbox
  74
• 3.1 Removing and installing gearbox
  74
• 4 Checking gear oil
  88
• 4.1 Checking gear oil
  88
• 5 Dismantling and assembling gearbox
  89
• 5.1 Dismantling and assembling gearbox
  89
• 5.2 Overview
  89
• 5.3 Assembly overview
  91
• 5.4 Removing and installing cover for gearbox housing and 5th gear
  92
• 5.5 Removing and installing gearbox housing and selector mechanism
  95
• 5.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  97
• 5.7 Assembly sequence
  100
• 6 Servicing gearbox housing and clutch housing
  118
• 6.1 Servicing gearbox housing and clutch housing
  118
• 7 Dismantling and assembling gearbox selector mechanism up to 09.99
  128
• 7.1 Dismantling and assembling gearbox selector mechanism up to 09.99
  128
• 8 Dismantling and assembling gearbox selector mechanism from 10.99
  133
• 8.1 Dismantling and assembling gearbox selector mechanism from 10.99
  133
• 9 Dismantling and assembling selector forks
  139
• 9.1 Dismantling and assembling selector forks
  139
• Gears, Shafts
  146
• 1 Dismantling and assembling input shaft
  146
• 1.1 Dismantling and assembling input shaft
  146
• 2 Adjusting input shaft
  160
• 2.1 Adjusting input shaft
  160
• 2.2 Table of adjustment shims
  162
• 2.3 Performing measurement check
  164
• 3 Dismantling and assembling output shaft
  165
• 3.1 Dismantling and assembling output shaft
  165
• 4 Adjusting output shaft
  195
• 4.1 Adjusting output shaft
  195
• 5 Dismantling and assembling reverse shaft
  198
• 5.1 Dismantling and assembling reverse shaft
  198
• Final drive, Differential rear
  203
• 1 Renewing flanged shaft oil seals (gearbox installed)
  203
• 1.1 Renewing flanged shaft oil seals (gearbox installed)
  203
• 2 Dismantling and assembling differential
  206
• 2.1 Dismantling and assembling differential
  206
• 3 Adjustment overview
  220
• 3.1 Adjustment overview
  220
• 4 Adjusting differential
  221
• 4.1 Adjusting differential
  221