5-speed manual gearbox 02K

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox through 06.99
  1
• 1.2 Location on gearbox from 07.99
  1
• 1.3 Codes and date of manufacture arrow 1
  1
• 1.4 Identification code, assembly allocation, ratios, capacities
  2
• 2 Overview - power transmission
  4
• 3 Calculating overall gear ratio “i”
  6
• 4 General repair notes
  7
• 4.1 Components
  7
• Clutch
  10
• 1 Repairing clutch mechanism
  10
• 1.1 Overview
  10
• 1.2 Assembly overview - pedal cluster
  11
• 1.3 Distinguishing between clutch pedal switches F36
  12
• 1.4 Removing and installing clutch pedal switch F36 with rectangular housing
  12
• 1.5 Removing and installing clutch pedal switch F36 with round housing
  13
• 1.6 Removing and installing over-centre spring
  13
• 1.7 Removing and installing clutch pedal
  15
• 1.8 Assembly overview - hydraulic system
  16
• 1.9 Removing and installing master cylinder
  17
• 1.10 Bleeding clutch system
  20
• 2 Repairing clutch
  22
• 2.1 Removing and installing clutch
  23
• Controls, housing
  26
• 1 Repairing selector mechanism
  26
• 1.1 Installation position of selector mechanism
  26
• 1.2 Assembly overview - selector lever housing and selector lever
  28
• 1.3 Removing and installing selector lever and selector rod
  29
• 1.4 Removing selector lever from and installing in selector lever housing
  31
• 1.5 Assembly overview - gear selector relay points on gearbox
  32
• 1.6 Adjusting selector mechanism
  37
• 2 Removing and installing gearbox
  42
• 2.1 Removing gearbox
  43
• 2.2 Transporting gearbox
  48
• 2.3 Installing gearbox
  49
• 3 Checking gearbox oil
  55
• 4 Dismantling and assembling gearbox
  56
• 4.1 Overview - gearbox
  56
• 4.2 Assembly overview
  57
• 4.3 Removing and installing cover for gearbox housing and 5th gear
  58
• 4.4 Removing and installing gearbox housing and selector mechanism
  59
• 4.6 Dismantling and assembling procedure
  63
• 5 Repairing gearbox housing and selector shaft
  80
• 6 Repairing clutch housing
  84
• 7 Repairing gearbox housing cover
  89
• Gears, shafts
  93
• 1 Input shaft
  93
• 1.1 Dismantling and assembling input shaft
  93
• 2 Output shaft
  101
• 2.1 Dismantling and assembling output shaft
  101
• 2.2 Adjusting output shaft
  106
• Final drive - differential
  109
• 1 Renewing flange shaft oil seals (gearbox installed)
  109
• 1.1 Removing
  109
• 1.2 Installing
  110
• 2 Adjustment overview
  111
• 3 Differential
  112
• 3.1 Dismantling and assembling differential
  112
• 3.2 Adjusting differential
  119