5-speed manual gearbox 02K from 10.99

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, assembly 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
  9
• 1 Servicing clutch control
  9
• 1.1 Servicing clutch control
  9
• 1.2 Assembly overview - Pedal cluster
  10
• 1.3 Removing and installing over-centre spring
  13
• 1.4 Removing and installing clutch pedal
  14
• 1.5 Removing and installing mounting bracket
  16
• 1.6 Assembly overview - Hydraulic system
  20
• 1.7 Removing and installing master cylinder
  23
• 1.8 Bleeding clutch system
  25
• 2 Servicing clutch
  26
• 2.1 Servicing clutch
  26
• 2.2 Removing and installing clutch
  29
• Controls, Housing
  32
• 1 Servicing gear selector mechanism
  32
• 1.1 Servicing gear selector mechanism
  32
• 1.2 Installation position of gear selector mechanism
  32
• 1.3 Removing and installing selector lever knob and gaiter
  35
• 1.4 Assembly overview - Gearstick housing/gearstick
  36
• 1.5 Assembly overview - gear selector relay points at gearbox
  41
• 1.6 Removing and installing gear stick lever/selector rod
  45
• 1.7 Adjusting gear selector mechanism
  47
• 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
  65
• 4.1 Dismantling and assembling gearbox
  65
• 4.2 Overview
  66
• 4.3 Assembly overview
  67
• 4.4 Removing and installing gearbox housing cover and 5th gear
  68
• 4.5 Removing and installing gearbox housing and selector mechanism
  70
• 4.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  74
• 4.7 Dismantling and assembling sequence
  80
• 5 Servicing gearbox housing and selector shaft
  100
• 5.1 Servicing gearbox housing and selector shaft
  100
• 6 Servicing clutch housing
  107
• 6.1 Servicing clutch housing
  107
• 7 Servicing gearbox housing cover
  115
• 7.1 Servicing gearbox housing cover
  115
• Gears, Shafts
  120
• 1 Dismantling and assembling input shaft
  120
• 1.1 Dismantling and assembling input shaft
  120
• 2 Dismantling and assembling output shaft
  132
• 2.1 Dismantling and assembling output shaft
  132
• 3 Adjusting output shaft
  143
• 3.1 Adjusting output shaft
  143
• Final drive, Differential
  147
• 1 Renewing flanged shaft oil seals (gearbox installed)
  147
• 1.1 Renewing flanged shaft oil seals (gearbox installed)
  147
• 2 Dismantling and assembling differential
  150
• 2.1 Dismantling and assembling differential
  150
• 3 Adjustment overview
  161
• 3.1 Adjustment overview
  161
• 4 Adjusting differential
  162
• 4.1 Adjusting differential
  162