5-speed manual gearbox 02T

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 over-centre spring
  12
• 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 Removing and installing slave cylinder
  23
• 1.8 Bleeding clutch system
  24
• 2 Servicing clutch release mechanism
  26
• 2.1 Servicing clutch release mechanism
  26
• 3 Servicing clutch
  29
• 3.1 Servicing clutch
  29
• Controls, Housing
  34
• 1 Servicing gear selector mechanism
  34
• 1.1 Servicing gear selector mechanism
  34
• 1.2 Installation position of gear selector mechanism
  34
• 1.3 Removing and installing selector lever knob and gaiter
  37
• 1.4 Servicing gear stick and gear stick housing
  39
• 1.5 Assembly overview - removing and installing selector cables
  43
• 1.6 Removing and installing gear selector mechanism
  47
• 1.7 Adjusting gear selector mechanism
  50
• 2 Removing and installing gearbox
  54
• 2.1 Removing and installing gearbox
  54
• 3 Checking gear oil
  68
• 3.1 Checking gear oil
  68
• 4 Dismantling and assembling gearbox
  69
• 4.1 Dismantling and assembling gearbox
  69
• 4.2 Overview
  69
• 4.3 Removing and installing cover for gearbox housing and 5th gear
  72
• 4.4 Removing and installing clutch housing
  74
• 4.6 Assembly sequence
  79
• 5 Servicing gearbox housing and clutch housing
  89
• 5.1 Servicing gearbox housing and clutch housing
  89
• 6 Dismantling and assembling gearbox selector mechanism
  97
• 6.1 Dismantling and assembling gearbox selector mechanism
  97
• 7 Dismantling and assembling selector forks
  100
• 7.1 Dismantling and assembling selector forks
  100
• Gears, Shafts
  108
• 1 Dismantling and assembling input shaft
  108
• 1.1 Dismantling and assembling input shaft
  108
• 2 Dismantling and assembling output shaft
  124
• 2.1 Dismantling and assembling output shaft
  124
• Final drive, Differential
  139
• 1 Renewing oil seals for flanged shafts
  139
• 1.1 Renewing oil seals for flanged shafts
  139
• 1.2 Renewing oil seal for left flanged shaft
  139
• 1.3 Renewing oil seal for right flanged shaft
  142
• 2 Dismantling and assembling differential
  144
• 2.1 Dismantling and assembling differential
  144
• 3 Adjusting differential
  157
• 3.1 Adjusting differential
  157