5-speed manual gearbox 02T

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Prefix, correspondence, gearbox ratio, filling volume
  2
• 2 gearbox assembly scheme
  3
• 2.1 Nomenclature
  3
• 2.2 Gear ratios
  3
• 3 Gearbox ratio “i”
  5
• 3.1 Gearbox ratio “i” - calculation
  5
• 4 General repair instructions
  6
• 4.1 gearbox
  6
• 4.2 Gaskets and retainers
  6
• 4.3 Screws, nuts
  7
• 4.4 Roller Bearings
  7
• 4.5 Adjustment shims
  8
• 4.6 Synchronizer rings
  8
• Clutch
  9
• 1 Command system
  9
• 1.1 Command system - component overview
  9
• 1.2 Command pedals - assembly overview
  10
• 1.3 Clutch pedal switch F36 - remove and install
  12
• 1.4 Clutch pedal return spring - remove and install
  14
• 1.5 Clutch pedal support - remove and install
  16
• 1.6 Clutch pedal - remove install
  19
• 1.7 Hydraulic system - assembly overview
  20
• 1.8 Transmitting cylinder - clutch hydraulic drive - remove and install
  22
• 2 Clutch drive mechanism
  26
• 2.1 Clutch drive mechanism - assembly overview
  26
• 2.2 Clutch slave cylinder - remove and install
  29
• 2.3 Clutch drive mechanism - bleed
  30
• 3 Clutch
  32
• 3.1 Clutch - assembly overview
  32
• 3.2 Clutch - repair
  33
• Controls, housing
  37
• 1 Shift mechanism
  37
• 1.1 Shift mechanism - installation position
  37
• 1.2 Gearshift mechanism - component overview
  38
• 1.3 Handle and boot on the gear lever - assembly overview
  38
• 1.4 Handle and boot on the gear lever - remove and install
  39
• 1.5 Gearshift lever and mechanism - repair
  41
• 1.6 Drive cables - remove and install
  46
• 1.7 Gearshift mechanism - remove and install
  50
• 1.8 Gear selection mechanism - adjust
  54
• 2 gearbox - remove and install
  59
• 2.1 gearbox - remove and install
  59
• 2.2 Gearbox - transport
  82
• 3 Gearbox oil level
  84
• 3.1 Oil level - check
  84
• 3.2 Oil level - replenish
  85
• 4 gearbox - disassemble and assemble
  87
• 4.1 Gearbox - overview
  87
• 4.2 gearbox - assembly overview
  87
• 4.3 Gearbox housing cover and 5th gear
  88
• 4.4 Clutch housing
  89
• 4.5 Input shaft, planet pinion, differential, selection mechanism and selector forks
  90
• 5 Gearbox and clutch housings
  102
• 5.1 Gearbox and clutch housings - repair
  102
• 6 Gear selection mechanism - adjust
  108
• 6.1 Gear selection mechanism - disassemble and assemble
  108
• 7 Selector forks
  111
• 7.1 Selector forks - disassemble and assemble
  111
• Gears, shafts
  117
• 1 Input shaft
  117
• 1.1 Primary shaft - general overview of assembly
  117
• 1.2 Input shaft - disassemble and assemble
  119
• 2 Planet pinion
  131
• 2.1 Pinion shaft - general overview of assembly
  131
• 2.2 Planet pinion - disassemble and assemble
  134
• Final drive - differential
  142
• 1 Drive flange
  142
• 1.1 Left drive flange retainer (left side) - replace
  142
• 1.2 Drive flange retainer (right side) - replace
  146
• 2 Differential
  149
• 2.1 Differential - general overview of assembly
  149
• 2.2 Differential - disassemble and assemble
  151
• 2.3 Differential - adjust
  159