5-speed manual gearbox 02T and 0AP

Chapter overview

• Technical data
  1
• 1 Transmission identification
  1
• 1.1 Location on transmission
  1
• 1.2 Prefix, correspondence, transmission ratio, filling volume
  1
• 2 Transmission assembly scheme
  4
• 2.1 Nomenclature
  4
• 2.2 Gear ratios
  5
• 3 Gear ratio calculation“i”
  6
• 4 General repair instructions
  7
• 4.1 Gearbox
  7
• 4.2 Gaskets and retainers
  7
• 4.3 Screws, nuts
  8
• 4.4 Roller Bearings
  8
• 4.5 Adjustment shims
  8
• 4.6 Synchronizer rings
  8
• Clutch - control system
  9
• 1 Control system - repair
  9
• 1.1 I - Command pedals - assembly overview
  9
• 1.2 Clutch pedal switch F36 with rectangular case - remove and install
  11
• 1.3 Clutch pedal switch F36 with round case - remove and install
  12
• 1.4 Clutch pedal return spring - remove and install
  12
• 1.5 Clutch pedal support - remove and install
  13
• 1.6 Clutch pedal - remove install
  16
• 1.7 II - Hydraulic system - assembly overview
  18
• 1.8 Transmitting cylinder - clutch hydraulic drive - remove and install
  19
• 1.9 Clutch hydraulic drive slave cylinder - remove and install
  21
• 1.10 Clutch system - bleed
  22
• 2 Clutch drive mechanism - repair
  24
• 3 Clutch - repair
  26
• Drive, housing
  29
• 1 Shift mechanism
  29
• 1.1 Shift mechanism - Installation position
  29
• 1.2 I - Drive cables
  32
• 1.3 II - Handle and bellows on the gearshift lever - assembly overview
  36
• 1.4 Handle and bellows on the gearshift lever - remove and install
  37
• 1.5 Handle and caul on the gearshift lever - disassemble and assemble
  38
• 1.6 III - Gearshift lever and mechanism - repair
  39
• 1.7 Gearshift mechanism - remove and install
  41
• 1.8 Gear selection mechanism - adjust
  43
• 2 Transmission - remove and install
  48
• 2.1 Removal
  49
• 2.2 Installation
  56
• 3 Transmission oil level - check and replenish
  63
• 3.1 Oil level - check
  63
• 3.2 Oil level - replenish
  63
• 4 Transmission - disassemble and assemble
  65
• 4.1 Transmission overview
  65
• 4.2 Transmission - assembly overview
  66
• 4.3 I - Gearcase housing cover and 5nd. gear
  67
• 4.4 II - Clutch case
  68
• 5 Transmission and clutch cases - repair
  78
• 6 Gear selection mechanism - disassemble and assemble
  84
• 7 Selection forks - disassemble and assemble
  86
• Gears and shafts
  90
• 1 Primary shaft - disassemble and assemble
  90
• 2 Pinion shaft - disassemble and assemble
  101
• Transmission shafts, differential
  109
• 1 Retainer for the propelling flange - replace
  109
• 1.1 Left propelling flange retainer - replace
  109
• 1.2 Right propelling flange retainer - replace
  110
• 2 Differential - repair
  113
• 2.1 Differential - disassemble and assemble
  113
• 3 Differential - adjust
  122