5-speed manual gearbox 02Z

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 2 Technical data
  2
• 2.1 Technical data, gearbox
  2
• 2.2 Calculating overall gear ratio “i”
  8
• 3 Overview - power transmission
  10
• 3.1 Overview - power transmission
  10
• 4 Repair notes
  12
• 4.1 General repair instructions
  12
• 5 Electrical components
  15
• 5.1 Overview of fitting locations - electrical components, manual gearbox
  15
• 5.2 Overview of fitting locations – electrical components, clutch mechanism
  15
• Clutch
  16
• 1 Clutch operation
  16
• 1.1 Assembly overview - pedal cluster
  16
• 1.2 Assembly overview - clutch hydraulics
  18
• 1.3 Assembly overview - clutch release mechanism
  20
• 1.4 Removing and installing clutch pedal switch F36
  22
• 1.5 Removing and installing mounting bracket for clutch pedal
  22
• 1.6 Removing and installing clutch pedal with mounting bracket removed
  24
• 1.8 Removing and installing clutch master cylinder
  26
• 1.9 Removing and installing clutch slave cylinder
  31
• 1.10 Bleeding clutch mechanism
  34
• 2 Clutch
  35
• 2.1 Assembly overview - clutch
  35
• 2.2 Removing and installing clutch
  37
• Controls, housing
  40
• 1 Selector mechanism
  40
• 1.1 Installation position - selector mechanism
  40
• 1.2 Assembly overview - gear knob and cover
  42
• 1.3 Assembly overview - Gear lever and selector housing
  43
• 1.5 Assembly overview - selector cables
  47
• 1.6 Removing and installing selector mechanism
  49
• 1.7 Distinguishing between selector mechanisms
  51
• 1.8 Adjusting selector mechanism in neutral, selector gate for 1st and 2nd gears
  52
• 1.9 Adjusting selector mechanism with 2nd gear engaged
  55
• 1.10 Renewing selector shaft seal
  59
• 1.11 Removing and installing relay lever
  60
• 2 Removing and installing gearbox
  63
• 2.1 Specified torques for gearbox
  63
• 2.2 Removing gearbox
  63
• 2.3 Removing gearbox, 2010►
  69
• 2.4 Installing gearbox
  76
• 2.5 Installing gearbox, 2010►
  80
• 3 Transporting gearbox
  86
• 3.1 Transporting gearbox
  86
• 4 Gear oil
  87
• 4.1 Checking gear oil level
  87
• 5 Dismantling and assembling gearbox
  88
• 5.1 Schematic overview - gearbox
  88
• 5.2 Assembly overview - cover for gearbox housing and 5th gear
  90
• 5.3 Assembly overview - gearbox housing and selector mechanism
  91
• 5.4 Assembly overview - selector unit
  92
• 5.5 Assembly overview - input shaft, output shaft, differential and selector forks
  93
• 5.6 Assembly overview - selector forks
  94
• 5.7 Dismantling and assembling gearbox
  95
• 5.8 Dismantling and assembling selector unit
  108
• 5.9 Dismantling and assembling selector forks
  109
• 5.10 Removing cover for gearbox housing and 5th gear
  113
• 5.11 Installing cover for gearbox housing and 5th gear
  120
• 6 Gearbox housing, clutch housing
  124
• 6.1 Assembly overview - gearbox housing
  124
• 6.2 Assembly overview - clutch housing
  125
• 6.3 Repairing gearbox housing
  127
• 6.4 Repairing clutch housing
  134
• Gears, shafts
  141
• 1 Input shaft
  141
• 1.1 Assembly overview - input shaft
  141
• 1.2 Dismantling and assembling input shaft
  142
• 2 Output shaft
  149
• 2.1 Assembly overview - output shaft
  149
• 2.2 Dismantling and assembling output shaft
  151
• 2.3 Adjusting output shaft
  163
• 3 Reverse shaft
  168
• 3.1 Assembly overview - reverse shaft
  168
• 3.2 Dismantling and assembling reverse shaft
  169
• Final drive - differential
  171
• 1 Oil seals
  171
• 1.1 Overview of fitting locations - seals
  171
• 1.2 Renewing left seal
  172
• 1.3 Renewing right oil seal
  173
• 1.4 Renewing input shaft seal
  177
• 2 Differential
  180
• 2.1 Assembly overview - differential
  180
• 2.2 Dismantling and assembling differential
  182
• 2.3 Adjusting differential
  185
• 3 Adjustment overview
  190