5-speed manual gearbox 02Z

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Repair notes
  3
• 3.1 Rules for cleanliness
  3
• 3.2 Special tool
  3
• 3.3 Gearbox
  3
• 3.4 Clutch
  4
• 3.5 Nuts and bolts
  4
• 3.6 Gaskets and seals
  4
• 3.7 Pipe/wire routing and attachment
  5
• 3.8 Locking devices
  5
• 3.9 Mountings
  6
• 3.10 Shims
  6
• 3.11 Synchro-rings
  7
• 3.12 Gear wheels, synchro-hubs
  7
• 3.13 Synchromeshed gears
  7
• 4 Technical data
  8
• 4.1 Capacities
  8
• 4.2 Allocation gearbox - engine
  8
• 4.3 Calculation of gear ratios
  8
• 5 Overview - power transmission
  9
• 5.1 Overview - power transmission - front-wheel drive
  9
• 6 Electrical components
  11
• 6.1 Overview of fitting locations - electrical components
  11
• Clutch
  13
• 1 Clutch mechanism
  13
• 1.1 Assembly overview - pedal cluster
  13
• 1.2 Assembly overview - clutch hydraulics
  15
• 1.3 Assembly overview - clutch release mechanism
  16
• 1.4 Removing and installing clutch pedal
  18
• 1.5 Removing and installing over-centre spring
  22
• 1.6 Removing and installing mounting bracket
  25
• 1.7 Removing and installing bearing bush
  34
• 1.8 Checking clutch master cylinder and clutch slave cylinder
  35
• 1.9 Removing and installing clutch position sender G476
  35
• 1.10 Removing and installing clutch master cylinder
  36
• 1.11 Removing and installing clutch slave cylinder
  37
• 1.12 Bleeding clutch mechanism
  42
• 1.13 Repairing clutch release mechanism
  43
• 2 Clutch
  45
• 2.1 Assembly overview - clutch
  45
• 2.2 Removing and installing clutch
  47
• Controls, housing
  62
• 1 Selector mechanism
  62
• 1.1 Installation position - selector mechanism
  62
• 1.2 Assembly overview - Gear lever and selector housing
  63
• 1.3 Removing and installing selector mechanism
  65
• 1.4 Adjusting selector mechanism
  67
• 1.5 Removing and installing gear selector cable
  70
• 1.6 Removing and installing selector lever handle
  75
• 1.7 Renewing selector shaft seal
  76
• 1.8 Checking selector mechanism
  78
• 2 Removing and installing gearbox
  79
• 2.1 Specified torques for gearbox
  79
• 2.2 Removing gearbox
  79
• 2.3 Installing gearbox
  88
• 3 Assembly mountings
  95
• 3.1 Assembly overview - assembly mountings
  95
• 4 Transporting gearbox
  96
• 5 Dismantling and assembling gearbox
  98
• 5.1 Schematic overview - gearbox
  98
• 5.2 Assembly overview - cover for gearbox housing and 5th gear
  99
• 5.3 Assembly overview - gearbox housing and selector mechanism
  100
• 5.4 Assembly overview - selector unit
  101
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  102
• 5.6 Assembly overview - selector forks
  103
• 5.7 Repairing selector forks
  105
• 5.8 Dismantling and assembling gearbox
  109
• 5.9 Removing cover for gearbox housing and 5th gear
  126
• 5.10 Installing cover for gearbox housing and 5th gear
  133
• 6 Gearbox housing, clutch housing
  140
• 6.1 Assembly overview - gearbox housing
  140
• 6.2 Assembly overview - clutch housing
  142
• 6.3 Repairing gearbox housing
  144
• 6.4 Repairing clutch housing
  151
• 7 Securing to engine and gearbox support
  159
• 8 Gear oil
  161
• 8.1 Checking gear oil level and replenishing gear oil
  161
• Gears, shafts
  163
• 1 Input shaft
  163
• 1.1 Assembly overview - input shaft
  163
• 1.2 Dismantling and assembling input shaft
  165
• 2 Output shaft
  172
• 2.1 Assembly overview - output shaft
  172
• 2.2 Dismantling and assembling output shaft
  175
• 2.3 Adjusting output shaft
  188
• 3 Reverse shaft
  194
• 3.1 Assembly overview - reverse shaft
  194
• 3.2 Dismantling and assembling reverse shaft
  194
• Final drive - differential
  198
• 1 Oil seals
  198
• 1.1 Overview of fitting locations - oil seals
  198
• 1.2 Renewing left seal
  198
• 1.3 Renewing right seal
  202
• 1.4 Renewing input shaft seal
  206
• 2 Differential
  209
• 2.1 Assembly overview - differential
  209
• 2.2 Dismantling and assembling differential
  211
• 2.3 Adjusting differential
  214
• 3 Adjustment overview
  220