5-speed manual gearbox 085

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, gearbox allocation, ratios, capacities
  2
• 1.3 Code letters, gearbox allocation, ratios, capacities 2
  9
• 2 Transmission layout
  18
• 2.1 Transmission layout
  18
• 3 Calculating overall ratio "i"
  20
• 3.1 Calculating overall ratio "i"
  20
• 4 General repair instructions
  20
• 4.1 General repair instructions
  20
• Clutch
  22
• 1 Servicing clutch control
  22
• 1.1 Servicing clutch control
  22
• 1.2 Checking clutch cable function
  25
• 1.3 Removing and installing clutch cable (up to 26.04.95)
  27
• 1.4 Modifications to clutch cable (from 27.04.95)
  30
• 1.5 Removing and installing clutch cable (from 27.04.95)
  31
• 1.6 Clutch cable on RHD vehicles (from 27 04. 95)
  35
• 1.7 Removing and installing clutch pedal
  37
• 2 Servicing clutch release mechanism
  40
• 2.1 Servicing clutch release mechanism
  40
• 3 Servicing clutch
  45
• 3.1 Servicing clutch
  45
• Controls, Housing
  51
• 1 Servicing selector mechanism (rod selector mechanism)
  51
• 1.1 Servicing selector mechanism (rod selector mechanism)
  51
• 1.2 I - Servicing gear stick housing and selector rod
  52
• 1.3 Installing gear stick gaiter to gear stick knob
  55
• 1.4 II - Servicing gear stick and cable
  56
• 1.5 Removing and installing gear change mechanism
  60
• 1.6 Adjusting selector mechanism (rod selector mechanism)
  64
• 2 Servicing selector mechanism (cable selector mechanism)
  68
• 2.1 Servicing selector mechanism (cable selector mechanism)
  68
• 2.2 Installation position of gear selector mechanism
  68
• 2.3 I - Servicing gear stick housing
  70
• 2.4 Installing gear stick gaiter to gear stick knob
  72
• 2.5 II - Servicing gear stick
  73
• 2.6 III - Assembly overview - removing and installing - selector cables
  76
• 2.7 Removing and installing gear selector mechanism
  82
• 2.8 Adjusting gear selector mechanism (cable control gear selection)
  84
• 3 Removing and installing gearbox
  87
• 3.1 Removing and installing gearbox
  87
• 4 Checking gear oil
  102
• 4.1 Checking gear oil
  102
• 5 Dismantling and assembling gearbox
  103
• 5.1 Dismantling and assembling gearbox
  103
• 5.2 Dismantling and assembling sequence
  111
• 6 Servicing clutch housing
  125
• 6.1 Servicing clutch housing
  125
• 7 Adjusting selector finger and selector sleeve
  134
• 7.1 Adjusting selector finger and selector sleeve
  134
• Gears, Shafts
  136
• 1 Dismantling and assembling input shaft
  136
• 1.1 Dismantling and assembling input shaft
  136
• 2 Adjusting input shaft
  145
• 2.1 Adjusting input shaft
  145
• 3 Dismantling and assembling output shaft
  148
• 3.1 Dismantling and assembling output shaft
  148
• 4 Adjusting output shaft
  163
• 4.1 Adjusting output shaft
  163
• Final drive, Differential rear
  166
• 1 Renewing selector shaft seal with gearbox in situ
  166
• 1.1 Renewing selector shaft seal with gearbox in situ
  166
• 2 Renewing oil seals for flanged shafts with gearbox installed
  168
• 2.1 Renewing oil seals for flanged shafts with gearbox installed
  168
• 3 Dismantling and assembling differential
  170
• 3.1 Dismantling and assembling differential
  170
• 3.2 Removing and installing final drive gear wheel
  177
• 4 Adjustment overview
  180
• 4.1 Adjustment overview
  180
• 5 Adjusting differential
  180
• 5.1 Adjusting differential
  180