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
• 2 Transmission layout
  7
• 2.1 Transmission layout
  7
• 3 Calculating overall ratio "i"
  9
• 3.1 Calculating overall ratio "i"
  9
• 4 General repair instructions
  9
• 4.1 General repair instructions
  9
• Clutch
  12
• 1 Servicing clutch mechanism
  12
• 1.1 Servicing clutch mechanism
  12
• 1.2 Checking clutch cable function
  16
• 1.3 Removing and installing clutch cable
  17
• 1.4 Clutch cable on RHD vehicles
  21
• 1.5 Removing and installing clutch pedal
  22
• 2 Servicing clutch release mechanism
  25
• 2.1 Servicing clutch release mechanism
  25
• 3 Servicing clutch
  31
• 3.1 Servicing clutch
  31
• Controls, Housing
  37
• 1 Servicing gear selector mechanism
  37
• 1.1 Servicing gear selector mechanism
  37
• 1.2 Installation position of gear selector mechanism
  37
• 1.3 I - Servicing gear stick housing
  39
• 1.4 II - Servicing gear stick
  42
• 1.5 III - Assembly overview - removing and installing - selector cables
  45
• 1.6 Removing and installing gear change mechanism
  49
• 1.7 Adjusting gear change mechanism
  54
• 2 Removing and installing gearbox
  58
• 2.1 Removing and installing gearbox
  58
• 3 Checking gear oil
  74
• 3.1 Checking gear oil
  74
• 4 Dismantling and assembling gearbox
  76
• 4.1 Dismantling and assembling gearbox
  76
• 4.2 Dismantling and assembling sequence
  83
• 5 Servicing clutch housing
  99
• 5.1 Servicing clutch housing
  99
• 6 Adjusting selector finger and selector sleeve
  110
• 6.1 Adjusting selector finger and selector sleeve
  110
• Gears, Shafts
  113
• 1 Dismantling and assembling input shaft
  113
• 1.1 Dismantling and assembling input shaft
  113
• 2 Adjusting input shaft
  125
• 2.1 Adjusting input shaft
  125
• 3 Dismantling and assembling output shaft
  130
• 3.1 Dismantling and assembling output shaft
  130
• 4 Adjusting output shaft
  146
• 4.1 Adjusting output shaft
  146
• Final drive, Differential rear
  150
• 1 Renewing selector shaft seal with gearbox in situ
  150
• 1.1 Renewing selector shaft seal with gearbox in situ
  150
• 2 Renewing oil seals for flanged shafts with gearbox installed
  152
• 2.1 Renewing oil seals for flanged shafts with gearbox installed
  152
• 3 Dismantling and assembling differential
  154
• 3.1 Dismantling and assembling differential
  154
• 3.2 Removing and installing final drive gear wheel
  162
• 4 Adjustment overview
  166
• 4.1 Adjustment overview
  166
• 5 Adjusting differential
  167
• 5.1 Adjusting differential
  167