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
  10
• 2.1 Transmission layout
  10
• 3 Calculating overall ratio "i"
  12
• 3.1 Calculating overall ratio "i"
  12
• 4 General repair instructions
  12
• 4.1 General repair instructions
  12
• Clutch
  15
• 1 Servicing clutch control
  15
• 1.1 Servicing clutch control
  15
• 1.2 Assembly overview
  15
• 1.3 Checking function of clutch cable (automatic adjustment)
  19
• 1.4 Removing and installing clutch cable (automatic adjustment)
  20
• 1.5 Removing and installing clutch cable (no automatic adjustment)
  27
• 1.6 Removing and installing clutch pedal
  29
• 2 Servicing clutch release mechanism
  31
• 2.1 Servicing clutch release mechanism
  31
• 3 Servicing clutch
  36
• 3.1 Servicing clutch
  36
• Controls, Housing
  40
• 1 Servicing gear selector mechanism
  40
• 1.1 Servicing gear selector mechanism
  40
• 1.2 Assembly overview
  40
• 1.3 Installing gear stick gaiter to gear stick knob
  46
• 1.4 Removing and installing selector mechanism complete
  47
• 1.5 Adjusting gear selector mechanism
  49
• 2 Removing and installing gearbox
  52
• 2.1 Removing and installing gearbox
  52
• 3 Checking gearbox oil
  63
• 3.1 Checking gearbox oil
  63
• 4 Dismantling and assembling gearbox
  64
• 4.1 Dismantling and assembling gearbox
  64
• 4.2 Dismantling and assembling sequence
  70
• 5 Servicing clutch housing
  84
• 5.1 Servicing clutch housing
  84
• 6 Adjusting selector finger and selector sleeve
  92
• 6.1 Adjusting selector finger and selector sleeve
  92
• Gears, Shafts
  95
• 1 Dismantling and assembling input shaft
  95
• 1.1 Dismantling and assembling input shaft
  95
• 2 Adjusting input shaft
  104
• 2.1 Adjusting input shaft
  104
• 3 Dismantling and assembling output shaft
  107
• 3.1 Dismantling and assembling output shaft
  107
• 4 Adjusting output shaft
  122
• 4.1 Adjusting output shaft
  122
• Final drive, Differential rear
  125
• 1 Renewing selector shaft seal with gearbox in situ
  125
• 1.1 Renewing selector shaft seal with gearbox in situ
  125
• 2 Removing and installing oil seals for flanged shafts
  126
• 2.1 Removing and installing oil seals for flanged shafts
  126
• 2.2 Renewing oil seals for flanged shafts with gearbox installed
  127
• 3 Dismantling and assembling differential
  129
• 3.1 Dismantling and assembling differential
  129
• 3.2 Removing and installing final drive gear wheel
  136
• 4 Adjustment overview
  139
• 4.1 Adjustment overview
  139
• 5 Adjusting differential
  139
• 5.1 Adjusting differential
  139