5 - Speed automated transmission (ASG) 0C3

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Prefix, correspondence, and gear ratio
  1
• 1.3 Gearbox oil, supply capacity
  2
• 2 Transmission assembly scheme
  3
• 2.1 Nomenclature
  3
• 2.2 Gear ratios
  4
• 3 Gearbox ratio “i”
  5
• 3.1 Gear ratio calculation “i”
  5
• 4 General repair instructions
  6
• 4.1 Gearbox
  6
• 4.2 Gaskets and retainers
  6
• 4.3 Screws, nuts
  7
• 4.4 Roller bearings
  7
• 4.5 Adjustment shims
  8
• 4.6 Synchronizer rings
  8
• Clutch
  9
• 1 Hydraulic system
  9
• 1.1 Hydraulic system - assembly overview
  9
• 1.2 Clutch slave cylinder - remove and install
  10
• 2 Clutch drive mechanism
  13
• 2.1 Clutch drive mechanism - assembly overview
  13
• 3 Clutch
  15
• 3.1 Clutch - assembly overview
  15
• 3.2 Clutch - repair
  17
• Controls, housing
  19
• 1 Vehicle diagnostic and service information system
  19
• 1.1 Diagnosis, measurement and information system - connect
  19
• 2 Electronic components and installation locations
  20
• 2.1 Electric and electronic components - overview
  20
• 2.3 Sensor 2 for gear detection G616
  23
• 2.4 Gearbox input speed sender G182
  24
• 2.5 Gear detection sensor G604
  25
• 2.6 Diagnosis socket
  26
• 2.7 Selector lever position display Y6
  27
• 2.8 Automatic gearbox control unit J217
  27
• 3 Selector lever
  29
• 3.1 Selector lever - assembly overview
  29
• 3.2 Selector lever handle - remove and install
  30
• 3.3 Upper selector lever cover - remove and install
  31
• 3.4 Selector lever - remove and install
  32
• 3.5 Lower selector lever cover - remove and install
  33
• 3.6 Selection lever boot - adjust
  34
• 3.7 Selector lever operation - check
  35
• 4 Gear selection mechanism - adjust
  36
• 4.1 Gear selection mechanism - assembly overview
  36
• 4.2 Gear selection mechanism - remove and install
  38
• 4.3 Gear selection mechanism - components
  46
• 4.4 Gear selection mechanism - repair
  49
• 5 Transmission - remove and install
  61
• 5.1 Gearbox for vehicles with engines (CCRA, CFZA) - remove and install
  61
• 5.2 Gearbox for vehicles with engines (CNXA) - remove and install
  73
• 5.3 Gearbox - transport
  86
• 6 Gearbox - disassemble and assemble
  88
• 6.1 Gearbox - overview
  88
• 6.2 gearbox - assembly overview
  89
• 6.3 Gearbox housing cover and 5th gear
  89
• 6.4 Clutch housing
  91
• 6.5 Input shaft, planet pinion, differential, selection mechanism and selector forks
  92
• 7 Gearbox oil level
  102
• 7.1 Oil level - check
  102
• 7.2 Oil level - replenish
  102
• 8 Gear selector mechanism oil level
  104
• 8.1 Oil level - check
  104
• 8.2 Oil level - replenish
  105
• 9 Gearbox and clutch housings
  106
• 9.1 Transmission and clutch housings - repair
  106
• 10 Selector forks
  112
• 10.1 Selector forks - disassemble and assemble
  112
• Gears, shafts
  117
• 1 Input shaft
  117
• 1.1 Primary shaft - general overview of assembly
  117
• 1.2 Input shaft - disassemble and assemble
  120
• 2 Planet pinion
  129
• 2.1 Pinion shaft - general overview of assembly
  129
• 2.2 Planet pinion - disassemble and assemble
  132
• Final drive - differential
  138
• 1 Drive flange
  138
• 1.1 Left drive flange retainer (left side) - replace
  138
• 1.2 Drive flange retainer (right side) - replace
  141
• 2 Differential
  144
• 2.1 Differential - general overview of assembly
  144
• 2.2 Differential - disassemble and assemble
  147
• 2.3 Differential - adjust
  153