5 - Speed automated transmission (ASG) 0C3

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 2.2 Prefix, Assignment, and gear ratio
  2
• 2.3 Gearbox oil, supply capacity
  3
• 3 Transmission assembly scheme
  4
• 3.1 Nomenclature
  4
• 3.2 Gear ratios
  5
• 4 Gearbox ratio “i”
  6
• 4.1 Gear ratio calculation “i”
  6
• 5 General repair instructions
  7
• 5.1 Gearbox
  7
• 5.2 Gaskets and retainers
  7
• 5.3 Screws, nuts
  8
• 5.4 Roller bearings
  8
• 5.5 Adjustment shims
  9
• 5.6 Synchronizer rings
  9
• Clutch
  10
• 1 Hydraulic system
  10
• 1.1 Hydraulic system - assembly overview
  10
• 1.2 Clutch slave cylinder - remove and install
  11
• 2 Clutch drive mechanism
  14
• 2.1 Clutch drive mechanism - assembly overview
  14
• 3 Clutch
  16
• 3.1 Clutch - assembly overview
  16
• 3.2 Clutch - repair
  18
• Controls, housing
  20
• 1 Diagnosis, measurement and information system
  20
• 1.1 Diagnosis, measurement and information system - connect
  20
• 2 Electronic components and installation locations
  21
• 2.1 Electric and electronic components - overview
  21
• 2.3 Sensor 2 for gear detection G616
  24
• 2.4 Gearbox input speed sender G182
  25
• 2.5 Gear detection sensor G604
  26
• 2.6 Diagnosis socket
  28
• 2.7 Selector lever position display Y6
  28
• 2.8 Automatic gearbox control unit J217
  28
• 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 Gearbox - remove and install
  62
• 5.1 Gearbox for vehicles with engines (CCRA, CFZA) - remove and install
  62
• 5.2 Gearbox - transport
  73
• 6 Gearbox - disassemble and assemble
  75
• 6.1 Gearbox - overview
  75
• 6.2 gearbox - assembly overview
  76
• 6.3 Gearbox housing cover and 5th gear
  76
• 6.4 Gearbox housing Cover and 5th gear - remove and install (gearbox installed)
  78
• 6.5 Clutch housing
  79
• 6.6 Input shaft, output shaft, differential, selection mechanism and selector forks
  80
• 7 Gearbox oil level
  91
• 7.1 Oil level - check
  91
• 7.2 Oil level - replenish
  91
• 8 Gear selector mechanism oil level
  93
• 8.1 Oil level - check
  93
• 8.2 Oil level - replenish
  94
• 9 Gearbox and clutch housings
  95
• 9.1 Transmission and clutch housings - repair
  95
• 10 Selector forks
  101
• 10.1 Selector forks - disassemble and assemble
  101
• Gears, shafts
  106
• 1 Input shaft
  106
• 1.1 Input shaft - general overview of assembly
  106
• 1.2 Input shaft - disassemble and assemble
  109
• 2 Output shaft
  118
• 2.1 Output shaft - general overview of assembly
  118
• 2.2 Output shaft - disassemble and assemble
  121
• Final drive - differential
  127
• 1 Drive flange
  127
• 1.1 Left drive flange retainer (left side) - replace
  127
• 1.2 Drive flange retainer (right side) - replace
  130
• 2 Differential
  133
• 2.1 Differential - general overview of assembly
  133
• 2.2 Differential - disassemble and assemble
  136
• 2.3 Differential - adjust
  142