5 - Speed manual gearbox (0AP, 02T)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Identification on the gearbox
  1
• 1.2 Prefix, Assignment, gear ratio, filling volume
  2
• 2 Transmission assembly scheme
  4
• 2.1 Nomenclature
  4
• 2.2 Gear ratios
  5
• 3 Gearbox ratio “i”
  6
• 3.1 Gearbox ratio “i” - calculation
  6
• 4 General repair instructions
  7
• 4.1 Gearbox
  7
• 4.2 Gaskets and retainers
  7
• 4.3 Bolts, nuts
  8
• 4.4 Roller bearings
  8
• 4.5 Adjustment shims
  9
• 4.6 Synchronizer rings
  9
• Clutch
  10
• 1 Command system
  10
• 1.1 Command system - component overview
  10
• 1.2 Command pedals - assembly overview
  11
• 1.3 Clutch pedal switch F36 - remove and install
  12
• 1.4 Clutch pedal return spring - remove and install
  13
• 1.5 Clutch pedal support - remove and install
  14
• 1.6 Clutch pedal - remove install
  18
• 1.7 Hydraulic system - assembly overview
  19
• 1.8 Transmitting cylinder - clutch hydraulic drive - remove and install
  21
• 2 Clutch drive mechanism
  24
• 2.1 Clutch drive mechanism - assembly overview
  24
• 2.2 Clutch slave cylinder - remove and install
  25
• 2.3 Clutch system - bleed
  26
• 3 Clutch
  28
• 3.1 Clutch - assembly overview
  28
• 3.2 Clutch - repair
  30
• Controls, housing
  32
• 1 Shift mechanism
  32
• 1.1 Shift mechanism - installation position
  32
• 1.2 Selector mechanism - component overview
  34
• 1.3 Drive cables
  35
• 1.4 Handle and boot on the gear lever - assembly overview
  41
• 1.5 Handle and boot on the gear lever - remove and install
  41
• 1.6 Gear shift lever and shifting mechanism - remove and install
  43
• 1.7 Gearshift lever and mechanism - repair
  46
• 1.8 Lever and Gear shifting mechanism - adjusting
  49
• 1.9 Selector and lever - functional check
  51
• 2 Transmission - remove and install
  53
• 2.1 Transmission - remove and install
  53
• 3 Gearbox oil level
  71
• 3.1 Oil level - check
  71
• 3.2 Oil level - replenish
  72
• 4 Gearbox - disassemble and assemble
  74
• 4.1 Gearbox - overview
  74
• 4.2 gearbox - assembly overview
  75
• 4.3 Gearbox housing cover and 5th gear
  76
• 4.4 Clutch housing
  77
• 4.5 Input shaft, planet pinion, differential, selection mechanism and selector forks
  78
• 5 Gearbox and clutch housings
  88
• 5.1 Transmission and clutch housings - repair
  88
• 6 Gear selection mechanism - adjust
  94
• 6.1 Gear selection mechanism - disassemble and assemble
  94
• 7 Selector forks - disassemble and assemble
  97
• 7.1 Selector forks - disassemble and assemble
  97
• Gears, shafts
  102
• 1 Input shaft
  102
• 1.1 Primary shaft - general overview of assembly
  102
• 1.2 Input shaft - disassemble and assemble
  105
• 2 Planet pinion
  114
• 2.1 Pinion shaft - general overview of assembly
  114
• 2.2 Planet pinion - disassemble and assemble
  117
• Final drive - differential
  123
• 1 Drive flange
  123
• 1.1 Left drive flange retainer (left side) - replace
  123
• 1.2 Drive flange retainer (right side) - replace
  126
• 2 Differential
  129
• 2.1 Differential - general overview of assembly
  129
• 2.2 Differential - disassemble and assemble
  131
• 2.3 Differential - adjust
  137