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

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Identification
  2
• 2.1 Identification on the gearbox
  2
• 2.2 Prefix, Assignment, gear ratio, filling volume
  3
• 3 Transmission assembly scheme
  5
• 3.1 Nomenclature
  5
• 3.2 Gear ratios
  6
• 4 Gearbox ratio “i”
  7
• 4.1 Gearbox ratio “i” - calculation
  7
• 5 General repair instructions
  8
• 5.1 Gearbox
  8
• 5.2 Gaskets and retainers
  8
• 5.3 Bolts, nuts
  9
• 5.4 Roller bearings
  9
• 5.5 Adjustment shims
  10
• 5.6 Synchronizer rings
  10
• Clutch
  11
• 1 Command system
  11
• 1.1 Command system - component overview
  11
• 1.2 Command pedals - assembly overview
  12
• 1.3 Clutch pedal switch F36 - remove and install
  13
• 1.4 Clutch pedal return spring - remove and install
  14
• 1.5 Clutch pedal support - remove and install
  15
• 1.6 Clutch pedal - remove install
  18
• 1.7 Hydraulic system - assembly overview
  20
• 1.8 Transmitting cylinder - clutch hydraulic drive - remove and install
  23
• 2 Clutch mechanism
  27
• 2.1 Clutch drive mechanism - assembly overview
  27
• 2.2 Clutch slave cylinder - remove and install
  29
• 2.3 Clutch drive mechanism - bleed
  30
• 3 Clutch
  31
• 3.1 Clutch - assembly overview
  31
• 3.2 Clutch - repair
  32
• Controls, housing
  34
• 1 Shift mechanism
  34
• 1.1 Shift mechanism - installation position
  34
• 1.2 Selector mechanism - component overview
  36
• 1.3 Selector cables - installation position
  37
• 1.4 Handle and boot on the gear lever - assembly overview
  45
• 1.5 Handle and boot on the gear lever - remove and install
  45
• 1.6 Gear shift lever and shifting mechanism - remove and install
  47
• 1.7 Gearshift lever and mechanism - repair
  49
• 1.8 Lever and Gear shifting mechanism - adjusting
  52
• 1.9 Selector and lever - functional check
  54
• 2 Gearbox - remove and install
  55
• 2.1 Gearbox for vehicles with engines (CCRA, CFZA) - remove and install
  55
• 2.2 Gearbox for vehicles with engines (CSEA, CNXA and CWSA) - remove and install
  69
• 2.3 Gearbox - transport
  80
• 3 Gearbox oil level
  82
• 3.1 Oil level - check:
  82
• 3.2 Oil level - replenish
  82
• 4 Gearbox - disassemble and assemble
  84
• 4.1 Gearbox - overview
  84
• 4.2 gearbox - assembly overview
  85
• 4.3 Transmission housing cover and 5th gear - assembly overview
  85
• 4.4 Gearbox housing Cover and 5th gear - remove and install (gearbox installed)
  87
• 4.5 Clutch housing
  88
• 4.6 Input shaft, output shaft, differential, selection mechanism and selector forks
  90
• 5 Gearbox and clutch housings
  100
• 5.1 Transmission and clutch housings - repair
  100
• 6 Selector mechanism - adjust
  106
• 6.1 Gear selection mechanism - disassemble and assemble
  106
• 7 Selector forks
  110
• 7.1 Selector forks - disassemble and assemble
  110
• Gears, shafts
  115
• 1 Input shaft
  115
• 1.1 Input shaft - general overview of assembly
  115
• 1.2 Input shaft - disassemble and assemble
  118
• 2 Output shaft
  127
• 2.1 Output shaft - general overview of assembly
  127
• 2.2 Output shaft - disassemble and assemble
  130
• Final drive - differential
  136
• 1 Drive flange
  136
• 1.1 Left drive flange retainer (left side) - replace
  136
• 1.2 Drive flange retainer (right side) - replace
  139
• 2 Differential
  142
• 2.1 Differential - general overview of assembly
  142
• 2.2 Differential - disassemble and assemble
  145
• 2.3 Differential - adjust
  151