5 - Speed manual gearbox 0DF

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  3
• 3.1 Assignment (gearbox / engine)
  3
• 3.2 Supply capacity (gearbox oil)
  3
• 3.3 Gear ratio calculation “i”
  3
• 4 Transmission assembly scheme
  4
• 4.1 Transmission assembly scheme
  4
• 5 Repair instructions
  6
• 5.1 General repair instructions
  6
• Clutch
  10
• 1 Clutch control
  10
• 1.1 Clutch control - overview
  10
• 1.2 Clutch drive pedal - assembly overview
  12
• 1.3 Hydraulic clutch system - assembly overview
  13
• 1.4 Clutch release mechanism - assembly overview
  15
• 1.5 Support shell - remove and install
  16
• 1.6 Clutch pedal switch F36 - remove and install
  16
• 1.7 Spring - remove and install
  17
• 1.8 Clutch pedal - remove and install
  18
• 1.9 Support with clutch pedal - remove and install
  18
• 1.10 Clutch transmitter cylinder - remove and install
  23
• 1.11 Clutch slave cylinder - remove and install
  24
• 1.12 Clutch system line - remove and install
  25
• 1.13 Clutch system - bleed
  26
• 1.14 Clutch release mechanism - repair
  28
• 2 Clutch
  30
• 2.1 Clutch - assembly overview
  30
• 2.2 Clutch - remove and install
  31
• Controls, housing
  35
• 1 Gearshift mechanism
  35
• 1.1 Gearshift mechanism - installation position
  35
• 1.2 Gear selection mechanism - assembly overview
  37
• 1.3 Handle and boot on the gear lever - assembly overview
  38
• 1.4 Gear selection lever and control - assembly overview
  39
• 1.5 Handle and boot on the gear lever - remove and install
  40
• 1.6 Gearshift control and lever - remove and install
  41
• 1.7 Gearshift operation command - repair
  44
• 1.8 Selector lever - replace seal
  48
• 1.9 Gear selection mechanism - adjust
  49
• 1.10 Gearshift mechanism - check operation
  52
• 2 Gearbox - remove and install
  53
• 2.1 Transmission - removal
  53
• 2.2 Gearbox - installation
  61
• 2.3 Transmission - tightening torques
  66
• 3 Auxiliary frame
  67
• 3.1 Assembly mountings - assembly overview
  67
• 4 Gearbox - transport
  69
• 4.1 Gearbox - transport
  69
• 5 Gearbox oil
  70
• 5.1 Gearbox oil - check and refill
  70
• 5.2 Gearbox oil - drain and fill
  71
• 6 Transmission - fasten to support
  72
• 6.1 Transmission - fasten to the Support 3221A
  72
• 7 Gearbox - disassemble and assemble
  74
• 7.1 Gearbox - schematic overview
  74
• 7.2 gearbox - assembly overview
  75
• 7.3 Gearbox housing cover and 5th gear
  75
• 7.4 Gearbox housing Cover and 5th gear - remove and install (gearbox installed)
  77
• 7.5 Clutch housing
  78
• 7.6 Input shaft, output shaft, differential, selection mechanism and selector forks
  79
• 8 Gearbox and clutch housings
  88
• 8.1 Transmission housing and transmission housing - assembly overview
  88
• 8.2 Transmission and clutch housings - repair
  90
• 9 Selector mechanism - adjust
  92
• 9.1 Gear selection mechanism - disassemble and assemble
  92
• 10 Selector forks
  94
• 10.1 Selector forks - assembly overview
  94
• 10.2 Selector forks - repair
  95
• Gears, shafts
  99
• 1 Input shaft
  99
• 1.1 Input shaft - general overview of assembly
  99
• 1.2 Input shaft - disassemble and assemble
  102
• 1.3 Input shaft - replace seal
  110
• 2 Output shaft
  112
• 2.1 Output shaft - general overview of assembly
  112
• 2.2 Output shaft - disassemble and assemble
  115
• Final drive - differential
  121
• 1 Seals
  121
• 1.1 Seals - assembly overview
  121
• 1.2 Seal (left-hand side) - replace
  122
• 1.3 Seal (right-hand side) - replace
  123
• 2 Differential
  126
• 2.1 Differential - general overview of assembly
  126
• 2.2 Differential - disassemble and assemble
  128
• 2.3 Differential - adjust
  134