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
  4
• 3.1 Correspondence (gearbox / engine)
  4
• 3.2 Supply capacity (gearbox oil)
  4
• 3.3 Gear ratio calculation “i”
  4
• 4 Transmission assembly scheme
  5
• 4.1 Transmission assembly scheme
  5
• 5 Repair instructions
  7
• 5.1 General repair instructions
  7
• Clutch
  12
• 1 Clutch control
  12
• 1.1 Clutch drive system - assembly locations overview
  12
• 1.2 Clutch drive pedal - assembly overview
  13
• 1.3 Hydraulic clutch system - assembly overview
  15
• 1.4 Clutch release mechanism - assembly overview
  17
• 1.5 Support shell - remove and install
  18
• 1.6 Clutch position sender G476 - remove and install
  19
• 1.7 Pedal return spring - remove and install
  21
• 1.8 Clutch drive pedal - remove and install
  23
• 1.9 Clutch drive pedal support - remove and install
  24
• 1.10 Clutch transmitter cylinder - remove and install
  27
• 1.11 Clutch slave cylinder - remove and install
  28
• 1.12 Clutch drive system line - remove and install
  31
• 1.13 Hydraulic clutch mechanism - bleed
  33
• 1.14 Clutch release mechanism - repair
  35
• 2 Clutch
  37
• 2.1 Clutch - assembly overview
  37
• 2.2 Clutch - remove and install
  38
• Controls, housing
  43
• 1 Gearshift mechanism
  43
• 1.1 Gearshift mechanism - installation position
  43
• 1.2 Gear lever - assembly overview
  44
• 1.3 Handle and boot on the gear lever - assembly overview
  46
• 1.4 Gear knob - remove and install
  47
• 1.5 Gearshift mechanism - remove and install
  49
• 1.6 Gearshift mechanism - repair
  53
• 1.7 Gearshift mechanism - adjust
  57
• 1.8 Gearshift mechanism - check operation
  60
• 1.9 Gearshift lever and mechanism - remove and install
  61
• 1.10 Selector cables - remove and install
  66
• 1.11 Selector rod - replace seal
  68
• 1.12 Selector rod and the selector mechanism cover - assembly overview
  70
• 1.13 Selector rod and selector mechanism cover - remove and install with the gearbox installed
  72
• 2 Gearbox - remove and install
  76
• 2.1 Transmission - removal
  76
• 2.2 Gearbox - installation
  88
• 2.3 Transmission - tightening torques
  93
• 3 Assembly mountings
  94
• 3.1 Assembly mountings - assembly overview
  94
• 4 Gearbox - transport
  97
• 4.1 Gearbox - transport
  97
• 5 Gearbox oil
  98
• 5.1 Gearbox oil - check and refill
  98
• 5.2 Gearbox oil - drain and fill
  99
• 6 Transmission - fasten to support
  101
• 6.1 Transmission - fasten to the Support 3221A
  101
• 7 Gearbox - disassemble and assemble
  103
• 7.1 Gearbox - schematic overview
  103
• 7.2 gearbox - assembly overview
  103
• 7.3 Transmission housing cover and 5th gear - assembly overview
  104
• 7.4 Gearbox housing Cover and 5th gear - remove and install (gearbox installed)
  106
• 7.5 Clutch housing - assembly overview
  108
• 7.6 Input shaft, output shaft, differential, selection mechanism and selector forks
  109
• 8 Gearbox and clutch housings
  121
• 8.1 Transmission housing and transmission housing - assembly overview
  121
• 8.2 Transmission and clutch housings - repair
  123
• 9 Selector forks
  125
• 9.1 Selector forks - assembly overview
  125
• 9.2 Selector forks - repair
  125
• Gears, shafts
  131
• 1 Input shaft
  131
• 1.1 Input shaft - general overview of assembly
  131
• 1.2 Input shaft - remove and install
  133
• 1.3 Input shaft - replace seal
  144
• 2 Output shaft
  147
• 2.1 Output shaft - general overview of assembly
  147
• 2.2 Output shaft- remove and install
  150
• Final drive - differential
  158
• 1 Seals
  158
• 1.1 Seals - assembly overview
  158
• 1.2 Seal (left-hand side) - replace
  158
• 1.3 Seal (right-hand side) - replace
  161
• 2 Differential
  164
• 2.1 Differential - general overview of assembly
  164
• 2.2 Differential - remove and install
  166
• 2.3 Differential - adjust
  173