5 Speed Manual Gearbox 02C four wheel drive

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, gearbox allocation, ratios, capacities
  2
• 2 Rear final drive identification
  3
• 2.1 Rear final drive identification
  3
• 2.2 Code letters, assembly allocation, ratios, capacities
  3
• 3 Transmission layout
  4
• 3.1 Transmission layout
  4
• 4 Calculating overall ratio (i)
  6
• 4.1 Calculating overall ratio (i)
  6
• 4.2 Notes on brake and performance tests and towing
  6
• 5 General repair instructions
  6
• 5.1 General repair instructions
  6
• Clutch
  9
• 1 Servicing clutch control
  9
• 1.1 Servicing clutch control
  9
• 1.2 Assembly overview - Pedal cluster
  10
• 1.3 Removing and installing over-centre spring
  13
• 1.4 Removing and installing clutch pedal
  14
• 1.5 Assembly overview - Hydraulic system
  14
• 1.6 Removing and installing master cylinder
  17
• 1.7 Bleeding clutch system
  18
• 2 Servicing clutch release mechanism
  19
• 2.1 Servicing clutch release mechanism
  19
• 3 Servicing clutch
  22
• 3.1 Servicing clutch
  22
• Controls, Housing
  26
• 1 Servicing gear selector mechanism
  26
• 1.1 Servicing gear selector mechanism
  26
• 1.2 Installation position of gear selector mechanism
  26
• 1.3 Removing and installing gear selector cables
  29
• 1.4 Removing and installing gear stick housing
  35
• 1.5 Removing and installing gear stick
  39
• 1.6 Adjusting gear selector mechanism
  43
• 2 Removing and installing gearbox
  46
• 2.1 Removing and installing gearbox
  46
• 2.2 Removing and installing gearbox and bevel box (Vehicles with 4 cylinder engine)
  46
• 2.3 Removing and installing gearbox and bevel box (Vehicles with 6 cylinder fuel injection engine)
  57
• 3 Removing and installing bevel box
  69
• 3.1 Removing and installing bevel box
  69
• 4 Checking oil in manual gearbox with bevel box
  80
• 4.1 Checking oil in manual gearbox with bevel box
  80
• 5 Dismantling and assembling gearbox
  81
• 5.1 Dismantling and assembling gearbox
  81
• 5.2 Removing and installing cover for gearbox housing and 5th gear
  82
• 5.3 Removing and installing gearbox housing and selector mechanism
  85
• 5.4 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  87
• 5.5 Dismantling and assembling sequence
  89
• 6 Servicing gearbox housing and clutch housing
  106
• 6.1 Servicing gearbox housing and clutch housing
  106
• 7 Dismantling and assembling gearbox selector mechanism
  114
• 7.1 Dismantling and assembling gearbox selector mechanism
  114
• 8 Dismantling and assembling selector forks
  119
• 8.1 Dismantling and assembling selector forks
  119
• Gears, Shafts
  125
• 1 Dismantling and assembling input shaft
  125
• 1.1 Dismantling and assembling input shaft
  125
• 2 Adjusting input shaft
  136
• 2.1 Adjusting input shaft
  136
• 2.2 Table of adjustment shims
  137
• 2.3 Carrying out check measurement
  139
• 3 Dismantling and assembling output shaft (pinion shaft)
  140
• 3.1 Dismantling and assembling output shaft (pinion shaft)
  140
• 4 Adjusting output shaft
  164
• 4.1 Adjusting output shaft
  164
• 5 Dismantling and assembling reverse shaft
  167
• 5.1 Dismantling and assembling reverse shaft
  167
• Final drive, Differential rear
  171
• 1.2 Renewing left-hand flange shaft oil seal
  171
• 1.3 Renewing right-hand drive flange oil seal
  172
• 2 Renewing bevel box output flange oil seal (bevel box removed)
  173
• 2.1 Renewing bevel box output flange oil seal (bevel box removed)
  173
• 3 Dismantling and assembling differential
  175
• 3.1 Dismantling and assembling differential
  175
• 4 Adjustment overview
  187
• 4.1 Adjustment overview
  187
• 5 Adjusting differential
  187
• 5.1 Adjusting differential
  187
• 6 Dismantling and assembling bevel box
  190
• 6.1 Dismantling and assembling bevel box
  190
• 6.2 Assembly overview
  190
• 6.3 Dismantling and assembling sequence
  200
• 7 Adjusting shaft bevel gear and bevel gear (gear set)
  210
• 7.1 Adjusting shaft bevel gear and bevel gear (gear set)
  210
• 7.2 General notes
  210
• 7.3 Adjusting and marking of gear sets
  210
• 7.4 Position of shims
  211
• 7.5 Adjustment overview (bevel box)
  211
• 7.6 Recommended sequence for adjusting gear set
  212
• 7.7 Determining shim "S4" thickness when replacing output flange
  212
• 7.8 Adjusting shaft bevel gear
  213
• 7.9 Adjusting bevel gear
  218
• 8 Removing and installing propshaft
  221
• 8.1 Removing and installing propshaft
  221
• 9 Servicing propshaft
  225
• 9.1 Servicing propshaft
  225
• 10 Checking function of viscous coupling
  233
• 10.1 Checking function of viscous coupling
  233
• 11 Removing and installing viscous coupling
  233
• 11.1 Removing and installing viscous coupling
  233
• 13 Removing and installing drive flange oil seal (rear final drive installed)
  235
• 13.1 Removing and installing drive flange oil seal (rear final drive installed)
  235
• 14 Functional check of free-wheel
  237
• 14.1 Functional check of free-wheel
  237
• 15 Functional check of free-wheel lock
  237
• 15.1 Functional check of free-wheel lock
  237
• 16 Removing and installing rear final drive
  238
• 16.1 Removing and installing rear final drive
  238
• 17 Checking rear final drive oil
  241
• 17.1 Checking rear final drive oil
  241
• 18 Dismantling and assembling rear final drive
  242
• 18.1 Dismantling and assembling rear final drive
  242
• 18.2 Removing viscous coupling and rear axle housing from bevel gear housing
  254
• 18.3 Servicing shaft bevel gear bearings
  256
• 18.4 Pressing bevel gear off and on input shaft
  260
• 18.5 Servicing bevel gear/input shaft bearings
  261
• 18.6 Servicing differential bearings
  264
• 18.7 Installing rear axle housing on bevel gear housing and building on viscous coupling
  266
• 19 Dismantling and assembling differential and freewheel (assembly overview)
  270
• 19.1 Dismantling and assembling differential and freewheel (assembly overview)
  270
• 20 Dismantling and assembling differential (sequence)
  274
• 20.1 Dismantling and assembling differential (sequence)
  274
• 21 Removing and installing freewheel (sequence)
  275
• 21.1 Removing and installing freewheel (sequence)
  275
• 22 Dismantling and assembling freewheel (sequence)
  276
• 22.1 Dismantling and assembling freewheel (sequence)
  276
• 23 Adjusting bevel gear and shaft bevel gear (gear set)
  277
• 23.1 Adjusting bevel gear and shaft bevel gear (gear set)
  277
• 23.2 General notes
  277
• 23.3 Adjusting and marking of gear sets
  278
• 23.4 Position of shims
  279
• 23.5 Adjustment overview (rear final drive)
  279
• 23.6 Recommended sequence for adjusting gear set
  280
• 23.7 Adjusting shaft bevel gear
  280
• 23.8 Adjusting bevel gear
  284