5 Speed Manual Gearbox 094

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Identification
  1
• 2 Warning
  2
• 2.1 Warning
  2
• 2.2 Code letters, allocation, gearbox ratios, oil capacity
  2
• 2.3 Code letters, gearbox allocation, ratios capacities
  3
• 2.4 Code letters, allocation, gearbox ratios, oil capacity
  9
• 2.5 Oil splash plate location
  10
• 2.6 Checking the Oil Level
  11
• 3 Transmission layout
  12
• 3.1 Transmission layout
  12
• 3.2 Direction of motion
  12
• 4 Calculating ratios"i"
  13
• 4.1 Calculating ratios"i"
  13
• Clutch
  15
• 1 Repairs to hydraulic clutch control
  15
• 1.1 Repairs to hydraulic clutch control
  15
• 1.2 Self-centering release bearing
  20
• 2 Clutch repairs
  21
• 2.1 Clutch repairs
  21
• 2.2 Removing, installing and checking clutch
  22
• 2.3 A -Modified gear lever bearing
  23
• 2.4 B - Amendments
  25
• Controls, Housing
  27
• 1 Repairing gear shift mechanism
  27
• 1.1 Repairing gear shift mechanism
  27
• 1.2 Repairing gearshift linkage
  32
• 1.3 Adjusting gearshift linkage
  33
• 1.4 Correct selection procedure for reverse gear-caravelle
  33
• 2 Adjusting gearshift linkage
  34
• 2.1 Adjusting gearshift linkage
  34
• 3 Removing and installing gearbox
  36
• 3.1 Removing and installing gearbox
  36
• 4 Dismantling and assembling gearbox
  39
• 4.1 Dismantling and assembling gearbox
  39
• 4.2 Removing and installing clutch housing/differential
  39
• 4.3 Dismantling and assembling gearbox
  46
• 4.4 Modifications from Assy. dates 12 10 2, 03 12 2 and 15 12 2
  51
• 4.5 Gear lever plan location altered
  52
• 4.6 Gearshift shaft cover with guide shoulder
  52
• 4.7 Gearshift shaft modified
  52
• 4.8 Modifications from Assy. dates 19 11 2 and 25 11 2
  53
• 4.9 Synchronizer hub with improved method of preventing jumping out of gear
  54
• 4.10 Shift forks and rails
  54
• 4.11 List of service parts required
  54
• 4.12 Dismantling and assembling gearbox
  55
• 4.13 Removing pinion shaft from transmission housing
  57
• 4.14 Determining the thickness of thrust washer for reverse gear
  59
• 4.15 Determining thrust washer from table
  60
• 4.16 Determining thickness of shim for gear 1st gear
  60
• 4.17 Determining shim from table
  62
• 4.18 Dismantling and assembling gearbox
  63
• 4.19 Dismantling and assembling gearbox
  66
• 4.20 Removal Instructions
  69
• 4.21 Installation Instructions
  69
• 4.22 Checking Input shaft surface damage
  69
• 4.23 Checking Input Shaft nose damage
  70
• Gears, Shafts
  71
• 1 General view
  71
• 1.1 General view
  71
• 2 Dismantling and assembling input shaft
  72
• 2.1 Dismantling and assembling input shaft
  72
• 2.2 Modified circlip
  78
• 2.3 Removing and installing the modified circlip
  79
• 2.4 Dismantling and assembling pinion
  79
• Final drive, Differential rear
  92
• 1 Renewing drive flange oil seal
  92
• 1.1 Renewing drive flange oil seal
  92
• 2 Dismantling and assembling differential
  94
• 2.1 Dismantling and assembling differential
  94
• 2.2 Differential with four pinions
  98
• 2.3 Dismantling and assembling differential
  98
• 2.4 Adjusting axial play of differential gears
  105
• 3 Dismantling and assembling limited slip differential
  107
• 3.1 Dismantling and assembling limited slip differential
  107
• 3.2 Locking effect approx. 45%
  107
• 4 Adjusting crown wheel and pinion
  113
• 4.1 Adjusting crown wheel and pinion
  113
• 4.2 General instructions
  113
• 5 Adjustment table
  115
• 5.1 Adjustment table
  115
• 5.2 Finding position of pinion
  115
• 5.3 Adjusting pinion
  116
• 5.4 Adjusting crown wheel
  119