5 and 6-speed manual gearbox 02M

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation, ratios, capacities
  1
• 2 Overview - power transmission
  6
• 3 Calculating overall gear ratio „i“
  8
• 4 General repair notes
  9
• 4.1 Components
  9
• Clutch
  12
• 1 Fault finding, power transmission
  12
• 2 Repairing clutch mechanism
  13
• 2.1 Overview
  13
• 2.2 Assembly overview - pedal cluster
  14
• 2.3 Distinguishing between clutch pedal switches F36
  15
• 2.4 Removing and installing clutch pedal switch F36 with rectangular housing
  15
• 2.5 Removing and installing clutch pedal switch F36 with round housing
  16
• 2.6 Removing and installing over-centre spring
  16
• 2.7 Removing and installing clutch pedal
  18
• 2.8 Assembly overview - hydraulic system
  19
• 2.9 Removing and installing master cylinder
  21
• 2.10 Bleeding clutch system
  24
• 3 Repairing clutch release mechanism
  26
• 4 Repairing clutch
  29
• Controls, housing
  32
• 1 Fault finding, power transmission
  32
• 2 Repairing selector mechanism
  33
• 2.1 Installation position of selector mechanism
  33
• 2.2 Removing and installing gear knob and cover
  35
• 2.3 Separating gaiter from gear lever and assembling with gear knob
  36
• 2.4 Repairing gear lever and selector housing
  37
• 2.5 Assembly overview - removing and installing selector cables
  39
• 2.6 Removing and installing selector mechanism
  40
• 2.7 Adjusting selector mechanism, gearbox with retaining pin (through gearbox date 18 05 3)
  44
• 2.9 Functional check
  50
• 3 Removing and installing gearbox
  51
• 3.1 Removing
  53
• 3.2 Transporting gearbox
  58
• 3.3 Installing
  58
• 4 Checking gear oil
  65
• 5 Dismantling and assembling gearbox
  66
• 5.1 Overview - gearbox
  66
• 5.2 Assembly overview
  67
• 18 05 3
  68
• 19 05 3
  69
• 5.5 Removing and installing input shaft, output shafts, differential and selector rods
  71
• 5.6 Installing to engine and gearbox support
  73
• 6 Repairing gearbox housing
  90
• 6.1 Repairing gearbox housing, through gearbox date 18 05 3
  90
• 6.2 Repairing gearbox housing, from gearbox date 19 05 3
  94
• 7 Repairing clutch housing
  105
• 7.1 Repairing clutch housing, through gearbox date 18 05 3
  105
• 7.2 Repairing clutch housing, from gearbox date 19 05 3
  108
• 8 Dismantling and assembling selector mechanism on gearbox side
  113
• 18 05 3
  113
• 19 05 3
  115
• 9 Repairing selector forks
  119
• 9.1 Repairing selector forks, through gearbox date 18 05 3
  119
• 9.2 Repairing selector forks, from gearbox date 19 05 3
  121
• Gears, shafts
  124
• 1 Input shaft
  124
• 1.1 Dismantling and assembling input shaft, through gearbox date 18 05 3
  124
• 1.2 Adjusting input shaft (through gearbox date 18 05 3)
  131
• 1.3 Dismantling and assembling input shaft, from gearbox date 19 05 3
  135
• 2 Output shaft for 1st through 4th gears
  142
• 2.1 Dismantling and assembling output shaft for 1st through 4th gears
  142
• 2.2 Adjusting output shaft for 1st through 4th gears
  154
• 3 Output shaft for 5th, 6th and reverse gears
  160
• 3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears
  160
• 3.2 Adjusting output shaft for 5th, 6th and reverse gears
  171
• Final drive - differential
  177
• 1 Renewing flange shaft oil seals with gearbox installed
  177
• 1.1 Renewing oil seal for left flange shaft
  177
• 1.2 Renewing seal for right flange shaft
  178
• 2 Adjustment overview
  181
• 3 Differential
  182
• 3.1 Dismantling and assembling differential
  182
• 3.2 Adjusting differential
  189