6-speed direct shift gearbox 02E, four-wheel drive

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 2 Code letters, engine allocation
  2
• 3 Capacities
  3
• 3.1 Direct shift gearbox
  3
• 3.2 Front bevel box
  3
• 4 General repair instructions
  4
• 4.1 Information on the direct shift gearbox DSG
  4
• 4.2 Special tools
  5
• 4.3 Gearbox
  5
• 4.4 Seals and sealing rings
  6
• 4.5 Checking oil and oil level
  6
• 4.6 Overview
  7
• 4.7 Nuts and bolts
  8
• 4.8 Electrical components
  8
• 4.9 Guided fault finding, vehicle self-diagnosis and testing
  8
• Clutch
  9
• 1 Notes on clutch*
  9
• 2 Removing and installing clutch
  10
• 2.1 Removing clutch cover (end cover)
  10
• 2.2 Installing clutch cover (end cover)
  11
• 2.3 Removing clutch
  13
• 2.4 Preparing installation of multi-clutch
  14
• 2.5 Installing and adjusting clutch
  16
• Controls, housing
  23
• 1 Electrical and electronic components and their locations DSG
  23
• 2 Removing and installing oil cooler
  40
• 2.1 Removing
  40
• 2.2 Installing
  41
• 3 Removing and installing oil pump
  43
• 3.1 Removing oil pump
  43
• 3.2 Installing oil pump
  44
• 3.3 Renew seal on selector shaft lever
  45
• 4 Repairing selector mechanism
  48
• 5 Adjust selector lever cable
  50
• 6 Removing and installing gearbox
  52
• 6.1 Removing
  52
• 6.2 Transporting gearbox
  54
• 6.3 Installing
  54
• 6.4 Torque settings
  54
• 7 Changing oil and filter of direct shift gearbox and adjusting oil level
  56
• 7.1 Changing oil and filter
  57
• Gears, shafts
  61
• 1 Currently, no repairs can be made to gears and shafts
  61
• Final drive - rear differential
  62
• 1 Propshaft, Haldex coupling and rear final drive
  62
• 2 Identifying rear final drive
  63
• 2.1 Location on rear final drive
  63
• 2.2 Identification code, assembly allocation, ratios, capacities
  63
• 3 Notes on performance test
  66
• 3.1 Radial oil seal for propshaft flange and shaft bevel gear on rear final drive
  66
• 4 Electrical and electronic components and their locations
  67
• 4.1 Removing and installing electrical and electronic components
  68
• 4.2 Removing and installing Haldex coupling pump V181
  70
• 5 Checking Haldex coupling
  72
• 5.1 Electrical check of Haldex coupling
  72
• 6 Propshaft
  77
• 6.1 Removing and installing propshaft
  77
• 6.2 Removing and installing front flexible coupling
  81
• 6.3 Removing and installing rear flexible coupling
  83
• 6.4 Repairing propshaft
  86
• 7 Checking function of Haldex coupling
  93
• 8 Oil seals
  94
• 8.1 Renewing propshaft flange oil seal on rear final drive (final drive removed)
  94
• 8.2 Renewing oil seals for flange shafts on rear final drive
  96
• 9 Renewing O-rings
  99
• 9.2 Renewing O-ring for rear axle housing cover (final drive installed)
  101
• 10 Removing and installing rear final drive
  103
• 10.1 Removing
  103
• 10.2 Installing
  105
• 11 Checking oil in rear final drive
  108
• 12 Checking oil level or changing oil in Haldex coupling
  109
• 12.1 Checking oil level in Haldex coupling
  109
• 12.2 Changing oil in Haldex coupling
  110
• 12.3 Changing oil filter for Haldex coupling
  111
• 13 Dismantling and assembling rear final drive
  113
• 13.1 Dismantling and assembling rear final drive
  113
• 13.2 Removing and installing cover for Haldex coupling and plates
  114
• 13.3 Removing and installing pinion housing
  115
• 13.4 Removing and installing differential and bevel gear with stub shaft
  117
• 13.5 Removing and installing cover for Haldex coupling from plate housing
  120
• 13.6 Dismantling and assembling procedure
  123
• 14 Differential for rear final drive
  135
• 14.1 Dismantling and assembling differential
  135
• 15 Repairing shaft bevel gear bearing
  140
• 15.1 Assembly overview
  140
• 16 Repairing bearing for bevel gear with stub shaft
  151
• 16.1 Assembly overview
  151
• 17.1 General notes
  159
• 17.2 Adjustment and marking of final drive gear sets
  159
• 17.3 Position of shims
  162
• 17.4 Adjustment overview - rear final drive
  162
• 17.5 Recommended sequence for new adjustment of final drive gear set
  163
• 17.6 Adjusting shaft bevel gear
  163
• 17.7 Adjusting bevel gear
  169
• Final drive - front differential
  175
• 1 Renewing oil seals for flange shafts
  175
• 1.1 Renewing oil seal for left flange shaft
  175
• 1.2 Renewing seal for right flange shaft
  176
• 1.3 Checking oil level in front bevel box
  178