6-speed dual clutch gearbox 02E

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Safety precautions when tow-starting or towing
  2
• 1.4 General safety provisions
  3
• 2 Identification
  4
• 2.1 Gearbox identification
  4
• 2.2 Identification of bevel box
  5
• 3 Repair notes
  7
• 3.1 Rules for cleanliness
  7
• 3.2 General repair instructions
  7
• 3.3 Gaskets and seals
  9
• 3.4 Nuts and bolts
  9
• 3.5 Electrical components
  10
• 4 Technical data
  11
• 4.1 Capacities
  11
• 4.2 Allocation gearbox - engine
  11
• 4.3 Calculation of gear ratios
  12
• 5 Electrical components
  14
• 5.1 Overview of fitting locations - electrical components
  14
• 6 Hazard classification of high-voltage system
  15
• Clutch
  16
• 1 Clutch
  16
• 1.1 Assembly overview - dual clutch
  16
• 1.2 Removing and installing clutch end cover
  18
• 1.3 Removing dual clutch
  26
• 1.4 Installing dual clutch
  28
• Controls, housing
  37
• 1 Mechatronic unit
  37
• 1.1 Removing and installing mechatronic unit
  37
• 2 Bevel box
  66
• 2.1 Assembly overview - bevel box
  66
• 2.2 Removing bevel box
  69
• 2.3 Installing bevel box
  78
• 3 Selector mechanism
  85
• 3.1 Assembly overview - selector mechanism
  85
• 3.2 Manual release from position P
  87
• 3.3 Removing and installing selector mechanism
  88
• 3.4 Checking selector mechanism
  93
• 3.5 Checking and adjusting selector lever cable
  94
• 3.6 Removing and installing selector lever handle
  97
• 3.7 Moving push-button in the handle to installation position
  101
• 3.8 Renewing selector shaft seal
  103
• 4 Removing and installing gearbox
  106
• 4.1 Specified torques for gearbox
  106
• 4.2 Removing gearbox
  107
• 4.3 Installing gearbox
  141
• 5 Assembly mountings
  153
• 5.1 Assembly overview - assembly mountings
  153
• 6 Transporting gearbox
  157
• 7 Dismantling and assembling gearbox
  159
• 7.1 Assembly overview - gearbox
  159
• 8 Securing to engine and gearbox support
  164
• 9 Gear oil circuit
  166
• 9.1 Removing and installing gear oil cooler
  166
• 9.2 Removing and installing gear oil pump
  171
• 9.3 Removing and installing gear oil filter
  175
• 10 Gear oil
  178
• 10.1 Checking gear oil level
  178
• 10.2 Draining and filling gear oil
  183
• Gears, shafts
  187
• 1 Currently, no repairs can be made to gears and shafts
  187
• Final drive - differential
  188
• 1 Gear oil
  188
• 1.1 Checking gear oil level
  188
• 1.2 Draining and filling gear oil
  190
• 2 Oil seals
  196
• 2.1 Overview of fitting locations - seals
  196
• 2.2 Renewing left seal
  197
• 2.3 Renewing right seal
  202
• 3 Differential
  213
• 3.1 Assembly overview - differential
  213
• 4 Components of bevel box
  214
• 4.1 Assembly overview - components of bevel box
  214
• 4.2 Renewing bevel box seals
  216
• 4.3 Renewing output flange and redetermining thickness of shim
  229