6-speed dual clutch gearbox 0D9

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 General safety provisions
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Safety precautions when tow-starting or towing
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 2.2 Identification of bevel box
  4
• 3 Repair instructions
  5
• 3.1 General information
  5
• 3.2 Rules for cleanliness
  5
• 3.3 General repair instructions
  6
• 3.4 Gaskets and seals
  7
• 3.5 Nuts and bolts
  7
• 4 Technical data
  8
• 4.1 Capacities
  8
• 4.2 Allocation gearbox - engine
  8
• 4.3 Calculation of gear ratios
  9
• 5 Electrical components
  10
• 5.1 Overview of fitting locations - electrical components
  10
• Clutch
  12
• 1 Clutch
  12
• 1.1 Assembly overview - dual clutch
  12
• 1.2 Removing and installing clutch end cover
  14
• 1.3 Installing dual clutch
  18
• 1.4 Removing dual clutch
  23
• Controls, housing
  26
• 1 Mechatronic unit
  26
• 1.1 Assembly overview - mechatronic unit
  26
• 1.2 Removing and installing mechatronic unit
  28
• 1.3 Removing and installing sump
  33
• 2 Bevel box
  39
• 2.1 Assembly overview - bevel box
  39
• 2.2 Removing bevel box
  40
• 2.3 Installing bevel box
  46
• 3 Selector mechanism
  50
• 3.1 Assembly overview - selector mechanism
  50
• 3.2 Emergency release from position P
  53
• 3.3 Removing and installing selector lever handle
  54
• 3.4 Moving push-button in the handle to installation position
  56
• 3.5 Removing and installing selector mechanism
  58
• 3.6 Removing and installing gear selector cable
  64
• 3.7 Checking selector mechanism
  68
• 3.8 Checking and adjusting selector lever cable
  69
• 3.9 Renewing selector shaft seal
  71
• 4 Removing and installing gearbox
  74
• 4.1 Specified torques for gearbox
  74
• 4.2 Removing gearbox
  75
• 4.3 Installing gearbox
  104
• 5 Assembly mountings
  110
• 5.1 Assembly overview - assembly mountings
  110
• 6 Transporting gearbox
  113
• 7 Dismantling and assembling gearbox
  115
• 7.1 Assembly overview - gearbox
  115
• 8 Securing to engine and gearbox support
  118
• 8.1 Installing gearbox to engine and gearbox support
  118
• 8.2 Securing front differential lock to engine and gearbox support
  119
• 9 Gear oil circuit
  121
• 9.1 Removing and installing gear oil cooler
  121
• 9.2 Removing and installing cover for gear oil pump
  123
• 9.3 Removing and installing gear oil pump
  126
• 9.4 Removing and installing gear oil filter
  127
• 10 Gear oil
  129
• 10.1 Checking gear oil level
  129
• 10.2 Draining and filling gear oil
  132
• 11 Front differential lock
  136
• 11.1 Assembly overview - front differential lock
  136
• 11.2 Removing front differential lock
  136
• 11.3 Installing front differential lock
  139
• 11.4 Removing and installing differential lock control unit J647
  141
• Gears, shafts
  143
• 1 Dismantling and assembling gears and shafts
  143
• Final drive - differential
  144
• 1 Gear oil
  144
• 1.1 Checking and topping up gear oil level
  144
• 2 Oil for front differential lock
  147
• 2.1 Checking oil level for front differential lock
  147
• 2.2 Draining and filling oil for front differential lock
  148
• 3 Oil seals
  152
• 3.1 Overview of fitting locations - seals
  152
• 3.2 Renewing left seal
  153
• 3.3 Renewing right oil seal
  156
• 4 Components of front differential lock
  162
• 4.1 Assembly overview - components of front differential lock
  162
• 4.2 Checking function
  163
• 4.3 Removing and installing pump for front differential lock V181
  163
• 4.4 Removing and installing coupling for front differential lock
  165
• 4.5 Renewing seals for front differential lock
  165
• 4.6 Renewing ball bearing for flange shaft
  172
• 5 Components of bevel box
  175
• 5.1 Assembly overview - components of bevel box
  175
• 5.2 Removing and installing right flange shaft
  176
• 5.3 Renewing needle bearing (polygon bearing) for right flange shaft
  178
• 5.4 Renewing output flange and redetermining thickness of shim, bevel box removed
  180
• 5.5 Renewing bevel box seals
  190