6-speed manual gearbox 01E, four-wheel drive

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation, capacities
  1
• 2 Identifying rear final drive
  4
• 2.1 Location on final drive
  4
• 2.2 Identification code, assembly allocation, capacities
  4
• 3 Overview - power transmission
  6
• 4 Calculating overall gear ratio “i”
  8
• 5 General repair instructions
  9
• 5.1 Components
  9
• Clutch
  12
• 1 Functional check of clutch master and slave cylinders
  12
• 2 Distinguishing clutch control mechanisms
  14
• 3 Repairing clutch control mechanism (master cylinder secured to clutch pedal with a pin)
  15
• 3.1 Overview
  15
• 3.2 Assembly overview - pedal cluster (LHD vehicles)
  16
• 3.3 Removing and installing clutch pedal and over-centre spring
  17
• 3.4 Assembly overview - pedal cluster (RHD vehicles)
  18
• 3.5 Assembly overview - hydraulic system
  20
• 3.6 Removing and installing master cylinder
  21
• 4.1 Overview
  25
• 4.2 Assembly overview - pedal cluster (LHD vehicles)
  26
• 4.3 Removing and installing clutch pedal and over-centre spring
  27
• 4.4 Assembly overview - pedal cluster (RHD vehicles)
  28
• 4.5 Assembly overview - hydraulic system
  30
• 4.6 Removing and installing master cylinder
  32
• 5 Clutch pedal switch
  37
• 5.4 Bleeding clutch system
  39
• 6 Repairing clutch release mechanism
  41
• 6.1 Removing and installing slave cylinder
  44
• 7 Repairing clutch
  49
• Controls, housing
  55
• 1 Repairing selector mechanism
  55
• 1.1 Installation position of selector mechanism
  55
• 1.2 Repairing selector lever and selector lever mounting
  57
• 1.3 Repairing selector rod, connecting rod and push rod
  59
• 1.4 Removing and installing selector lever with selector lever mounting
  61
• 1.5 Removing and installing selector mechanism
  62
• 1.6 Adjusting selector mechanism
  67
• 2 Removing and installing gearbox
  71
• 2.1 Removing and installing gearbox (vehicles with 4 and 6-cylinder engines)
  71
• 2.2 Removing and installing gearbox (vehicles with 8-cylinder engine)
  81
• 3 Checking gearbox oil
  98
• 4 Dismantling and assembling gearbox
  100
• 4.1 Removing and installing bearing housing, Torsen differential and end cover
  101
• 4.2 Removing and installing gearbox and selector shaft
  102
• 4.3 5\. Removing and installing 5th and 6th gear
  103
• 4.5 Dismantling and assembling procedure
  105
• 5 Dismantling and assembling bearing housing
  125
• 6 Repairing bearings for Torsen differential
  131
• 7 Repairing end cover
  136
• 8 Repairing bearing plate
  141
• 8.1 Redetermining shim S4
  144
• 9 Repairing gearbox housing
  149
• 9.1 Dismantling and assembling selector shaft complete
  157
• 10 Oil pump
  160
• 10.1 Removing and installing oil pump
  160
• 10.2 Repairing oil pump
  161
• 11 Removing and installing oil pressure lines
  163
• Gears, shafts
  165
• 1 Dismantling and assembling input shaft
  165
• 2 Dismantling and assembling pinion shaft and hollow shaft
  171
• Final drive - rear differential
  181
• 1 Removing and installing propshaft
  181
• 1.1 Assembly overview
  181
• 1.2 Dismantling and assembling procedure
  182
• 1.3 Adjusting propshaft
  185
• 2 Renewing oil seals for flange shafts (rear final drive installed)
  189
• 2.1 Renewing oil seal for left and right flange shafts
  189
• 3 Renewing oil seal for propshaft flange
  192
• 3.1 Renewing oil seal for propshaft flange (rear final drive installed)
  192
• 4 Measuring and marking radial run-out on propshaft flange
  197
• 5 Removing and installing rear final drive
  199
• 5.1 Removing and installing rear final drive
  199
• 6 Checking oil in rear final drive
  203
• 7 Dismantling and assembling rear final drive
  204
• 7.1 Overview - rear final drive
  204
• 8 Rear differential
  205
• 8.1 Removing and installing rear differential
  205
• 8.2 Dismantling and assembling rear differential
  208
• 9 Removing and installing pinion shaft and dismantling and assembling
  217
• 10 Adjusting pinion shaft and crown wheel
  227
• 10.1 General notes
  227
• 10.2 Adjustment and marking of final drive gear sets
  227
• 10.3 Position of shims
  228
• 10.4 Adjustment overview
  228
• 10.5 Recommended sequence for new adjustment of final drive gear set
  229
• 10.6 Adjusting pinion shaft
  229
• 10.7 Adjusting crown wheel
  233
• Final drive - front differential
  239
• 1 Renewing oil seals for flange shafts
  239
• 1.1 Renewing oil seal for left and right flange shafts
  239
• 2.1 Assembly overview
  244
• 2.2 Dismantling and assembling procedure
  244
• 3 Renewing speedometer sender and drive wheel
  248
• 3.1 Renewing speedometer sender G22
  248
• 3.2 Renewing speedometer drive wheel
  248
• 4 Differential
  251
• 4.1 Removing and installing differential
  251
• 4.2 Dismantling and assembling differential (gearbox without oil pump)
  252
• 4.3 Dismantling and assembling (gearbox with oil pump)
  260
• 5 Adjusting pinion shaft and crown wheel
  269
• 5.1 General notes
  269
• 5.2 Adjustment and marking of final drive gear sets
  269
• 5.3 Position of shims
  270
• 5.4 Adjustment overview
  270
• 5.5 Recommended sequence for new adjustment of final drive gear set
  271
• 5.6 Adjusting pinion shaft
  271
• 5.7 Adjusting crown wheel
  279