6-speed manual gearbox 02M, 02Y, all-wheel drive

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Code letters, allocation, ratios, capacities
  1
• 2 Identifying rear final drive
  7
• 2.1 Location on final drive
  7
• 2.2 Code letters, allocation, ratios, capacities
  7
• 3 Overview - power transmission
  10
• 4 Calculation of gear ratios
  12
• 4.1 Notes on performance test
  12
• 5 General repair instructions
  13
• 5.1 Components
  13
• Clutch
  16
• 1 Fault finding, power transmission
  16
• 2 Repairing clutch mechanism
  17
• 2.1 Overview
  17
• 2.2 Assembly overview - pedal cluster
  18
• 2.3 Distinguishing between clutch pedal switches F36
  19
• 2.4 Removing and installing clutch pedal switch F36 with rectangular housing
  19
• 2.5 Removing and installing clutch pedal switch F36 with round housing
  20
• 2.6 Removing and installing over-centre spring
  20
• 2.7 Removing and installing clutch pedal
  22
• 2.8 Assembly overview - hydraulic system
  23
• 2.9 Removing and installing master cylinder
  25
• 2.10 Bleeding clutch system
  28
• 3 Repairing clutch release mechanism
  30
• 4 Repairing clutch
  33
• Controls, housing
  36
• 1 Vehicle diagnostic, testing and information system VAS 5051
  36
• 2 Electrical/electronic components and fitting locations
  38
• 2.1 Removing and installing electrical and electronic components
  39
• 2.2 Removing and installing Haldex coupling pump V181
  41
• 3 Checking Haldex coupling
  43
• 3.1 Electrical check of Haldex coupling
  43
• 4 Fault finding, power transmission
  48
• 5 Repairing selector mechanism
  49
• 5.1 Installation position of selector mechanism
  49
• 5.2 Removing and installing gear knob and cover
  51
• 5.3 Separating gaiter from gear lever and assembling with gear knob
  52
• 5.4 Repairing gear lever and selector housing
  52
• 5.5 Assembly overview - removing and installing selector cables
  54
• 5.6 Removing and installing selector mechanism
  57
• 5.7 Adjusting selector mechanism, gearbox with retaining pin (through gearbox date 18 05 3)
  61
• 19 05 3)
  63
• 5.9 Function
  66
• 6 Removing and installing gearbox
  67
• 6.1 Removing and installing gearbox (vehicles with 4-cylinder engine)
  67
• 6.2 Removing and installing gearbox (vehicles with 5-cylinder engine)
  84
• 6.3 Removing and installing gearbox (vehicles with 6-cylinder engine)
  101
• 7 Removing and installing bevel box
  119
• 7.1 Removing and installing bevel box (vehicles with 4-cylinder engine)
  119
• 7.2 Removing and installing bevel box (vehicles with 5 and 6-cylinder engines)
  123
• 8 Checking gearbox oil
  127
• 9 Dismantling and assembling gearbox
  128
• 9.1 Overview - gearbox
  128
• 9.2 Assembly overview
  129
• 18 05 3
  130
• 19 05 3
  132
• 9.5 Removing and installing input shaft, output shafts, differential, bevel box and selector rods
  134
• 9.6 Installing to engine and gearbox support
  137
• 10 Repairing gearbox housing
  157
• 10.1 Repairing gearbox housing, through gearbox date 18 05 3
  157
• 10.2 Repairing gearbox housing, from gearbox date 19 05 3
  162
• 11 Repairing clutch housing
  172
• 11.1 Repairing clutch housing, through gearbox date 18 05 3
  172
• 11.2 Repairing clutch housing, from gearbox date 19 05 3
  175
• 12 Dismantling and assembling selector mechanism in gearbox
  180
• 18 05 3
  180
• 19 05 3
  182
• 13 Repairing selector forks
  186
• 13.1 Repairing selector forks, through gearbox date 18 05 3
  186
• 13.2 Repairing selector forks, from gearbox date 19 05 3
  188
• Gears, shafts
  191
• 1 Input shaft
  191
• 1.1 Dismantling and assembling input shaft, through gearbox date 18 05 3
  191
• 1.2 Adjusting input shaft (gearboxes manufactured up to 18 05 3)
  198
• 2 Output shaft for 1st to 4th gears
  209
• 2.1 Dismantling and assembling output shaft for 1st through 4th gears
  209
• 2.2 Adjusting output shaft for 1st through 4th gears
  221
• 3 Output shaft for 5th and 6th gears and reverse gear
  227
• 3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears
  227
• 3.2 Adjusting output shaft for 5th, 6th and reverse gears
  237
• Final drive - rear differential
  243
• 1 Propshaft
  243
• 1.1 Removing and installing propshaft
  243
• 1.2 Removing and installing front flexible coupling
  247
• 1.3 Removing and installing rear flexible coupling
  249
• 1.4 Repairing propshaft
  252
• 2 Checking function of Haldex coupling
  259
• 3 Seals
  260
• 3.1 Renewing seal for propshaft flange on rear final drive (final drive removed)
  260
• 3.2 Renewing oil seals for flange shafts on rear final drive
  262
• 4 Renewing O-rings
  265
• 4.2 Renewing O-rings for rear final drive housing cover (final drive installed)
  267
• 5 Removing and installing rear final drive
  269
• 5.1 Removing
  269
• 5.2 Installing
  271
• 6 Checking gear oil in rear final drive
  274
• 7 Checking oil level or changing oil in Haldex coupling
  275
• 7.1 Checking oil level in Haldex coupling
  275
• 7.2 Changing oil in Haldex coupling
  276
• 7.3 Changing oil filter for Haldex coupling
  277
• 8 Dismantling and assembling rear final drive
  279
• 8.1 Dismantling and assembling rear final drive
  279
• 8.2 Removing and installing cover for Haldex coupling and plates
  280
• 8.3 Removing and installing pinion housing
  281
• 8.4 Removing and installing differential and bevel gear with stub shaft
  283
• 8.5 Removing and installing cover for Haldex coupling from plate housing
  286
• 8.6 Assembly procedure
  289
• 9 Differential for rear final drive
  302
• 9.1 Dismantling and assembling differential
  302
• 10 Repairing shaft bevel gear bearing
  307
• 10.1 Assembly overview
  307
• 11 Repairing bearing for bevel gear with stub shaft
  318
• 11.1 Assembly overview
  318
• 12.1 General information
  326
• 12.2 Adjustment and marking of final drive gear sets
  326
• 12.3 Position of shims
  329
• 12.4 Adjustment overview - rear final drive
  329
• 12.5 Recommended sequence for new adjustment of final drive gear set
  330
• 12.6 Adjusting shaft bevel gear
  330
• 12.7 Adjusting bevel gear (with stub shaft)
  336
• Final drive - front differential
  342
• 1 Renewing flange shaft oil seals with gearbox and bevel box installed
  342
• 1.1 Renewing oil seal for left flange shaft
  342
• 1.2 Renewing seal for right flange shaft
  343
• 2 Renewing bevel box output flange oil seal (bevel box removed)
  346
• 2.1 Removing
  347
• 2.2 Installing
  349
• 3 Differential for manual gearbox
  350
• 3.1 Dismantling and assembling differential
  350
• 3.2 Adjusting differential
  358
• 4 Adjustment overview - manual gearbox
  362
• 5 Bevel box
  363
• 5.1 Dismantling and assembling bevel box
  363
• 6 Renewing needle bearing
  379
• 6.1 Renewing needle bearing (polygon bearing) for right flange shaft
  379
• 7.1 General information
  383
• 7.2 Adjustment and marking of final drive gear sets
  383
• 7.3 Position of shims
  384
• 7.4 Adjustment overview - bevel box
  384
• 7.5 Recommended sequence for new adjustment of final drive gear set
  385
• 7.6 Determining shim "S4" thickness when renewing output flange
  385
• 7.7 Adjusting shaft bevel gear
  386
• 7.8 Adjusting bevel gear (with stub shaft)
  393