6-speed manual gearbox 02N, all-wheel drive

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation, ratios, capacities
  2
• 2 Identifying rear final drive
  5
• 2.1 Location on rear final drive
  5
• 2.2 Identification code, assembly allocation, ratios, capacities
  5
• 3 Overview - power transmission
  7
• 4 Calculation of gear ratios
  9
• 4.1 Notes on performance test
  9
• 5 General repair notes
  10
• 5.1 Contact corrosion!
  10
• Clutch
  14
• 1 Repairing clutch mechanism
  14
• 1.1 Overview
  14
• 1.2 Assembly overview - pedal cluster
  15
• 1.3 Removing and installing mounting bracket
  16
• 1.4 Removing and installing clutch pedal
  20
• 1.5 Distinguishing between clutch pedal switches F36
  24
• 1.6 Removing and installing clutch pedal switch F36 with rectangular housing
  24
• 1.7 Removing and installing clutch pedal switch F36 with round housing
  25
• 1.8 Adjusting clutch pedal travel
  25
• 1.9 Removing and installing over-centre spring
  26
• 1.10 Assembly overview - hydraulics (LHD)
  29
• 1.11 Assembly overview - hydraulics (RHD)
  32
• 1.12 Removing and installing master cylinder
  34
• 1.13 Removing and installing pipe/hose line
  38
• 1.14 Bleeding clutch system
  41
• 2 Repairing clutch release mechanism
  43
• 3 Repairing clutch
  44
• Controls, housing
  49
• 1 Vehicle diagnosis testing and information system VAS 5051
  49
• 2 Electrical and electronic components and their locations
  51
• 2.1 Removing and installing electrical and electronic components
  53
• 2.2 Removing and installing Haldex coupling pump V181
  54
• 3 Repairing selector mechanism
  57
• 3.1 Installation position of selector mechanism
  57
• 3.2 Removing and installing gear knob and cover
  59
• 3.3 Repairing gear lever and selector housing
  61
• 3.4 Assembly overview - removing and installing selector cables
  63
• 3.5 Removing and installing selector housing and gear lever
  66
• 3.6 Removing and installing selector cables
  68
• 3.7 Adjusting selector mechanism, gearbox with retaining pin (through gearbox date 12 01 3)
  74
• 3.9 Functional check
  80
• 4 Removing and installing gearbox
  81
• 4.1 Identifying gearbox for removal and installation
  81
• 4.2 Removing and installing gearbox (vehicles with 4-cylinder engine)
  81
• 4.3 Removing and installing gearbox (vehicles with 6-cylinder engine)
  102
• 5 Removing and installing bevel box
  122
• 5.1 Removing
  122
• 5.2 Specified torque
  125
• 6 Checking oil level in manual gearbox with bevel box
  127
• 7 Dismantling and assembling gearbox
  129
• 7.1 Overview - gearbox
  129
• 7.2 Assembly overview
  130
• 12 01 3
  131
• 13 01 3
  133
• 7.5 Removing and installing input shaft, output shafts, differential, bevel box and selector rods
  135
• 7.6 Installing to engine and gearbox support
  138
• 7.7 Dismantling and assembling procedure through gearbox date 12 01 3
  139
• 13 01 8
  146
• 8 Repairing gearbox housing
  173
• 8.1 Repairing gearbox housing, through gearbox date 12 01 3
  173
• 8.2 Repairing gearbox housing, from gearbox date 13 01 3 onwards
  177
• 9 Repairing clutch housing
  188
• 9.1 Repairing clutch housing, through gearbox date 12 01 3
  188
• 9.2 Repairing clutch housing, from gearbox date 13 01 3 onwards
  192
• 10 Dismantling and assembling selector mechanism on gearbox side
  198
• 12 01 3
  198
• 13 01 3
  200
• 11 Repairing selector forks
  204
• 11.1 Repairing selector forks, through gearbox date 12 01 3
  204
• 11.2 Repairing selector forks, from gearbox date 13 01 3 onwards
  206
• Gears, shafts
  209
• 1 Input shaft
  209
• 1.1 Dismantling and assembling input shaft, through gearbox date 12 01 3
  209
• 1.2 Adjusting input shaft, through gearbox date 12 01 3
  216
• 1.3 Dismantling and assembling input shaft from gearbox date 13 01 3
  220
• 2 Output shaft for 1st through 4th gears
  228
• 2.1 Assembly overview - output shaft for 1st through 4th gears
  228
• 2.2 Dismantling and assembling output shaft for 1st through 4th gears
  230
• 2.3 Adjusting output shaft for 1st through 4th gears
  248
• 3 Output shaft for 5th, 6th and reverse gears
  254
• 3.1 Assembly overview - output shaft for 5th, 6th and reverse gears
  254
• 3.2 Dismantling and assembling output shaft for 5th, 6th and reverse gears
  256
• 3.3 Adjusting output shaft for 5th, 6th and reverse gears
  265
• Final drive - rear differential
  270
• 1 Propshaft
  270
• 1.1 Removing and installing propshaft
  270
• 1.2 Removing and installing rear flexible coupling
  273
• 1.3 Repairing propshaft
  276
• 2 Checking function of Haldex coupling
  284
• 3 Oil seals
  285
• 3.1 Renewing seal for propshaft flange on removed rear final drive
  285
• 3.2 Renewing oil seals for flange shafts on installed rear final drive
  287
• 4 Renew O-rings
  290
• 5 Removing and installing rear final drive
  294
• 5.1 Removing
  294
• 5.2 Installing
  296
• 5.3 Specified torque
  297
• 6 Check gear oil in rear final drive
  298
• 7 Checking oil level or changing oil in Haldex coupling
  299
• 7.1 Checking oil level in Haldex coupling
  299
• 7.2 Changing oil in Haldex coupling
  300
• 7.3 Changing oil filter for Haldex coupling
  301
• 8 Dismantling and assembling rear final drive
  303
• 8.1 Assembly overview
  303
• 8.2 Removing and installing cover for Haldex coupling and plates
  304
• 8.3 Removing and installing pinion housing
  305
• 8.4 Removing and installing differential and bevel gear with stub shaft
  307
• 8.5 Removing and installing cover for Haldex coupling from plate housing
  310
• 8.6 Dismantling and assembling procedure
  313
• 9 Differential for rear final drive
  325
• 9.1 Dismantling and assembling differential
  325
• 10 Repair shaft bevel gear mounting
  330
• 10.1 Assembly overview
  330
• 11 Repairing bearings for bevel gear with stub shaft
  341
• 11.1 Assembly overview
  341
• 12.1 General notes
  349
• 12.2 Adjustment and marking of final drive gear sets
  349
• 12.3 Position of shims
  352
• 12.4 Adjustment overview - rear final drive
  352
• 12.5 Recommended sequence for new adjustment of final drive gear set
  353
• 12.6 Adjusting shaft bevel gear
  353
• 12.7 Adjusting bevel gear (with stub shaft)
  359
• Final drive - front differential
  364
• 1 Renewing flange shaft oil seals with gearbox and bevel box installed
  364
• 1.1 Renewing oil seal for left flange shaft
  364
• 1.2 Renewing seal for right flange shaft
  366
• 2 Renewing bevel box output flange oil seal (bevel box removed)
  369
• 2.1 Removing
  370
• 2.2 Installing
  371
• 3 Differential for manual gearbox
  372
• 3.1 Dismantling and assembling differential
  372
• 3.2 Adjusting differential
  380
• 4 Adjustment overview - manual gearbox
  385
• 5 Bevel box
  386
• 5.1 Dismantling and assembling bevel box
  386
• 6.1 General notes
  403
• 6.2 Adjustment and marking of final drive gear sets
  403
• 6.3 Position of shims
  404
• 6.4 Adjustment overview - bevel box
  404
• 6.5 Recommended sequence for new adjustment of final drive gear set
  405
• 6.6 Determining shim "S4" thickness when renewing output flange
  405
• 6.7 Adjusting shaft bevel gear
  406
• 6.8 Adjusting bevel gear (with stub shaft)
  412