6-speed manual gearbox 02N

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation, ratios, capacities
  1
• 2 Overview - power transmission
  13
• 3 Calculation of gear ratios
  15
• 4 General repair notes
  16
• 4.1 Contact corrosion!
  16
• 4.2 Repair instructions
  16
• Clutch
  19
• 1 Repairing clutch mechanism
  19
• 1.1 Overview
  19
• 1.2 Assembly overview - pedal cluster
  20
• 1.3 Removing and installing mounting bracket
  21
• 1.4 Removing and installing clutch pedal
  25
• 1.5 Distinguishing between clutch pedal switches F36
  29
• 1.6 Removing and installing clutch pedal switch F36 with rectangular housing
  29
• 1.7 Removing and installing clutch pedal switch F36 with round housing
  30
• 1.8 Adjusting clutch pedal travel
  30
• 1.9 Removing and installing over-centre spring
  31
• 1.10 Assembly overview - hydraulics (LHD)
  34
• 1.11 Assembly overview - hydraulics (RHD)
  37
• 1.12 Removing and installing master cylinder
  39
• 1.13 Removing and installing pipe/hose line
  43
• 1.14 Bleeding clutch system
  46
• 2 Repairing clutch release mechanism
  48
• 3 Repairing clutch
  49
• Controls, housing
  54
• 1 Repairing selector mechanism
  54
• 1.1 Installation position of selector mechanism
  54
• 1.2 Removing and installing gear knob and cover
  56
• 1.3 Repairing gear lever and selector housing
  58
• 1.4 Assembly overview - removing and installing selector cables
  60
• 1.5 Removing and installing selector housing and gear lever
  63
• 1.6 Removing and installing selector cables
  65
• 1.7 Adjusting selector mechanism, gearbox with retaining pin (through gearbox date 12 01 3)
  71
• 1.9 Functional check
  77
• 2 Identifying gearbox for removal and installation
  78
• 3.1 Removing and installing gearbox (vehicles with 4-cylinder engine)
  79
• 3.2 Specified torque
  95
• 3.3 Removing and installing gearbox (vehicles with 6-cylinder engine)
  97
• 3.4 Specified torque
  111
• 4.1 Removing and installing gearbox (vehicles with 4-cylinder engine)
  113
• 4.2 Specified torque
  130
• 4.3 Removing and installing gearbox (vehicles with 6-cylinder engine)
  132
• 4.4 Specified torque
  147
• 5 Checking gear oil
  149
• 6 Dismantling and assembling gearbox
  151
• 6.1 Overview - gearbox
  151
• 6.2 Assembly overview
  152
• 12 01 3
  153
• 13 01 3
  154
• 6.5 Removing and installing input shaft, output shafts, differential and selector rods
  156
• 6.6 Installing to engine and gearbox support
  158
• 6.7 Dismantling and assembling procedure through gearbox date 12 01 3
  159
• 13 01 8
  165
• 7 Repairing gearbox housing
  187
• 7.1 Repairing gearbox housing, through gearbox date 12 01 3
  187
• 7.2 Repairing gearbox housing, from gearbox date 13 01 3 onwards
  191
• 8 Repairing clutch housing
  202
• 8.1 Repairing clutch housing, through gearbox date 12 01 3
  202
• 8.2 Repairing clutch housing, from gearbox date 13 01 3 onwards
  207
• 9 Dismantling and assembling selector mechanism on gearbox side
  214
• 12 01 3
  214
• 13 01 3
  216
• 10 Repairing selector forks
  220
• 10.1 Repairing selector forks, through gearbox date 12 01 3
  220
• 10.2 Repairing selector forks, from gearbox date 13 01 3 onwards
  222
• Gears, shafts
  225
• 1 Input shaft
  225
• 1.1 Dismantling and assembling input shaft, through gearbox date 12 01 3
  225
• 1.2 Adjusting input shaft, through gearbox date 12 01 3
  232
• 1.3 Dismantling and assembling input shaft from gearbox date 13 01 3
  236
• 2 Output shaft for 1st through 4th gears
  244
• 2.1 Assembly overview - output shaft for 1st through 4th gears
  244
• 2.2 Dismantling and assembling output shaft for 1st through 4th gears
  246
• 2.3 Adjusting output shaft for 1st through 4th gears
  264
• 3 Output shaft for 5th, 6th and reverse gears
  270
• 3.1 Assembly overview - output shaft for 5th, 6th and reverse gears
  270
• 3.2 Dismantling and assembling output shaft for 5th, 6th and reverse gears
  272
• 3.3 Adjusting output shaft for 5th, 6th and reverse gears
  281
• Final drive - differential
  286
• 1 Renewing seals for flange shaft or stub shaft with gearbox installed
  286
• 1.1 Renewing oil seal for left flange shaft
  286
• 1.2 Renewing seal for stub shaft
  288
• 2 Adjustment overview
  293
• 3 Differential
  294
• 3.1 Dismantling and assembling differential
  294
• 3.2 Adjusting differential
  313