6-speed manual gearbox 02N four-wheel drive

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Code letters, assembly allocation, ratios, capacities
  2
• 2 Rear final drive identification
  3
• 2.1 Rear final drive identification
  3
• 2.2 Code letters, assembly allocation, ratios, capacities
  4
• 3 Transmission layout
  5
• 3.1 Transmission layout
  5
• 4 Calculating overall ratio "i"
  7
• 4.1 Calculating overall ratio "i"
  7
• 4.2 Notes on brake and performance tests and towing
  7
• 5 General repair instructions
  7
• 5.1 General repair instructions
  7
• Clutch
  10
• 1 Servicing clutch control
  10
• 1.1 Servicing clutch control
  10
• 1.2 Assembly overview - Pedal cluster
  11
• 1.3 Removing and installing mounting bracket
  16
• 1.4 Removing and installing clutch pedal
  21
• 1.5 Adjusting clutch pedal travel
  26
• 1.6 Removing and installing over-centre spring
  27
• 1.7 Assembly overview - Hydraulic system (left-hand drive)
  31
• 1.8 Assembly overview - Hydraulic system (right-hand drive)
  36
• 1.9 Removing and installing master cylinder
  41
• 1.10 Removing and installing pipe/hose assembly
  46
• 1.11 Bleeding clutch system
  51
• 2 Servicing clutch release mechanism
  52
• 2.1 Servicing clutch release mechanism
  52
• 3 Servicing clutch
  54
• 3.1 Servicing clutch
  54
• 3.2 Adjusting ring of self-adjusting pressure plate on vehicles with 6-cylinder engines
  59
• Controls, Housing
  62
• 1 Connecting VAS 5051 and selecting functions
  62
• 1.1 Connecting VAS 5051 and selecting functions
  62
• 2 Locations of electrical/electronic components
  64
• 2.1 Locations of electrical/electronic components
  64
• 2.2 Removing and installing four-wheel drive control unit -J492
  70
• 2.3 Removing and installing Haldex coupling pump -V181-
  71
• 3 Servicing gear selector mechanism
  74
• 3.1 Servicing gear selector mechanism
  74
• 3.2 Installation position of gear selector mechanism
  74
• 3.3 Removing and installing selector lever knob and gaiter
  77
• 3.4 Servicing gear stick and gear stick housing
  79
• 3.5 Assembly overview - removing and installing selector cables
  83
• 3.6 Removing and installing gear stick and gear stick housing
  88
• 3.7 Removing and installing operating cables
  90
• 3.8 Adjusting gear selector mechanism
  98
• 4 Removing and installing gearbox
  101
• 4.1 Removing and installing gearbox
  101
• 4.2 Removing and installing gearbox (vehicles with 4 cylinder engine)
  101
• 4.3 Removing and installing gearbox (vehicles with 6-cylinder engine)
  125
• 5 Removing and installing bevel box
  147
• 5.1 Removing and installing bevel box
  147
• 6 Checking oil in manual gearbox with bevel box
  153
• 6.1 Checking oil in manual gearbox with bevel box
  153
• 7 Dismantling and assembling gearbox
  155
• 7.1 Dismantling and assembling gearbox
  155
• 7.2 Overview
  155
• 7.3 Assembly overview
  157
• 7.4 Removing and installing gearbox housing and selector mechanism
  158
• 7.6 Assembly sequence
  167
• 8 Servicing gearbox housing
  175
• 8.1 Servicing gearbox housing
  175
• 9 Servicing clutch housing
  184
• 9.1 Servicing clutch housing
  184
• 10 Dismantling and assembling gearbox selector mechanism
  191
• 10.1 Dismantling and assembling gearbox selector mechanism
  191
• 11 Dismantling and assembling selector forks
  195
• 11.1 Dismantling and assembling selector forks
  195
• Gears, Shafts
  198
• 1 Dismantling and assembling input shaft
  198
• 1.1 Dismantling and assembling input shaft
  198
• 2 Adjusting input shaft
  208
• 2.1 Adjusting input shaft
  208
• 3 Dismantling and assembling output shaft, 1st-4th gear
  212
• 3.1 Dismantling and assembling output shaft, 1st-4th gear
  212
• 4 Adjusting output shaft for 1st-4th gears
  233
• 4.1 Adjusting output shaft for 1st-4th gears
  233
• 5 Dismantling and assembling output shaft for 5th, 6th and reverse gear
  238
• 5.1 Dismantling and assembling output shaft for 5th, 6th and reverse gear
  238
• 6 Adjusting output shaft for 5th, 6th and reverse gear
  254
• 6.1 Adjusting output shaft for 5th, 6th and reverse gear
  254
• Final drive, Differential
  259
• 1 Renewing oil seals for flanged shafts
  259
• 1.1 Renewing oil seals for flanged shafts
  259
• 1.2 Renewing oil seal for left flanged shaft
  259
• 1.3 Renewing oil seal for right flanged shaft
  263
• 2 Replacing bevel box output flange oil seal (bevel box removed)
  265
• 2.1 Replacing bevel box output flange oil seal (bevel box removed)
  265
• 3 Dismantling and assembling differential
  268
• 3.1 Dismantling and assembling differential
  268
• 4 Adjustment overview
  282
• 4.1 Adjustment overview
  282
• 5 Adjusting differential
  283
• 5.1 Adjusting differential
  283
• 6 Dismantling and assembling bevel box
  288
• 6.1 Dismantling and assembling bevel box
  288
• 7 Adjusting shaft bevel gear and bevel gear (gear set)
  312
• 7.1 Adjusting shaft bevel gear and bevel gear (gear set)
  312
• 7.2 General notes
  312
• 7.3 Adjusting and marking of gear sets
  313
• 7.4 Position of shims
  315
• 7.5 Adjustment overview (bevel box)
  315
• 7.6 Recommended sequence for adjusting gear set
  316
• 7.7 Determining shim "S4" thickness when replacing output flange
  316
• 7.8 Adjusting shaft bevel gear
  317
• 7.9 Adjusting bevel gear
  325
• 8 Removing and installing propshaft
  329
• 8.1 Removing and installing propshaft
  329
• 8.2 Removing and installing rear flexible coupling
  334
• 9 Servicing propshaft
  337
• 9.1 Servicing propshaft
  337
• 10 Checking function of Haldex coupling
  348
• 10.1 Checking function of Haldex coupling
  348
• 11 Renewing propshaft flange oil seal on rear final drive (final drive removed)
  349
• 11.1 Renewing propshaft flange oil seal on rear final drive (final drive removed)
  349
• 12 Renewing flange shaft oil seal (final drive installed)
  353
• 12.1 Renewing flange shaft oil seal (final drive installed)
  353
• 14 Renewing O-rings for rear axle housing cover (final drive installed)
  359
• 14.1 Renewing O-rings for rear axle housing cover (final drive installed)
  359
• 15 Removing and installing rear final drive
  361
• 15.1 Removing and installing rear final drive
  361
• 16 Checking rear final drive oil
  365
• 16.1 Checking rear final drive oil
  365
• 17 Checking oil level in Haldex coupling or changing oil
  366
• 17.1 Checking oil level in Haldex coupling or changing oil
  366
• 17.2 Checking Haldex coupling oil level
  366
• 17.3 Changing oil in Haldex coupling
  368
• 17.4 Changing Haldex coupling oil filter
  369
• 18 Dismantling and assembling rear final drive
  371
• 18.1 Dismantling and assembling rear final drive
  371
• 18.2 Removing and installing Haldex coupling cover and plates
  372
• 18.3 Removing and installing pinion housing
  376
• 18.4 Removing and installing differential and input shaft bevel gear
  380
• 18.5 Removing and installing Haldex coupling plate housing cover
  384
• 18.6 Assembly sequence
  389
• 19 Dismantling and assembling differential
  402
• 19.1 Dismantling and assembling differential
  402
• 20 Servicing shaft bevel gear bearings
  408
• 20.1 Servicing shaft bevel gear bearings
  408
• 21 Servicing input shaft bevel gear bearings
  421
• 21.1 Servicing input shaft bevel gear bearings
  421
• 22 Adjusting bevel gear and shaft bevel gear (gear set)
  431
• 22.1 Adjusting bevel gear and shaft bevel gear (gear set)
  431
• 22.2 General notes
  431
• 22.3 Adjusting and marking of gear sets
  432
• 22.4 Position of shims
  434
• 22.5 Adjustment overview (rear final drive)
  434
• 22.6 Recommended sequence for adjusting gear set
  435
• 22.7 Adjusting shaft bevel gear
  436
• 22.8 Adjusting bevel gear
  441