6-speed manual gearbox 02Q, four-wheel drive

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 1.2 Notes on performance test
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Code letters, allocation, ratios, capacities
  3
• 3.1 Allocation gearbox - engine
  3
• 3.2 Capacities
  3
• 3.3 Calculation of gear ratios
  4
• 4 Overview - power transmission
  5
• 5 General repair instructions
  7
• 6 Electrical components
  10
• 6.1 Overview of fitting locations - electrical components
  10
• Clutch
  12
• 1 Clutch operation
  12
• 1.1 Overview - clutch actuation
  12
• 1.2 Assembly overview - pedal cluster
  14
• 1.3 Assembly overview - clutch hydraulics
  16
• 1.4 Removing and installing mounting bracket
  19
• 1.5 Removing and installing over-centre spring
  25
• 1.6 Removing and installing clutch pedal
  29
• 1.7 Removing and installing master cylinder
  34
• 1.8 Removing and installing clutch position sender G476
  36
• 1.9 Removing line and bleeder from and installing on slave cylinder
  40
• 1.10 Removing and installing line for clutch mechanism
  42
• 1.11 Bleeding clutch system
  44
• 2 Clutch release mechanism
  46
• 2.1 Assembly overview - clutch release mechanism
  46
• 2.2 Removing and installing slave cylinder with release bearing
  47
• 3 Clutch
  49
• 3.1 Determining clutch manufacturer
  49
• 3.2 Assembly overview - “Sachs” clutch
  50
• 3.3 Removing and installing “Sachs” clutch
  52
• 3.4 Assembly overview - “LuK” clutch
  55
• 3.5 Removing and installing “LuK” clutch
  56
• Controls, housing
  59
• 1 Selector mechanism
  59
• 1.1 Installation position of selector mechanism
  59
• 1.2 Overview - selector mechanism
  60
• 1.3 Assembly overview - gear knob and cover
  61
• 1.4 Removing and installing gear knob
  61
• 1.5 Assembly overview - Gear lever and selector housing
  63
• 1.6 Dismantling and assembling selector mechanism
  65
• 1.7 Assembly overview - Selector cables
  69
• 1.8 Removing and installing selector mechanism
  75
• 1.9 Adjusting selector mechanism
  77
• 1.10 Checking selector mechanism
  80
• 2 Removing and installing gearbox
  81
• 2.1 Removing gearbox
  81
• 2.2 Installing gearbox
  91
• 2.3 Specified torques for gearbox
  101
• 3 Transporting gearbox
  102
• 4 Assembly mountings
  103
• 4.1 Assembly overview - assembly mountings
  103
• 5 Gear oil
  106
• 5.1 Distinguishing between different manual gearbox types when filling oil
  106
• 5.2 Checking gear oil level
  106
• 6 Bevel box
  110
• 6.1 Assembly overview - bevel box
  110
• 6.2 Distinguishing between different types of bevel boxes
  111
• 6.3 Removing bevel box
  112
• 6.4 Installing bevel box
  116
• 7 Dismantling and assembling gearbox
  121
• 7.1 Overview - gearbox
  121
• 7.2 Overview - dismantling and assembling gearbox
  122
• 7.3 Assembly overview - removing and installing gear housing and selector unit
  123
• 7.5 Securing to engine and gearbox support
  126
• 7.6 Assembly procedure
  127
• 8 Gearbox housing and clutch housing
  142
• 8.1 Assembly overview - gearbox housing
  142
• 8.2 Repairing gearbox housing
  144
• 8.3 Assembly overview - clutch housing
  152
• 8.4 Repairing clutch housing
  154
• 9 Selector unit
  157
• 9.1 Assembly overview - selector unit
  157
• 9.2 Renewing selector shaft seal
  158
• 10 Selector forks
  160
• 10.1 Assembly overview - selector forks
  160
• 10.2 Repairing reverse gear selector fork
  161
• Gears, shafts
  163
• 1 Input shaft
  163
• 1.1 Assembly overview - input shaft
  163
• 1.2 Dismantling and assembling input shaft
  164
• 1.3 Renewing input shaft seal
  168
• 2 Output shaft
  170
• 2.1 Assembly overview - output shaft
  170
• 2.2 Dismantling and assembling output shaft
  178
• 2.3 Adjusting output shaft
  200
• Final drive - differential
  211
• 1 Oil seals
  211
• 1.1 Overview of fitting locations - seals
  211
• 1.2 Renewing left seal
  212
• 1.3 Renewing right oil seal
  214
• 2 Differential
  220
• 2.1 Assembly overview - differential
  220
• 2.2 Dismantling and assembling differential
  222
• 2.3 Adjusting differential
  227
• 3 Adjustment overview
  232
• 4 Components of bevel box
  233
• 4.1 Assembly overview - components of bevel box
  233
• 4.2 Renewing bevel box seals
  238
• 4.3 Renewing output flange and redetermining thickness of shim
  261
• 4.4 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  262
• 5 Gear oil
  266
• 5.1 Checking gear oil level
  266