6-speed manual gearbox 02Q

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 2 Safety information
  2
• 2.2 Safety measures when working on vehicles with a start/stop system
  3
• 3 Repair instructions
  4
• 3.1 General repair instructions
  4
• 3.2 Contact corrosion
  7
• 4 Technical data
  8
• 4.1 Allocation gearbox - engine
  8
• 4.2 Capacities
  8
• 4.3 Calculation of gear ratios
  8
• 5 Overview - power transmission
  9
• 5.1 Overview - power transmission - front-wheel drive
  9
• 6 Electrical components
  11
• 6.1 Overview of fitting locations - electrical components
  11
• Clutch
  13
• 1 Clutch mechanism
  13
• 1.1 Overview of fitting locations – clutch mechanism
  13
• 1.2 Assembly overview - pedal cluster
  15
• 1.3 Assembly overview - clutch hydraulics
  17
• 1.4 Assembly overview - clutch release mechanism
  22
• 1.5 Removing and installing over-centre spring
  23
• 1.6 Removing and installing clutch pedal
  28
• 1.7 Removing and installing mounting bracket
  34
• 1.8 Removing and installing clutch master cylinder
  40
• 1.9 Removing and installing clutch slave cylinder together with release bearing
  42
• 1.10 Removing and installing lines for clutch mechanism
  43
• 1.11 Removing and installing bleeder
  45
• 1.12 Checking clutch master cylinder and clutch slave cylinder
  46
• 1.13 Removing and installing clutch position sender G476
  46
• 1.14 Bleeding clutch mechanism
  49
• 2 Clutch
  51
• 2.1 Determining make of clutch
  51
• 2.2 Assembly overview - clutch
  52
• 2.3 Removing and installing clutch
  56
• Controls, housing
  69
• 1 Selector mechanism
  69
• 1.1 Installation position - selector mechanism
  69
• 1.2 Assembly overview - selector mechanism
  71
• 1.3 Assembly overview – gear knob and cover
  72
• 1.4 Assembly overview - Gear lever and selector housing
  73
• 1.5 Assembly overview - Selector cables
  75
• 1.6 Removing and installing gear knob
  77
• 1.7 Dismantling and assembling selector mechanism
  79
• 1.8 Removing and installing selector mechanism
  84
• 1.9 Removing and installing gear selector cable and gate selector cable
  90
• 1.10 Adjusting selector mechanism
  92
• 1.11 Checking selector mechanism
  94
• 1.12 Renewing selector shaft seal
  94
• 2 Removing and installing gearbox
  96
• 2.1 Removing gearbox
  96
• 2.2 Installing gearbox
  109
• 2.3 Specified torques for gearbox
  116
• 3 Assembly mountings
  118
• 3.1 Assembly overview – assembly mountings
  118
• 4 Transporting gearbox
  121
• 5 Dismantling and assembling gearbox
  122
• 5.1 Schematic overview - gearbox
  122
• 5.2 Assembly overview - gearbox
  123
• 5.3 Assembly overview - gearbox housing and selector mechanism
  124
• 5.4 Assembly overview - selector unit
  126
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  127
• 5.6 Assembly overview - selector forks
  129
• 5.7 Dismantling and assembling gearbox
  129
• 6 Gearbox housing, clutch housing
  144
• 6.1 Assembly overview - gearbox housing
  144
• 6.2 Assembly overview - clutch housing
  146
• 6.3 Repairing gearbox housing
  147
• 6.4 Repairing clutch housing
  154
• 7 Securing to engine and gearbox support
  157
• 8 Gear oil
  158
• 8.1 Checking gear oil level
  158
• Gears, shafts
  160
• 1 Input shaft
  160
• 1.1 Assembly overview - input shaft
  160
• 1.2 Dismantling and assembling input shaft
  161
• 1.3 Renewing input shaft seal
  165
• 2 Output shaft
  167
• 2.1 Assembly overview - output shaft
  167
• 2.2 Dismantling and assembling output shaft
  174
• 2.3 Adjusting output shaft
  196
• Final drive - differential
  207
• 1 Oil seals
  207
• 1.1 Overview of fitting locations - seals
  207
• 1.2 Renewing left seal
  208
• 1.3 Renewing right oil seal
  210
• 2 Differential
  214
• 2.1 Assembly overview - differential
  214
• 2.2 Dismantling and assembling differential
  216
• 2.3 Adjusting differential
  221
• 3 Adjustment overview
  225