6-speed manual gearbox 02Q

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation, capacities
  1
• 2 Overview - power transmission
  4
• 3 Calculating overall gear ratio “i”
  6
• 4 General repair notes
  7
• 4.1 Contact corrosion!
  7
• 4.2 Repair instructions
  7
• Clutch
  10
• 1 Fault finding, power transmission
  10
• 2 Repairing clutch mechanism
  11
• 2.1 Overview - clutch actuation
  11
• 2.3 Removing, installing and adjusting clutch pedal switch F36
  13
• 2.4 Removing and installing mounting bracket (all vehicles)
  14
• 2.5 Removing and installing master cylinder with mounting bracket removed (through 05.03)
  19
• 2.7 Assembly overview - pedal cluster with clutch pedal sender G476 (from 06.03)
  23
• 2.8 Removing and installing over-centre spring with mounting bracket installed
  24
• 2.9 Removing and installing clutch pedal with mounting bracket installed
  26
• 2.11 Removing and installing clutch position sender G476 (from 06.03)
  31
• 2.12 Assembly overview - hydraulic system
  34
• 2.13 Bleeding clutch system
  36
• 2.14 Repairing clutch release mechanism
  37
• 2.15 Removing pipe/hose line or plastic line and bleeder from and installing on slave cylinder
  39
• 2.16 Removing and installing slave cylinder with release bearing
  39
• 2.17 Removing and installing pipe/hose line or plastic line
  40
• 2.18 Renewing input shaft seal
  42
• 2.19 Repairing clutch
  44
• 2.0 l - 103 kW turbo diesel engine
  44
• 2.21 Removing and installing Sachs clutch
  46
• 2.22 Repairing Sachs clutch
  48
• 2.23 Removing and installing LuK clutch
  48
• 2.24 Repairing LuK clutch
  51
• Controls, housing
  52
• 1 Fault finding, power transmission
  52
• 2 Repairing selector mechanism
  53
• 2.1 Installation position of selector mechanism
  53
• 2.2 Removing and installing gear knob and cover
  56
• 2.3 Removing and installing gaiter with gear knob
  56
• 2.4 Repairing gear lever and selector housing (through 10.06)
  58
• 2.5 Repairing gear lever and selector housing (from 11.06)
  60
• 2.6 Assembly overview - removing and installing selector cables
  65
• 2.7 Removing and installing selector mechanism
  69
• 2.8 Adjusting selector mechanism
  72
• 2.9 Functional check
  74
• 4 Identifying gearbox for removal and installation
  77
• 5 Removing and installing gearbox with stub shaft on right
  78
• 5.1 Removing gearbox
  80
• 5.2 Installing gearbox
  86
• 6.1 Removing gearbox
  96
• 6.2 Installing gearbox
  105
• 7 Checking gear oil
  113
• 8 Dismantling and assembling gearbox
  115
• 8.1 Overview - gearbox
  115
• 8.2 Assembly overview
  116
• 8.5 Assembly order, gearbox “without” retaining ring A for input shaft sealing cover
  120
• 8.6 Assembly order, gearbox “with” retaining ring A for input shaft sealing cover
  131
• 9 Repairing gearbox housing
  141
• 10 Repairing clutch housing
  151
• 11 Repairing selector mechanism, gearbox side
  155
• 11.1 Renewing oil seal for selector shaft
  156
• 12 Repairing selector forks
  158
• Gears, shafts
  161
• 1 Input shaft
  161
• 1.1 Dismantling and assembling input shaft
  161
• 2 Output shaft for 1st through 4th gears
  168
• 2.1 Dismantling and assembling output shaft for 1st through 4th gears
  168
• 2.2 Adjusting output shaft for 1st through 4th gears
  181
• 3 Output shaft for 5th, 6th and reverse gears
  186
• 3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears
  186
• 3.2 Adjusting output shaft for 5th, 6th and reverse gears
  197
• Final drive - differential
  202
• 1 Renewing seals for flange shafts or stub shaft with gearbox installed
  202
• 1.1 Renewing oil seal for left flange shaft
  202
• 1.2 Distinguishing gearbox to renew seal for stub shaft or right flange shaft
  204
• 1.3 Renewing stub shaft seal - through gearbox date 31 10 4
  205
• 1.4 Renewing right flange shaft seal - from gearbox date 01 11 4
  206
• 2 Adjustment overview
  209
• 3 Differential
  210
• 3.1 Dismantling and assembling differential
  210
• 3.2 Adjusting differential
  217