6-speed manual gearbox 02Q

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Repair notes
  3
• 3.1 General repair instructions
  3
• 3.2 Contact corrosion
  6
• 4 Technical data
  7
• 4.1 Capacities
  7
• 4.2 Allocation gearbox - engine
  7
• 4.3 Calculation of gear ratios
  8
• 5 Overview - power transmission
  9
• 5.1 Overview - power transmission - front-wheel drive
  9
• Clutch
  11
• 1 Clutch operation
  11
• 1.1 Assembly overview - pedal cluster
  11
• 1.2 Assembly overview - clutch hydraulics
  14
• 1.3 Assembly overview - clutch release mechanism
  18
• 1.4 Removing and installing clutch pedal
  18
• 1.5 Removing and installing over-centre spring
  24
• 1.6 Removing and installing mounting bracket
  29
• 1.7 Removing and installing clutch master cylinder
  36
• 1.8 Removing and installing clutch slave cylinder together with release bearing
  38
• 1.9 Removing and installing lines for clutch mechanism
  39
• 1.10 Removing and installing bleeder
  42
• 1.11 Bleeding clutch mechanism
  43
• 1.12 Checking clutch master cylinder and clutch slave cylinder
  44
• 1.13 Removing and installing clutch position sender G476
  44
• 1.14 Repairing clutch release mechanism
  47
• 2 Clutch
  49
• 2.1 Determining make of clutch
  49
• 2.2 Assembly overview - clutch
  50
• 2.3 Removing and installing clutch
  54
• Controls, housing
  67
• 1 Selector mechanism
  67
• 1.1 Installation position - selector mechanism
  67
• 1.2 Assembly overview - gear knob and cover
  69
• 1.3 Assembly overview - Gear lever and selector housing
  70
• 1.4 Assembly overview - Selector cables
  72
• 1.5 Removing and installing gear knob
  75
• 1.6 Removing and installing selector mechanism
  78
• 1.7 Adjusting selector mechanism
  82
• 1.8 Checking selector mechanism
  86
• 1.9 Removing and installing gear selector cable and gate selector cable
  86
• 1.10 Renewing selector shaft seal
  88
• 1.11 Dismantling and assembling selector mechanism
  91
• 2 Removing and installing gearbox
  97
• 2.1 Specified torques for gearbox
  97
• 2.2 Removing gearbox
  97
• 2.3 Installing gearbox
  121
• 3 Assembly mountings
  129
• 3.1 Assembly overview - assembly mountings
  129
• 4 Transporting gearbox
  132
• 5 Dismantling and assembling gearbox
  133
• 5.1 Schematic overview - gearbox
  133
• 5.2 Assembly overview - gearbox housing and selector mechanism
  134
• 5.3 Assembly overview - selector unit
  136
• 5.4 Assembly overview - input shaft, output shafts, differential, selector rods
  137
• 5.5 Assembly overview - selector forks
  139
• 5.6 Dismantling and assembling gearbox
  139
• 6 Gearbox housing, clutch housing
  154
• 6.1 Assembly overview - gearbox housing
  154
• 6.2 Assembly overview - clutch housing
  156
• 6.3 Repairing gearbox housing
  157
• 6.4 Repairing clutch housing
  164
• 7 Securing to engine and gearbox support
  168
• 8 Gear oil
  169
• 8.1 Checking gear oil level
  169
• Gears, shafts
  171
• 1 Input shaft
  171
• 1.1 Assembly overview - input shaft
  171
• 1.2 Dismantling and assembling input shaft
  172
• 1.3 Renewing input shaft seal
  176
• 2 Output shaft
  178
• 2.1 Assembly overview - output shaft
  178
• 2.2 Dismantling and assembling output shaft
  185
• 2.3 Adjusting output shaft
  207
• Final drive - differential
  218
• 1 Oil seals
  218
• 1.1 Overview of fitting locations - seals
  218
• 1.2 Renewing left seal
  219
• 1.3 Renewing right oil seal
  222
• 2 Differential
  225
• 2.1 Assembly overview - differential
  225
• 2.2 Dismantling and assembling differential
  227
• 2.3 Adjusting differential
  232
• 3 Adjustment overview
  236