6-speed manual gearbox 02Q and 0BB

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 2 Technical data
  3
• 2.1 Allocation gearbox - engine
  3
• 2.2 Capacities
  5
• 2.3 Calculation of gear ratios
  5
• 3 Overview - power transmission
  6
• 3.1 Overview - power transmission - front-wheel drive
  6
• 3.2 Overview - power transmission - all-wheel drive
  8
• 4 Safety information
  10
• 4.2 Safety measures when working on vehicles with a start/stop system
  11
• 4.3 All-wheel drive - notes on performance test
  11
• 5 Repair notes
  12
• 5.1 Contact corrosion
  12
• 5.2 General repair instructions
  12
• Clutch
  16
• 1 Clutch mechanism
  16
• 1.1 Assembly overview - clutch release mechanism
  16
• 1.2 Assembly overview - pedal cluster
  18
• 1.3 Assembly overview - clutch hydraulics
  20
• 1.4 Checking clutch master cylinder and clutch slave cylinder
  22
• 1.5 Removing and installing mounting bracket
  22
• 1.6 Removing and installing clutch pedal
  27
• 1.7 Removing and installing over-centre spring
  31
• 1.8 Removing and installing clutch position sender G476
  34
• 1.9 Removing and installing clutch master cylinder
  36
• 1.10 Removing and installing line for clutch mechanism
  38
• 1.11 Bleeding clutch mechanism
  41
• 1.12 Removing and installing clutch slave cylinder together with release bearing
  42
• 2 Clutch
  44
• 2.1 Determining make of clutch
  44
• 2.2 Assembly overview - clutch
  45
• 2.3 Removing and installing Sachs clutch
  48
• Controls, housing
  56
• 1 Selector mechanism
  56
• 1.1 Installation position - selector mechanism
  56
• 1.2 Assembly overview – gear knob and cover
  58
• 1.3 Assembly overview - Gear lever and selector housing
  59
• 1.4 Assembly overview – selector cables
  61
• 1.5 Removing and installing relay lever
  62
• 1.6 Removing and installing gear knob
  65
• 1.7 Removing and installing selector mechanism
  66
• 1.8 Dismantling and assembling selector mechanism
  70
• 1.9 Removing and installing selector unit
  76
• 1.10 Removing and installing selector cables
  78
• 1.11 Adjusting selector mechanism
  80
• 1.12 Checking selector mechanism
  82
• 1.13 Renewing selector shaft seal
  82
• 2 Removing and installing gearbox
  85
• 2.1 Removing gearbox
  85
• 2.2 Installing gearbox
  100
• 2.3 Specified torques – gearbox
  110
• 3 Transporting gearbox
  112
• 4 Bevel box
  113
• 4.1 Removing bevel box
  113
• 4.2 Installing bevel box
  118
• 5 Gear oil
  122
• 5.1 Checking gear oil level
  122
• 5.2 Draining and filling gear oil
  123
• 6 Securing to engine and gearbox support
  127
• 6.1 Installing manual gearbox to engine and gearbox support
  127
• 6.2 Installing bevel box to engine and gearbox support
  127
• 7 Dismantling and assembling gearbox
  129
• 7.1 Schematic overview - gearbox
  129
• 7.2 Assembly overview - gearbox housing and selector mechanism
  132
• 7.3 Assembly overview - input shaft, output shafts, differential and selector rods
  134
• 7.4 Assembly overview - selector unit
  138
• 7.5 Assembly overview - selector forks
  140
• 7.6 Assembly order, gearbox »without« circlip A for input shaft cover made from sheet metal
  141
• 8 Gearbox housing, clutch housing
  173
• 8.1 Assembly overview - gearbox housing
  173
• 8.2 Assembly overview - clutch housing
  175
• 8.3 Repairing gearbox housing
  179
• 8.4 Repairing clutch housing
  188
• Gears, shafts
  191
• 1 Input shaft
  191
• 1.1 Assembly overview - input shaft
  191
• 1.2 Dismantling and assembling input shaft
  193
• 1.3 Modification in area of deep groove ball bearing
  198
• 1.4 Renewing input shaft seal
  199
• 2 Output shaft
  201
• 2.1 Assembly overview - output shaft
  201
• 2.2 Dismantling and assembling output shaft
  206
• 2.3 Adjusting output shaft
  240
• Final drive - differential
  251
• 1 Oil seals
  251
• 1.1 Overview of fitting locations - seals
  251
• 1.2 Renewing left seal
  252
• 1.3 Renewing right oil seal
  254
• 2 Differential
  262
• 2.1 Assembly overview - differential
  262
• 2.2 Dismantling and assembling differential
  267
• 2.3 Adjusting differential
  280
• 3 Adjustment overview
  285
• 4 Bevel box
  286
• 4.1 Assembly overview - bevel box
  286
• 4.2 Renewing bevel box seals
  288
• 4.3 Renewing output flange and redetermining thickness of shim
  300
• 4.4 Removing and installing right flange shaft
  300
• 5 Gear oil
  306
• 5.1 Checking gear oil level
  306
• 5.2 Draining and filling gear oil
  307