6-speed manual gearbox 02S

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
  3
• 2.1 Gearbox identification
  3
• 3 Repair notes
  4
• 3.1 General repair instructions
  4
• 4 Technical data
  8
• 4.1 Capacities
  8
• 4.2 Allocation gearbox - engine
  8
• 4.3 Calculation of gear ratios
  8
• 5 Overview - power transmission
  10
• 5.1 Overview - power transmission - front-wheel drive
  10
• 6 Electrical components
  12
• 6.1 Overview of fitting locations - electrical components
  12
• Clutch
  14
• 1 Clutch operation
  14
• 1.1 Assembly overview - pedal cluster
  14
• 1.2 Assembly overview - clutch hydraulics
  17
• 1.3 Assembly overview - clutch release mechanism
  21
• 1.4 Removing and installing over-centre spring
  22
• 1.5 Removing and installing clutch pedal
  26
• 1.6 Removing and installing mounting bracket
  32
• 1.7 Removing and installing clutch master cylinder
  38
• 1.8 Removing and installing clutch slave cylinder
  40
• 1.9 Checking clutch master cylinder and clutch slave cylinder
  42
• 1.10 Removing and installing clutch position sender G476
  42
• 1.11 Bleeding clutch mechanism
  45
• 1.12 Repairing clutch release mechanism
  46
• 2 Clutch
  48
• 2.1 Determining make of clutch
  48
• 2.2 Assembly overview - clutch
  49
• 2.3 Removing and installing clutch
  53
• Controls, housing
  63
• 1 Selector mechanism
  63
• 1.1 Installation position - selector mechanism
  63
• 1.2 Assembly overview - gear knob and cover
  65
• 1.3 Assembly overview - Gear lever and selector housing
  66
• 1.4 Assembly overview - Selector cables
  68
• 1.5 Removing and installing gear knob
  70
• 1.6 Dismantling and assembling selector mechanism
  72
• 1.7 Removing and installing selector mechanism
  78
• 1.8 Removing and installing gear selector cable and gate selector cable
  83
• 1.9 Adjusting selector mechanism
  85
• 1.10 Checking selector mechanism
  87
• 1.11 Renewing oil seal for selector shaft
  88
• 2 Removing and installing gearbox
  90
• 2.1 Specified torques for gearbox
  90
• 2.2 Removing gearbox
  90
• 2.3 Installing gearbox
  101
• 3 Assembly mounting
  109
• 3.1 Assembly overview - assembly mountings
  109
• 4 Transporting gearbox
  111
• 5 Dismantling and assembling gearbox
  112
• 5.1 Schematic overview - gearbox
  112
• 5.2 Assembly overview - cover for gearbox housing and 5th/6th gear
  114
• 5.3 Assembly overview - gearbox housing and selector mechanism
  116
• 5.4 Assembly overview - selector unit
  118
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  119
• 5.6 Assembly overview - selector forks
  120
• 5.7 Repairing selector unit
  123
• 5.8 Repairing selector forks
  124
• 5.9 Removing cover for gearbox housing and 5th and 6th gears
  127
• 5.10 Dismantling and assembling gearbox
  133
• 5.11 Installing cover for gearbox housing and 5th and 6th gears
  147
• 6 Gearbox housing, clutch housing
  152
• 6.1 Assembly overview - gearbox housing
  152
• 6.2 Assembly overview - clutch housing
  154
• 6.3 Assembly overview - gearbox housing cover
  155
• 6.4 Repairing gearbox housing
  156
• 6.5 Repairing clutch housing
  163
• 6.6 Repairing gearbox housing cover
  168
• 7 Installing to engine and gearbox support
  170
• 8 Gear oil
  171
• 8.1 Checking gear oil level
  171
• 8.2 Draining and filling gear oil
  171
• Gears, shafts
  174
• 1 Input shaft
  174
• 1.1 Assembly overview - input shaft
  174
• 1.2 Dismantling and assembling input shaft
  176
• 1.3 Adjusting input shaft
  180
• 2 Output shaft
  186
• 2.1 Assembly overview - output shaft
  186
• 2.2 Dismantling and assembling output shaft
  189
• 2.3 Adjusting output shaft
  199
• 3 Reverse shaft
  206
• 3.1 Assembly overview - reverse shaft
  206
• 3.2 Dismantling and assembling reverse shaft
  209
• Final drive - differential
  212
• 1 Oil seals
  212
• 1.1 Overview of fitting locations - seals
  212
• 1.2 Renewing left oil seal
  213
• 1.3 Renewing right oil seal
  215
• 1.4 Renewing input shaft seal
  219
• 2 Differential
  221
• 2.1 Assembly overview - differential
  221
• 2.2 Dismantling and assembling differential
  223
• 2.3 Adjusting differential
  228
• 3 Adjustment overview
  232