6-speed manual gearbox 02S

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
  5
• 2.1 Designation
  5
• 2.2 Gears
  6
• 3 Calculating overall gear ratio “i”
  7
• 4 General repair notes
  8
• 4.1 Components
  8
• Clutch
  11
• 1 Repairing clutch mechanism
  11
• 1.1 Overview
  11
• 1.2 Assembly overview - pedal cluster with clutch pedal switch F36 , through 05.03
  12
• 1.3 Removing and installing clutch pedal switch F36
  13
• 1.4 Removing and installing mounting bracket (all Tourans)
  15
• 1.5 Removing and installing master cylinder with mounting bracket removed (through 05.03)
  20
• 1.8 Removing and installing over-centre spring with mounting bracket installed
  25
• 1.9 Removing and installing clutch pedal with mounting bracket installed
  27
• 1.11 Removing and installing clutch position sender G476 (from 06.03)
  32
• 1.12 Assembly overview - hydraulics (LHD)
  35
• 1.13 Assembly overview - hydraulics (RHD)
  37
• 1.14 Removing and installing slave cylinder
  38
• 1.15 Bleeding clutch system
  40
• 2 Repairing clutch release mechanism
  42
• 3 Repairing clutch
  44
• 1.9 l - 77 kW turbo diesel engine
  44
• 3.2 Removing and installing Sachs clutch
  46
• 3.3 Repairing Sachs clutch
  48
• 3.4 Removing and installing LuK clutch
  48
• 3.5 Repairing LuK clutch
  51
• 4 Repairing clutch, in conjunction with one-piece flywheel
  52
• Controls, housing
  55
• 1 Repairing selector mechanism
  55
• 1.1 Installation position of selector mechanism
  55
• 1.2 Removing and installing gear knob and cover
  57
• 1.3 Removing and installing gaiter with gear knob
  57
• 1.4 Repairing gear lever and selector housing (through 10.06)
  59
• 1.5 Repairing gear lever and selector housing (from 11.06)
  61
• 1.6 Assembly overview - removing and installing selector cables
  66
• 1.7 Plastic relay lever
  69
• 1.8 Removing and installing selector mechanism
  71
• 1.9 Adjusting selector mechanism
  74
• 2.1 Removing gearbox
  80
• 2.2 Installing gearbox
  86
• 3.1 Removing gearbox
  95
• 3.2 Installing gearbox
  100
• 4 Transporting gearbox
  107
• 5 Checking and topping up gear oil
  108
• 5.1 Preparation
  108
• 5.2 Draining gear oil
  109
• 5.3 Fill with gear oil
  110
• 6 Dismantling and assembling gearbox
  111
• 6.1 Overview - gearbox
  111
• 6.2 Assembly overview
  112
• 6.3 Removing and installing cover for gearbox housing and 5th and 6th gears
  112
• 6.4 Removing and installing gearbox housing and shift mechanism
  115
• 6.5 Removing and installing input shaft, output shaft, differential and selector forks
  116
• 6.7 Assembly sequence - Dismantling and assembling gearbox completely
  123
• 7 Repairing gearbox housing and clutch housing
  141
• 8 Repairing gearbox housing cover
  147
• 9 Repairing selector unit
  151
• 10 Dismantling and assembling selector forks
  154
• Gears, shafts
  159
• 1 Input shaft
  159
• 1.1 Dismantling and assembling input shaft
  159
• 1.2 Adjusting input shaft
  167
• 1.3 Adjusting input shaft
  171
• 2 Output shaft
  175
• 2.1 Dismantling and assembling output shaft
  175
• 2.2 Adjusting output shaft
  188
• 3 Reverse shaft
  192
• 3.1 Dismantling and assembling reverse shaft
  192
• Final drive - differential
  195
• 1 Renewing flange shaft oil seals with gearbox installed
  195
• 1.1 Renewing oil seal for left flange shaft
  195
• 1.2 Distinguishing seals for right flange shaft
  196
• 1.3 Renewing seal (two-part seal and sleeve for right flange shaft)
  197
• 2 Adjustment overview
  203
• 3 Differential
  204
• 3.1 Dismantling and assembling differential
  204
• 3.2 Adjusting differential
  211