6-speed manual gearbox 02S

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  3
• 3.1 Allocation gearbox - engine
  3
• 3.2 Capacities
  7
• 3.3 Calculation of gear ratios
  7
• 4 Overview - power transmission
  8
• 5 Electrical components
  10
• 5.1 Overview of fitting locations - electrical components
  10
• 6 Repair instructions
  12
• 6.1 General repair instructions
  12
• Clutch
  15
• 1 Clutch mechanism
  15
• 1.1 Overview of fitting locations – clutch mechanism
  15
• 1.2 Assembly overview - pedal cluster
  17
• 1.3 Assembly overview - clutch hydraulics
  21
• 1.4 Assembly overview - clutch release mechanism
  27
• 1.5 Removing and installing bearing bush
  28
• 1.6 Checking function of clutch master cylinder and clutch slave cylinder
  29
• 1.7 Removing and installing clutch position sender G476
  30
• 1.8 Removing and installing return spring
  33
• 1.9 Removing and installing over-centre spring
  35
• 1.10 Removing and installing clutch pedal
  39
• 1.11 Removing and installing mounting bracket
  43
• 1.12 Removing and installing clutch master cylinder
  51
• 1.13 Removing and installing clutch slave cylinder
  53
• 1.14 Removing and installing lines for clutch mechanism
  56
• 1.15 Bleeding clutch mechanism
  59
• 1.16 Repairing clutch release mechanism
  61
• 2 Clutch
  62
• 2.1 Assembly overview - clutch
  62
• 2.2 Removing and installing clutch
  64
• Controls, housing
  79
• 1 Selector mechanism
  79
• 1.1 Installation position - selector mechanism
  79
• 1.2 Assembly overview - gear knob and cover
  81
• 1.3 Assembly overview - Gear lever and selector housing
  84
• 1.4 Assembly overview - selector mechanism
  85
• 1.5 Removing and installing gear knob
  86
• 1.6 Removing and installing selector mechanism
  91
• 1.7 Repairing selector mechanism
  95
• 1.8 Adjusting selector mechanism
  97
• 1.9 Checking selector mechanism
  101
• 2 Removing and installing gearbox
  102
• 2.1 Removing gearbox
  102
• 2.2 Installing gearbox
  162
• 2.3 Specified torques for gearbox
  192
• 3 Assembly mountings
  194
• 3.1 Assembly overview - assembly mountings
  194
• 4 Transporting gearbox
  196
• 5 Gear oil
  197
• 5.1 Checking gear oil level
  197
• 5.2 Draining and filling gear oil
  197
• 6 Securing to engine and gearbox support
  200
• 7 Dismantling and assembling gearbox
  204
• 7.1 Schematic overview - gearbox
  204
• 7.2 Assembly overview - gearbox
  206
• 7.3 Assembly overview - cover for gearbox housing and 5th/6th gear
  207
• 7.4 Assembly overview - gearbox housing and selector mechanism
  209
• 7.5 Assembly overview - selector unit
  211
• 7.6 Assembly overview - shafts, differential, selector mechanism
  212
• 7.7 Assembly overview - selector forks
  213
• 7.8 Repairing selector unit
  216
• 7.9 Renewing selector shaft seal
  217
• 7.10 Repairing selector forks
  218
• 7.11 Removing cover for gearbox housing and 5th and 6th gears
  221
• 7.12 Dismantling and assembling gearbox
  226
• 7.13 Installing cover for gearbox housing and 5th and 6th gears
  241
• 8 Gearbox housing, clutch housing
  249
• 8.1 Assembly overview - gearbox housing and clutch housing
  249
• 8.2 Assembly overview - gearbox housing cover
  251
• 8.3 Repairing gearbox housing
  252
• 8.4 Repairing clutch housing
  257
• 8.5 Repairing gearbox housing cover
  258
• Gears, shafts
  261
• 1 Input shaft
  261
• 1.1 Assembly overview - input shaft
  261
• 1.2 Dismantling and assembling input shaft
  263
• 1.3 Adjusting input shaft
  268
• 1.4 Renewing input shaft seal
  273
• 2 Output shaft
  275
• 2.1 Assembly overview - output shaft
  275
• 2.2 Dismantling and assembling output shaft
  278
• 2.3 Adjusting output shaft
  288
• 3 Reverse shaft
  293
• 3.1 Assembly overview - reverse shaft
  293
• 3.2 Dismantling and assembling reverse shaft
  296
• Final drive - differential
  299
• 1 Oil seals
  299
• 1.1 Overview of fitting locations - seals
  299
• 1.2 Renewing left seal
  300
• 1.3 Renewing right oil seal
  302
• 2 Differential
  306
• 2.1 Assembly overview - differential
  306
• 2.2 Dismantling and assembling differential
  308
• 2.3 Adjusting differential
  313
• 3 Adjustment overview
  317