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 instructions
  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
  9
• 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
  13
• 1 Clutch operation
  13
• 1.1 Assembly overview - pedal cluster
  13
• 1.2 Assembly overview - clutch hydraulics
  16
• 1.3 Assembly overview - clutch release mechanism
  19
• 1.4 Removing and installing clutch pedal
  20
• 1.5 Removing and installing over-centre spring
  21
• 1.6 Removing and installing return spring
  23
• 1.7 Removing and installing mounting bracket
  26
• 1.8 Removing and installing bearing bush
  30
• 1.9 Removing and installing clutch master cylinder
  31
• 1.10 Removing and installing clutch slave cylinder
  31
• 1.11 Removing and installing lines for clutch mechanism
  33
• 1.12 Bleeding clutch mechanism
  35
• 1.13 Checking clutch master cylinder and clutch slave cylinder
  36
• 1.14 Removing and installing clutch position sender G476
  36
• 1.15 Repairing clutch release mechanism
  37
• 2 Clutch
  39
• 2.1 Determining make of clutch
  39
• 2.2 Assembly overview - clutch
  40
• 2.3 Removing and installing clutch
  44
• Controls, housing
  56
• 1 Selector mechanism
  56
• 1.1 Installation position - selector mechanism
  56
• 1.2 Assembly overview - gear knob and cover
  57
• 1.3 Assembly overview - selector mechanism
  58
• 1.4 Removing and installing gear knob
  59
• 1.5 Removing and installing selector mechanism
  61
• 1.6 Adjusting selector mechanism
  67
• 1.7 Checking selector mechanism
  70
• 1.8 Renewing selector shaft seal
  70
• 2 Removing and installing gearbox
  72
• 2.1 Specified torques for gearbox
  72
• 2.2 Removing gearbox
  72
• 2.3 Installing gearbox
  86
• 3 Assembly mountings
  94
• 3.1 Assembly overview - assembly mountings
  94
• 4 Transporting gearbox
  96
• 5 Dismantling and assembling gearbox
  97
• 5.1 Schematic overview - gearbox
  97
• 5.2 Assembly overview - cover for gearbox housing and 5th/6th gear
  99
• 5.3 Assembly overview - gearbox housing and selector mechanism
  101
• 5.4 Assembly overview - selector unit
  102
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  103
• 5.6 Assembly overview - selector forks
  104
• 5.7 Repairing selector unit
  107
• 5.8 Repairing selector forks
  108
• 5.9 Removing cover for gearbox housing and 5th and 6th gears
  112
• 5.10 Dismantling and assembling gearbox
  119
• 5.11 Installing cover for gearbox housing and 5th and 6th gears
  133
• 6 Gearbox housing, clutch housing
  139
• 6.1 Assembly overview - gearbox housing
  139
• 6.2 Assembly overview - clutch housing
  141
• 6.3 Assembly overview - gearbox housing cover
  142
• 6.4 Repairing gearbox housing
  143
• 6.5 Repairing clutch housing
  150
• 6.6 Repairing gearbox housing cover
  155
• 7 Securing to engine and gearbox support
  157
• 8 Gear oil
  158
• 8.1 Checking gear oil level
  158
• 8.2 Draining and filling gear oil
  158
• Gears, shafts
  161
• 1 Input shaft
  161
• 1.1 Assembly overview - input shaft
  161
• 1.2 Dismantling and assembling input shaft
  164
• 1.3 Adjusting input shaft
  168
• 2 Output shaft
  174
• 2.1 Assembly overview - output shaft
  174
• 2.2 Dismantling and assembling output shaft
  177
• 2.3 Adjusting output shaft
  187
• 3 Reverse shaft
  194
• 3.1 Assembly overview - reverse shaft
  194
• 3.2 Dismantling and assembling reverse shaft
  197
• Final drive - differential
  200
• 1 Oil seals
  200
• 1.1 Overview of fitting locations - seals
  200
• 1.2 Renewing left seal
  201
• 1.3 Renewing right oil seal
  203
• 1.4 Renewing input shaft seal
  207
• 2 Differential
  209
• 2.1 Assembly overview - differential
  209
• 2.2 Dismantling and assembling differential
  211
• 2.3 Adjusting differential
  217
• 3 Adjustment overview
  221