6-speed manual gearbox 02U

Chapter overview

• Technical data
  1
• 1 Safety precautions for vehicles with a start-stop system
  1
• 2 Identification of gearbox
  2
• 2.1 Location on gearbox
  2
• 2.2 Identification code, assembly allocation, capacities
  2
• 3 Overview - power transmission
  4
• 4 Calculating overall gear ratio “i”
  6
• 5 General repair instructions
  7
• 5.1 Gearbox
  7
• 5.2 Gaskets and seals
  7
• 5.3 Sealant
  7
• 5.4 Locking devices
  8
• 5.5 Nuts and bolts
  8
• 5.6 Mountings
  8
• 5.7 Shims
  8
• 5.8 Synchro-rings
  9
• 5.9 Gear wheels
  9
• 5.10 Synchromeshed gears
  9
• 5.11 Clutch
  9
• 6 Electrical components
  10
• 6.1 Overview of fitting locations - electrical components
  10
• Clutch
  12
• 1 Repairing clutch mechanism
  12
• 1.1 Overview - clutch actuation
  12
• 1.2 Assembly overview - pedal cluster
  13
• 1.3 Removing, installing and adjusting clutch pedal switch F36
  15
• 1.4 Removing and installing mounting bracket with master cylinder
  16
• 1.5 Removing and installing clutch pedal with over-centre spring, LHD
  19
• 1.6 Removing and installing clutch pedal with extension spring, LHD
  22
• 1.7 Removing and installing clutch pedal, RHD
  25
• 1.8 Assembly overview - hydraulics (LHD)
  28
• 1.9 Assembly overview - hydraulics (RHD)
  30
• 1.10 Removing and installing master cylinder
  32
• 1.11 Removing and installing slave cylinder
  32
• 1.12 Bleeding clutch system
  33
• 2 Repairing clutch release mechanism
  35
• 3 Repairing clutch
  37
• 4 Renewing input shaft seal
  41
• Controls, housing
  43
• 1 Repairing selector mechanism
  43
• 1.1 Installation position of selector mechanism
  43
• 1.2 Overview of selector mechanism
  44
• 1.3 Assembly overview - gear knob and cover
  45
• 1.4 Removing and installing gear knob and cover
  45
• 1.5 Repairing gear lever and selector housing
  47
• 1.6 Assembly overview - removing and installing selector cables
  49
• 1.7 Removing and installing selector mechanism
  53
• 1.8 Adjusting selector mechanism
  56
• 2 Removing and installing gearbox
  60
• 2.1 Removing gearbox
  63
• 2.2 Installing gearbox
  68
• 2.3 Specified torques
  72
• 3 Checking gear oil
  74
• 4 Dismantling and assembling gearbox
  76
• 4.1 Overview - gearbox
  76
• 4.2 Assembly overview
  77
• 4.4 Assembly overview - removing and installing clutch housing
  80
• 4.6 Assembly sequence
  82
• 5 Repairing gearbox housing and clutch housing
  99
• 6 Repairing gearbox housing cover
  104
• 7 Repairing selector unit
  107
• 8 Dismantling and assembling selector forks
  110
• Gears, shafts
  115
• 1 Input shaft
  115
• 1.1 Assembly overview - input shaft
  115
• 1.2 Dismantling and assembling input shaft
  118
• 2 Output shaft
  127
• 2.1 Assembly overview - output shaft
  127
• 2.2 Dismantling and assembling output shaft
  130
• Final drive - differential
  137
• 1 Renewing flange shaft oil seals with gearbox installed
  137
• 1.1 Renewing oil seal for left flange shaft
  137
• 1.2 Renewing seal for right flange shaft
  139
• 2 Differential
  143
• 2.1 Assembly overview - differential
  143
• 2.2 Dismantling and assembling differential
  145
• 2.3 Adjusting differential
  151