6-speed manual gearbox 0A2

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Identification code, assembly allocation, ratios, capacities
  1
• 2 Overview - power transmission
  3
• 3 Calculating overall gear ratio “i”
  5
• 4 General repair notes
  6
• 4.1 Components
  6
• Clutch
  9
• 1 Functional check of clutch master and slave cylinders
  9
• 2 Distinguishing clutch control mechanisms
  11
• 3 Repairing clutch control mechanism (master cylinder secured to clutch pedal with a pin)
  12
• 3.1 Overview
  12
• 3.2 Assembly overview - pedal cluster (LHD vehicles)
  13
• 3.3 Removing and installing clutch pedal and over-centre spring
  14
• 3.4 Assembly overview - pedal cluster (RHD vehicles)
  15
• 3.5 Assembly overview - hydraulic system
  17
• 3.6 Removing and installing master cylinder
  18
• 4.1 Overview
  22
• 4.2 Assembly overview - pedal cluster (LHD vehicles)
  23
• 4.3 Removing and installing clutch pedal and over-centre spring
  24
• 4.4 Assembly overview - pedal cluster (RHD vehicles)
  25
• 4.5 Assembly overview - hydraulic system
  27
• 4.6 Removing and installing master cylinder
  29
• 5 Clutch pedal switch
  34
• 5.2 Checking and adjusting clutch pedal switch F36
  34
• 6 Bleeding clutch system
  37
• 7 Repairing clutch release mechanism
  38
• 7.1 Removing and installing slave cylinder
  41
• 8 Repairing clutch
  45
• 8.1 Resetting adjusting ring of self-adjusting pressure plate
  47
• Controls, housing
  50
• 1 Repairing selector mechanism
  50
• 1.1 Installation position of selector mechanism
  50
• 1.2 Repairing selector lever and selector lever mounting
  52
• 1.3 Repairing selector rod, connecting rod and push rod
  54
• 1.4 Removing and installing selector lever with selector lever mounting
  55
• 1.5 Removing and installing selector mechanism
  56
• 1.6 Adjusting selector mechanism
  59
• 2 Removing and installing gearbox
  61
• 2.1 Removing gearbox
  62
• 2.2 Transporting gearbox
  66
• 2.3 Installing gearbox
  66
• 3 Checking gearbox oil
  74
• 4 Dismantling and assembling gearbox
  75
• 4.1 Overview - gearbox construction
  75
• 4.2 Assembly overview
  76
• 4.4 Assembly overview - removing and installing 1st, 2nd and reverse gears
  79
• 4.6 Dismantling and assembling procedure
  85
• 5 Repairing gearbox cover
  114
• 6 Repairing gearbox housing
  119
• 8 Removing and installing selector shaft, seal for selector shaft and reversing light switch F4
  130
• 8.1 Removing and installing selector shaft with gearbox installed
  130
• 8.2 Renewing selector shaft oil seal with gearbox installed
  134
• 8.3 Renewing selector shaft oil seal with gearbox installed
  136
• 8.4 Removing and installing reversing light switch F4
  138
• Gears, shafts
  139
• 1 Input shaft
  139
• 1.1 Assembly overview - input shaft
  139
• 1.2 Assembly overview - dismantling and assembling input shaft
  143
• 2 Pinion shaft
  152
• 2.1 Assembly overview - pinion shaft
  152
• 2.2 Dismantling and assembling pinion shaft
  155
• 2.3 Redetermining shim “S5” for positioning 4th gear wheel
  157
• 2.4 Redetermining shim “S6” for positioning 2nd gear synchromeshed gear
  158
• Final drive - differential
  162
• 1 Renewing flange shaft oil seals with gearbox installed
  162
• 1.1 Renewing oil seal for left flange shaft
  162
• 1.2 Renewing seal for right flange shaft
  165
• 2 Removing and installing differential
  168
• 3 Dismantling and assembling differential
  172
• 4 Adjusting pinion shaft and crown wheel
  179
• 4.1 Adjustment and marking of final drive gear sets
  179
• 4.2 Adjusting pinion shaft
  182
• 4.3 Adjusting crown wheel
  188