6-speed manual gearbox 0BB and 02Q

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety precautions when working on vehicles with a start/stop system
  2
• 1.3 All-wheel drive - notes on performance test
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Technical data
  5
• 3.1 Allocation gearbox - engine
  5
• 3.2 Capacities
  7
• 3.3 Calculation of gear ratios
  7
• 4 Overview - power transmission
  9
• 4.1 Overview - power transmission - front-wheel drive
  9
• 4.2 Overview - power transmission - all-wheel drive
  11
• 5 Electrical components
  13
• 5.1 Overview of fitting locations - electrical components
  13
• 6 Repair notes
  14
• 6.1 General repair instructions
  14
• Clutch
  17
• 1 Clutch operation
  17
• 1.1 Overview of fitting locations – clutch mechanism
  17
• 1.2 Assembly overview - pedal cluster
  19
• 1.3 Assembly overview - clutch hydraulics
  21
• 1.4 Assembly overview - clutch release mechanism
  24
• 1.5 Removing and installing bearing bush
  25
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  26
• 1.7 Removing and installing clutch position sender G476
  26
• 1.8 Removing and installing return spring
  27
• 1.9 Removing and installing over-centre spring
  29
• 1.10 Removing and installing clutch pedal
  32
• 1.11 Removing and installing mounting bracket
  33
• 1.12 Removing and installing clutch master cylinder
  38
• 1.13 Removing and installing bleeder
  38
• 1.14 Removing and installing lines for clutch mechanism
  40
• 1.15 Removing and installing clutch slave cylinder together with release bearing
  43
• 1.16 Bleeding clutch mechanism
  44
• 1.17 Repairing clutch release mechanism
  46
• 2 Clutch
  48
• 2.1 Determining make of clutch
  48
• 2.2 Assembly overview - clutch
  49
• 2.3 Removing and installing clutch
  52
• Controls, housing
  66
• 1 Selector mechanism
  66
• 1.1 Installation position - selector mechanism
  66
• 1.2 Assembly overview - gear knob and cover
  68
• 1.3 Assembly overview - selector mechanism
  69
• 1.4 Removing and installing gear knob
  70
• 1.5 Removing and installing selector mechanism
  72
• 1.6 Repairing selector mechanism
  76
• 1.7 Adjusting selector mechanism
  79
• 1.8 Checking selector mechanism
  82
• 2 Removing and installing gearbox
  83
• 2.1 Removing gearbox
  83
• 2.2 Installing gearbox
  137
• 2.3 Specified torques for gearbox
  173
• 3 Assembly mounting
  175
• 3.1 Assembly overview - assembly mountings
  175
• 4 Bevel box
  178
• 4.1 Assembly overview - bevel box
  178
• 4.2 Distinguishing between different types of bevel boxes
  179
• 4.3 Removing bevel box
  180
• 4.4 Installing bevel box
  186
• 5 Transporting gearbox
  191
• 6 Gear oil
  192
• 6.1 Distinguishing between different manual gearbox types when filling oil
  192
• 6.2 Checking gear oil level
  192
• 7 Securing to engine and gearbox support
  196
• 7.1 Installing manual gearbox to engine and gearbox support
  196
• 7.2 Installing bevel box to engine and gearbox support
  197
• 8 Dismantling and assembling gearbox
  199
• 8.1 Schematic overview - gearbox
  199
• 8.2 Assembly overview - gearbox
  201
• 8.3 Assembly overview - gearbox housing and selector mechanism
  203
• 8.4 Assembly overview - selector unit
  205
• 8.5 Assembly overview - shafts, differential, selector mechanism
  206
• 8.6 Assembly overview - selector forks
  210
• 8.7 Renewing selector shaft seal
  210
• 8.8 Dismantling and assembling gearbox
  212
• 9 Gearbox housing, clutch housing
  228
• 9.1 Assembly overview - gearbox housing
  228
• 9.2 Assembly overview - clutch housing
  230
• 9.3 Repairing gearbox housing
  231
• 9.4 Repairing clutch housing
  239
• Gears, shafts
  243
• 1 Input shaft
  243
• 1.1 Assembly overview - input shaft
  243
• 1.2 Dismantling and assembling input shaft
  244
• 1.3 Renewing input shaft seal
  248
• 2 Output shaft
  250
• 2.1 Assembly overview - output shaft
  250
• 2.2 Dismantling and assembling output shaft
  258
• 2.3 Adjusting output shaft
  280
• Final drive - differential
  291
• 1 Oil seals
  291
• 1.1 Overview of fitting locations - seals
  291
• 1.2 Renewing left seal
  292
• 1.3 Renewing right oil seal
  295
• 2 Differential
  303
• 2.1 Assembly overview - differential
  303
• 2.2 Dismantling and assembling differential
  308
• 2.3 Adjusting differential
  319
• 3 Adjustment overview
  324
• 4 Components of bevel box
  325
• 4.1 Assembly overview - components of bevel box
  325
• 4.2 Renewing bevel box seals
  330
• 4.3 Renewing output flange and redetermining thickness of shim
  352
• 4.4 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  353
• 5 Gear oil
  357
• 5.1 Checking gear oil level
  357