6-speed manual gearbox 0BB and 02Q

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
  2
• 2.1 Gearbox identification
  2
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General repair instructions
  5
• 3.3 Contact corrosion
  9
• 3.4 Gaskets and seals
  9
• 3.5 Nuts and bolts
  10
• 4 Technical data
  11
• 4.1 Capacities
  11
• 4.2 Allocation gearbox - engine
  11
• 4.3 Calculation of gear ratios
  14
• 5 Overview - power transmission
  15
• 5.1 Overview - power transmission - front-wheel drive
  15
• 5.2 Overview - power transmission - all-wheel drive
  16
• 6 Electrical components
  19
• 6.1 Overview of fitting locations - electrical components
  19
• Clutch
  21
• 1 Clutch mechanism
  21
• 1.1 Assembly overview - pedal cluster
  21
• 1.2 Assembly overview - clutch hydraulics
  23
• 1.3 Assembly overview - clutch release mechanism
  27
• 1.4 Removing and installing bearing bush
  28
• 1.5 Checking clutch master cylinder and clutch slave cylinder
  30
• 1.6 Removing and installing clutch position sender G476
  31
• 1.7 Removing and installing return spring
  32
• 1.8 Removing and installing over-centre spring
  35
• 1.9 Removing and installing clutch pedal
  38
• 1.10 Removing and installing mounting bracket
  40
• 1.11 Removing and installing clutch master cylinder
  46
• 1.12 Removing and installing bleeder
  46
• 1.13 Removing and installing lines for clutch mechanism
  50
• 1.14 Removing and installing clutch slave cylinder together with release bearing
  53
• 1.15 Bleeding clutch mechanism
  55
• 1.16 Repairing clutch release mechanism
  56
• 2 Clutch
  58
• 2.1 Determining make of clutch
  58
• 2.2 Assembly overview - clutch
  60
• 2.3 Removing and installing clutch
  62
• Controls, housing
  80
• 1 Bevel box
  80
• 1.1 Assembly overview - bevel box
  80
• 1.2 Distinguishing between different types of bevel boxes
  82
• 1.3 Removing bevel box
  82
• 1.4 Installing bevel box
  91
• 2 Selector mechanism
  98
• 2.1 Installation position - selector mechanism
  98
• 2.2 Assembly overview – gear knob and cover
  99
• 2.3 Assembly overview - selector mechanism
  100
• 2.4 Removing and installing gear knob
  102
• 2.5 Removing and installing selector mechanism
  104
• 2.6 Repairing selector mechanism
  108
• 2.7 Adjusting selector mechanism
  113
• 2.8 Checking selector mechanism
  117
• 3 Removing and installing gearbox
  118
• 3.1 Specified torques for gearbox
  118
• 3.2 Removing gearbox
  119
• 3.3 Installing gearbox
  188
• 4 Assembly mountings
  233
• 4.1 Assembly overview - assembly mountings
  233
• 5 Transporting gearbox
  237
• 6 Dismantling and assembling gearbox
  239
• 6.1 Schematic overview - gearbox
  239
• 6.2 Assembly overview - gearbox
  241
• 6.3 Assembly overview - gearbox housing and selector mechanism
  243
• 6.4 Assembly overview - selector unit
  245
• 6.5 Assembly overview - input shaft, output shafts, differential, selector rods
  246
• 6.6 Assembly overview - selector forks
  250
• 6.7 Renewing selector shaft seal
  251
• 6.8 Dismantling and assembling gearbox
  253
• 7 Gearbox housing, clutch housing
  275
• 7.1 Assembly overview - gearbox housing
  275
• 7.2 Assembly overview - clutch housing
  277
• 7.3 Repairing gearbox housing
  279
• 7.4 Repairing clutch housing
  289
• 8 Securing to engine and gearbox support
  293
• 8.1 Securing to engine and gearbox support, manual gearbox
  293
• 8.2 Securing to engine and gearbox support, bevel box
  294
• 9 Gear oil
  296
• 9.1 Distinguishing between different manual gearbox types when filling oil
  296
• 9.2 Checking gear oil level
  296
• 9.3 Specified torque for oil filler and oil drain plugs
  299
• Gears, shafts
  301
• 1 Input shaft
  301
• 1.1 Assembly overview - input shaft
  301
• 1.2 Dismantling and assembling input shaft
  302
• 1.3 Renewing input shaft seal
  308
• 2 Output shaft
  310
• 2.1 Assembly overview - output shaft
  310
• 2.2 Dismantling and assembling output shaft
  317
• 2.3 Adjusting output shaft
  347
• Final drive - differential
  359
• 1 Gear oil
  359
• 1.1 Checking gear oil level
  359
• 2 Oil seals
  366
• 2.1 Overview of fitting locations - oil seals
  366
• 2.2 Renewing left seal
  368
• 2.3 Renewing right seal
  371
• 3 Differential
  381
• 3.1 Assembly overview - differential
  381
• 3.2 Dismantling and assembling differential
  386
• 3.3 Adjusting differential
  400
• 4 Adjustment overview
  405
• 5 Components of bevel box
  406
• 5.1 Assembly overview - components of bevel box
  406
• 5.2 Renewing bevel box seals
  410
• 5.3 Renewing output flange and redetermining thickness of shim
  438
• 5.4 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  439