6-speed manual gearboxes 02Q and 0BB, installed

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety measures 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
  6
• 4 Overview - power transmission
  7
• 4.1 Overview - power transmission - front-wheel drive
  7
• 4.2 Overview - power transmission - all-wheel drive
  9
• 5 Electrical components
  11
• 5.1 Overview of fitting locations - electrical components
  11
• 6 Repair instructions
  12
• 6.1 General repair instructions
  12
• Clutch
  14
• 1 Clutch operation
  14
• 1.1 Assembly overview - pedal cluster
  14
• 1.2 Assembly overview - clutch hydraulics
  17
• 1.3 Removing and installing bearing bush
  20
• 1.4 Checking clutch master cylinder and clutch slave cylinder
  21
• 1.5 Removing and installing clutch position sender G476
  21
• 1.6 Removing and installing return spring
  22
• 1.7 Removing and installing over-centre spring
  24
• 1.8 Removing and installing clutch pedal
  27
• 1.9 Removing and installing mounting bracket
  28
• 1.10 Removing and installing clutch master cylinder
  33
• 1.11 Removing and installing bleeder
  33
• 1.12 Removing and installing lines for clutch mechanism
  35
• 1.13 Bleeding clutch mechanism
  38
• 2 Clutch
  40
• 2.1 Determining make of clutch
  40
• Controls, housing
  42
• 1 Selector mechanism
  42
• 1.1 Installation position - selector mechanism
  42
• 1.2 Assembly overview - gear knob and cover
  43
• 1.3 Assembly overview - selector mechanism
  44
• 1.4 Removing and installing gear knob
  46
• 1.5 Removing and installing selector mechanism
  47
• 1.6 Adjusting selector mechanism
  55
• 1.7 Checking selector mechanism
  57
• 2 Removing and installing gearbox
  58
• 2.1 Removing gearbox
  58
• 2.2 Installing gearbox
  74
• 2.3 Specified torques for gearbox
  79
• 3 Assembly mountings
  80
• 3.1 Assembly overview - assembly mountings
  80
• 4 Bevel box
  83
• 4.1 Assembly overview - bevel box
  83
• 4.2 Distinguishing between different types of bevel boxes
  84
• 4.3 Removing bevel box
  85
• 4.4 Installing bevel box
  90
• 5 Transporting gearbox
  95
• 6 Gear oil
  96
• 6.1 Distinguishing between different manual gearbox types when filling oil
  96
• 6.2 Checking gear oil level
  96
• 7 Dismantling and assembling gearbox
  100
• 7.1 Assembly overview - selector unit
  100
• 7.2 Removing and installing selector unit with gearbox installed
  100
• 7.3 Renewing selector shaft seal
  104
• 8 Gearbox housing, clutch housing
  107
• Gears, shafts
  108
• 1 Input shaft
  108
• 2 Output shaft
  109
• Final drive - differential
  110
• 1 Oil seals
  110
• 1.1 Overview of fitting locations - seals
  110
• 1.2 Renewing left seal
  111
• 1.3 Renewing right oil seal
  114
• 2 Differential
  122
• 3 Components of bevel box
  123
• 3.1 Renewing bevel box seals
  123
• 3.2 Renewing output flange and redetermining thickness of shim
  123
• 3.3 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  123
• 4 Gear oil
  127
• 4.1 Checking gear oil level
  127