6-speed manual gearboxes 02Q and 0BB

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Safety precautions when tow-starting or towing
  2
• 1.4 All-wheel drive - notes on performance test
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Repair instructions
  6
• 3.1 Contact corrosion
  6
• 3.2 General repair instructions
  6
• 4 Technical data
  11
• 4.1 Allocation gearbox - engine
  11
• 4.2 Capacities
  13
• 4.3 Calculation of gear ratios
  13
• 5 Overview - power transmission
  14
• 5.1 Overview - power transmission - front-wheel drive
  14
• 5.2 Overview - power transmission - all-wheel drive
  15
• 6 Electrical components
  18
• 6.1 Overview of fitting locations - electrical components
  18
• Clutch
  20
• 1 Clutch mechanism
  20
• 1.1 Assembly overview - pedal cluster
  20
• 1.2 Assembly overview - clutch hydraulics
  22
• 1.3 Assembly overview - clutch release mechanism
  25
• 1.4 Removing and installing clutch pedal
  27
• 1.5 Removing and installing over-centre spring
  32
• 1.6 Removing and installing mounting bracket
  39
• 1.7 Removing and installing clutch master cylinder
  47
• 1.8 Removing and installing clutch slave cylinder together with release bearing
  50
• 1.9 Removing and installing lines for clutch mechanism
  53
• 1.10 Removing and installing bleeder
  55
• 1.11 Bleeding clutch mechanism
  56
• 1.12 Checking clutch master cylinder and clutch slave cylinder
  58
• 1.13 Removing and installing clutch position sender G476
  58
• 2 Clutch
  62
• 2.1 Assembly overview - clutch
  62
• 2.2 Removing and installing clutch
  63
• Controls, housing
  76
• 1 Bevel box
  76
• 1.1 Assembly overview - bevel box
  76
• 1.2 Removing bevel box
  79
• 1.3 Installing bevel box
  88
• 2 Selector mechanism
  94
• 2.1 Installation position - selector mechanism
  94
• 2.2 Assembly overview – gear knob and cover
  95
• 2.3 Assembly overview - Gear lever and selector housing
  96
• 2.4 Assembly overview – selector cables
  98
• 2.5 Removing and installing gear knob
  101
• 2.6 Removing and installing selector mechanism
  102
• 2.7 Adjusting selector mechanism
  111
• 2.8 Checking selector mechanism
  115
• 2.9 Removing and installing gear selector cable
  115
• 2.10 Renewing selector shaft seal
  118
• 2.11 Dismantling and assembling selector mechanism
  121
• 2.12 Removing and installing selector unit
  128
• 3 Removing and installing gearbox
  133
• 3.1 Specified torques for gearbox
  133
• 3.2 Removing gearbox
  133
• 3.3 Installing gearbox
  162
• 4 Assembly mountings
  182
• 4.1 Assembly overview - assembly mountings
  182
• 5 Transporting gearbox
  186
• 6 Dismantling and assembling gearbox
  187
• 6.1 Schematic overview - gearbox
  187
• 6.2 Assembly overview - gearbox
  188
• 6.3 Assembly overview - gearbox housing and selector mechanism
  190
• 6.4 Assembly overview - selector unit
  192
• 6.5 Assembly overview - input shaft, output shafts, differential, selector rods
  193
• 6.6 Assembly overview - selector forks
  197
• 6.7 Dismantling and assembling gearbox
  198
• 7 Gearbox housing, clutch housing
  220
• 7.1 Assembly overview - gearbox housing
  220
• 7.2 Assembly overview - clutch housing
  222
• 7.3 Repairing gearbox housing
  224
• 7.4 Repairing clutch housing
  233
• 8 Securing to engine and gearbox support
  237
• 8.1 Securing to engine and gearbox support
  237
• 8.2 Installing bevel box to engine and gearbox support
  238
• 9 Gear oil
  240
• 9.1 Checking gear oil level
  240
• 9.2 Draining and filling gear oil
  242
• Gears, shafts
  246
• 1 Input shaft
  246
• 1.1 Assembly overview - input shaft
  246
• 1.2 Dismantling and assembling input shaft
  247
• 1.3 Renewing input shaft seal
  253
• 2 Output shaft
  255
• 2.1 Assembly overview - output shaft
  255
• 2.2 Dismantling and assembling output shaft
  260
• 2.3 Adjusting output shaft
  290
• Final drive - differential
  302
• 1 Gear oil
  302
• 1.1 Checking gear oil level
  302
• 1.2 Draining and filling gear oil
  304
• 2 Oil seals
  310
• 2.1 Overview of fitting locations - oil seals
  310
• 2.2 Renewing left seal
  311
• 2.3 Renewing right seal
  316
• 3 Differential
  326
• 3.1 Assembly overview - differential
  326
• 3.2 Dismantling and assembling differential
  331
• 3.3 Adjusting differential
  345
• 4 Adjustment overview
  350
• 5 Components of bevel box
  351
• 5.1 Assembly overview - components of bevel box
  351
• 5.2 Renewing bevel box seals
  353
• 5.3 Renewing output flange and redetermining thickness of shim
  366
• 5.4 Removing and installing right flange shaft
  367