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

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 All-wheel drive - notes on performance test
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  5
• 3.1 Allocation gearbox - engine
  5
• 3.2 Capacities
  6
• 4 Overview - power transmission
  8
• 4.1 Overview - power transmission - front-wheel drive
  8
• 4.2 Overview - power transmission - all-wheel drive
  9
• 5 Electrical components
  12
• 5.1 Overview of fitting locations - electrical components
  12
• 6 Repair instructions
  14
• 6.1 General repair instructions
  14
• Clutch
  17
• 1 Clutch mechanism
  17
• 1.1 Overview of fitting locations – clutch mechanism
  17
• 1.2 Assembly overview - pedal cluster
  18
• 1.3 Assembly overview - clutch hydraulics
  20
• 1.4 Removing and installing bearing bush
  24
• 1.5 Checking clutch master cylinder and clutch slave cylinder
  25
• 1.6 Removing and installing clutch position sender G476
  26
• 1.7 Removing and installing return spring
  27
• 1.8 Removing and installing over-centre spring
  30
• 1.9 Removing and installing clutch pedal
  34
• 1.10 Removing and installing mounting bracket
  35
• 1.11 Removing and installing clutch master cylinder
  41
• 1.12 Removing and installing bleeder
  41
• 1.13 Removing and installing lines for clutch mechanism
  45
• 1.14 Bleeding clutch mechanism
  49
• 2 Clutch
  52
• 2.1 Determining make of clutch
  52
• Controls, housing
  54
• 1 Selector mechanism
  54
• 1.1 Installation position - selector mechanism
  54
• 1.2 Assembly overview – gear knob and cover
  55
• 1.3 Assembly overview - selector mechanism
  56
• 1.4 Removing and installing gear knob
  58
• 1.5 Removing and installing selector mechanism
  60
• 1.6 Repairing selector mechanism
  64
• 1.7 Adjusting selector mechanism
  70
• 1.8 Checking selector mechanism
  74
• 2 Removing and installing gearbox
  76
• 2.1 Removing gearbox
  76
• 2.2 Installing gearbox
  106
• 2.3 Specified torques for gearbox
  131
• 3 Assembly mountings
  132
• 3.1 Assembly overview - assembly mountings
  132
• 4 Bevel box
  136
• 4.1 Assembly overview - bevel box
  136
• 4.2 Distinguishing between different types of bevel boxes
  138
• 4.3 Removing bevel box
  138
• 4.4 Installing bevel box
  146
• 5 Front differential lock
  152
• 5.1 Assembly overview - front differential lock
  152
• 5.2 Allocation of front differential lock
  153
• 5.3 Removing front differential lock
  153
• 5.4 Installing front differential lock
  156
• 5.5 Removing and installing differential lock control unit J647
  158
• 6 Transporting gearbox
  160
• 7 Gear oil
  161
• 7.1 Distinguishing between different manual gearbox types when filling oil
  161
• 7.2 Checking gear oil level
  161
• 8 Dismantling and assembling gearbox
  166
• 8.1 Assembly overview - selector unit
  166
• 8.2 Removing and installing selector unit with gearbox installed
  167
• 8.3 Renewing selector shaft seal
  171
• 9 Gearbox housing, clutch housing
  174
• Gears, shafts
  175
• 1 Input shaft
  175
• 2 Output shaft
  176
• Final drive - differential
  177
• 1 Oil seals
  177
• 1.1 Overview of fitting locations - seals
  177
• 1.2 Renewing left seal
  179
• 1.3 Renewing right seal
  183
• 2 Differential
  198
• 3 Components of bevel box
  199
• 3.1 Renewing bevel box seals
  199
• 3.2 Renewing output flange and redetermining thickness of shim
  199
• 3.3 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  199
• 4 Components of front differential lock
  204
• 4.1 Checking function
  204
• 4.2 Removing and installing pump V181
  204
• 4.3 Removing and installing coupling for front differential lock
  205
• 4.4 Renewing seals for front differential lock
  206
• 5 Gear oil
  207
• 5.1 Checking gear oil level
  207
• 6 Oil for front differential lock
  213
• 6.1 Checking oil level for front differential lock
  213
• 6.2 Draining and filling oil for front differential lock
  214