6-speed manual gearboxes 02U and 0DQ

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  4
• 3.1 Allocation gearbox - engine
  4
• 3.2 Capacities
  5
• 3.3 Calculation of gear ratios
  5
• 4 Overview - power transmission
  6
• 5 Electrical components
  8
• 5.1 Overview of fitting locations - electrical components
  8
• 6 Repair notes
  9
• 6.1 General repair instructions
  9
• Clutch
  12
• 1 Clutch operation
  12
• 1.1 Overview of fitting locations – clutch mechanism
  12
• 1.2 Assembly overview - pedal cluster
  14
• 1.3 Assembly overview - clutch hydraulics
  16
• 1.4 Assembly overview - clutch release mechanism
  18
• 1.5 Removing and installing bearing bush
  19
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  20
• 1.7 Removing and installing clutch position sender G476
  20
• 1.8 Removing and installing over-centre spring
  22
• 1.9 Removing and installing extension spring
  23
• 1.10 Removing and installing clutch pedal
  23
• 1.11 Removing and installing mounting bracket
  25
• 1.12 Removing and installing clutch master cylinder
  29
• 1.13 Removing and installing clutch slave cylinder
  30
• 1.14 Removing and installing lines for clutch mechanism
  32
• 1.15 Bleeding clutch mechanism
  34
• 1.16 Repairing clutch release mechanism
  36
• 2 Clutch
  38
• 2.1 Assembly overview - clutch
  38
• 2.2 Removing and installing clutch
  39
• Controls, housing
  44
• 1 Selector mechanism
  44
• 1.1 Installation position - selector mechanism
  44
• 1.2 Assembly overview - gear knob and cover
  46
• 1.3 Assembly overview - selector mechanism
  47
• 1.4 Removing and installing gear knob
  48
• 1.5 Removing and installing selector mechanism
  50
• 1.6 Repairing selector mechanism
  54
• 1.7 Adjusting selector mechanism
  56
• 1.8 Checking selector mechanism
  59
• 2 Removing and installing gearbox
  60
• 2.1 Differentiating between gearboxes
  60
• 2.2 Removing gearbox
  60
• 2.3 Installing gearbox
  70
• 2.4 Specified torques for gearbox
  76
• 3 Assembly mounting
  77
• 3.1 Assembly overview - assembly mountings
  77
• 4 Transporting gearbox
  79
• 5 Gear oil
  80
• 5.1 Checking gear oil level
  80
• 5.2 Draining and filling gear oil
  81
• 6 Installing to engine and gearbox support
  83
• 7 Dismantling and assembling gearbox
  85
• 7.1 Schematic overview - gearbox
  85
• 7.2 Assembly overview - gearbox
  86
• 7.3 Assembly overview - cover for gearbox housing and 5th/6th gear
  87
• 7.4 Assembly overview - clutch housing
  89
• 7.5 Assembly overview - shafts, differential, selector mechanism
  91
• 7.6 Assembly overview - selector unit
  92
• 7.7 Assembly overview - selector forks
  94
• 7.8 Repairing selector forks
  95
• 7.9 Repairing selector unit
  98
• 7.10 Renewing oil seal for selector shaft
  101
• 7.11 Dismantling and assembling gearbox
  101
• 8 Gearbox housing, clutch housing
  117
• 8.1 Assembly overview - gearbox housing and clutch housing
  117
• 8.2 Assembly overview - gearbox housing cover
  121
• 8.3 Repairing gearbox housing cover
  122
• 8.4 Repairing clutch housing
  124
• Gears, shafts
  127
• 1 Input shaft
  127
• 1.1 Assembly overview - input shaft
  127
• 1.2 Dismantling and assembling input shaft
  130
• 1.3 Renewing input shaft seal
  138
• 2 Output shaft
  140
• 2.1 Assembly overview - output shaft
  140
• 2.2 Dismantling and assembling output shaft
  143
• Final drive - differential
  149
• 1 Oil seals
  149
• 1.1 Overview of fitting locations - seals
  149
• 1.2 Renewing left oil seal
  150
• 1.3 Renewing right oil seal
  154
• 2 Differential
  159
• 2.1 Assembly overview - differential
  159
• 2.2 Dismantling and assembling differential
  162
• 2.3 Adjusting differential
  169