7-speed dual clutch gearbox 0GC

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 General safety provisions
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Notes on tow-starting/towing
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Repair instructions
  4
• 3.1 General information
  4
• 3.2 Rules for cleanliness
  4
• 3.3 General repair instructions
  4
• 3.4 Gaskets and seals
  5
• 3.5 Nuts and bolts
  6
• 4 Technical data
  7
• 4.1 Capacities
  7
• 5 Electrical components
  8
• 5.1 Overview of fitting locations - electrical components
  8
• Clutch
  10
• 1 Clutch
  10
• 1.1 Assembly overview - dual clutch
  10
• 1.2 Removing and installing clutch end cover
  10
• 1.3 Removing dual clutch
  15
• 1.4 Installing dual clutch
  19
• Controls, housing
  29
• 1 Mechatronic unit
  29
• 1.1 Assembly overview - mechatronic unit
  29
• 1.2 Removing and installing sump
  30
• 1.3 Removing and installing mechatronic unit
  33
• 2 Bevel box
  36
• 2.1 Assembly overview - bevel box
  36
• 2.2 Distinguishing between different types of bevel boxes
  37
• 2.3 Removing bevel box
  38
• 2.4 Installing bevel box
  46
• 3 Selector mechanism
  52
• 3.1 Assembly overview - selector mechanism
  52
• 3.2 Emergency release from position P
  54
• 3.3 Removing and installing selector lever handle
  57
• 3.4 Moving push-button in the handle to installation position
  73
• 3.5 Removing and installing selector mechanism
  75
• 3.6 Removing and installing gear selector cable
  79
• 3.7 Checking selector mechanism
  82
• 3.8 Checking and adjusting selector lever cable
  83
• 3.9 Renewing selector shaft seal
  85
• 4 Removing and installing gearbox
  88
• 4.1 Specified torques for gearbox
  88
• 4.2 Removing gearbox
  90
• 4.3 Installing gearbox
  183
• 5 Assembly mountings
  187
• 5.1 Assembly overview - assembly mountings
  187
• 6 Transporting gearbox
  190
• 6.1 Transporting gearbox
  190
• 6.2 Transporting front differential lock
  191
• 7 Securing to engine and gearbox support
  192
• 7.1 Installing gearbox to engine and gearbox support
  192
• 7.2 Securing front differential lock to engine and gearbox support
  193
• 8 Gear oil circuit
  195
• 8.1 Assembly overview - gear oil circuit
  195
• 8.2 Removing and installing gear oil cooler
  195
• 8.3 Removing and installing gear oil filter
  198
• 8.4 Removing and installing motor for auxiliary hydraulic pump 1 for gearbox oil V475
  200
• 9 Gear oil
  203
• 9.1 Overview of oil drain and inspection plugs
  203
• 9.2 Tools for gear oil change
  203
• 9.3 Checking gear oil level
  205
• 9.4 Draining and filling gear oil
  209
• 10 Front differential lock
  213
• 10.1 Assembly overview - front differential lock
  213
• 10.2 Removing front differential lock
  213
• 10.3 Installing front differential lock
  218
• 10.4 Removing and installing differential lock control unit J647
  220
• Gears, shafts
  222
• 1 Currently, no repairs can be made to gears and shafts
  222
• Final drive - differential
  223
• 1 Gear oil
  223
• 1.1 Checking gear oil level
  223
• 1.2 Draining and filling gear oil
  224
• 2 Oil for front differential lock
  229
• 2.1 Checking oil level for front differential lock
  229
• 2.2 Draining and filling oil for front differential lock
  230
• 3 Seals
  235
• 3.1 Overview of fitting locations - seals
  235
• 3.2 Renewing left seal
  235
• 3.3 Renewing right seal
  238
• 4 Differential
  244
• 4.1 Removing and installing right flange shaft
  244
• 5 Components of front differential lock
  247
• 5.1 Assembly overview - components of front differential lock
  247
• 5.2 Checking function
  249
• 5.3 Removing and installing pump for front differential lock V181
  249
• 5.4 Removing and installing coupling for front differential lock
  251
• 5.5 Renewing seals for front differential lock
  251
• 5.6 Renewing ball bearing for flange shaft
  260
• 6 Components of bevel box
  263
• 6.1 Assembly overview - components of bevel box
  263
• 6.2 Renewing bevel box seals
  268
• 6.3 Renewing output flange and redetermining thickness of shim
  296