Installed 6-speed manual gearbox 02Q

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety precautions 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 Capacities
  5
• 4 Overview - power transmission
  6
• 4.1 Overview - power transmission - front-wheel drive
  6
• 4.2 Overview - power transmission - all-wheel drive
  7
• 5 Electrical components
  10
• 5.1 Overview of fitting locations - electrical components
  10
• 6 Repair instructions
  12
• 6.1 General repair instructions
  12
• Clutch
  15
• 1 Clutch mechanism
  15
• 1.1 Overview of fitting locations – clutch mechanism
  15
• 1.2 Assembly overview - pedal cluster
  16
• 1.3 Assembly overview - clutch hydraulics
  18
• 1.4 Removing and installing bearing bush
  22
• 1.5 Checking clutch master cylinder and clutch slave cylinder
  23
• 1.6 Removing and installing clutch position sender G476
  24
• 1.7 Removing and installing return spring
  25
• 1.8 Removing and installing over-centre spring
  28
• 1.9 Removing and installing clutch pedal
  32
• 1.10 Removing and installing mounting bracket
  33
• 1.11 Removing and installing clutch master cylinder
  39
• 1.12 Removing and installing bleeder
  40
• 1.13 Removing and installing lines for clutch mechanism
  43
• 1.14 Bleeding clutch mechanism
  47
• 2 Clutch
  50
• 2.1 Determining make of clutch
  50
• Controls, housing
  52
• 1 Selector mechanism
  52
• 1.1 Installation position - selector mechanism
  52
• 1.2 Assembly overview – gear knob and cover
  53
• 1.3 Assembly overview - selector mechanism
  55
• 1.4 Removing and installing gear knob
  57
• 1.5 Removing and installing selector mechanism
  59
• 1.6 Repairing selector mechanism
  63
• 1.7 Adjusting selector mechanism
  68
• 1.8 Checking selector mechanism
  72
• 2 Removing and installing gearbox
  74
• 2.1 Removing gearbox
  74
• 2.2 Installing gearbox
  111
• 2.3 Specified torques for gearbox
  116
• 3 Bevel box
  118
• 3.1 Assembly overview - bevel box
  118
• 3.2 Distinguishing between different types of bevel boxes
  120
• 3.3 Removing bevel box
  120
• 3.4 Installing bevel box
  128
• 4 Front differential lock
  134
• 4.1 Assembly overview - front differential lock
  134
• 4.2 Removing front differential lock
  134
• 4.3 Installing front differential lock
  138
• 4.4 Removing and installing differential lock control unit J647
  140
• 5 Transporting gearbox
  142
• 6 Gear oil
  143
• 6.1 Distinguishing between different manual gearbox types when filling oil
  143
• 6.2 Checking gear oil level
  143
• 7 Dismantling and assembling gearbox
  148
• 7.1 Assembly overview - selector unit
  148
• 7.2 Removing and installing selector unit with gearbox installed
  149
• 7.3 Renewing selector shaft seal
  153
• 8 Gearbox housing, clutch housing
  156
• Gears, shafts
  157
• 1 Input shaft
  157
• 2 Output shaft
  158
• Final drive - differential
  159
• 1 Oil seals
  159
• 1.1 Overview of fitting locations - oil seals
  159
• 1.2 Renewing left seal
  161
• 1.3 Renewing right seal
  164
• 2 Differential
  179
• 3 Components of bevel box
  180
• 3.1 Renewing bevel box seals
  180
• 3.2 Renewing output flange and redetermining thickness of shim
  180
• 3.3 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  180
• 4 Components of front differential lock
  185
• 4.1 Checking function
  185
• 4.2 Removing and installing pump V181
  185
• 4.3 Removing and installing coupling for front differential lock
  186
• 4.4 Renewing seals for front differential lock
  187
• 5 Gear oil
  188
• 5.1 Checking gear oil level
  188
• 6 Oil for front differential lock
  194
• 6.1 Checking oil level for front differential lock
  194
• 6.2 Draining and filling oil for front differential lock
  195