Installed 6-speed manual gearbox 02S

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  3
• 3.1 Allocation gearbox - engine
  3
• 3.2 Capacities
  3
• 4 Overview - power transmission
  4
• 5 Electrical components
  6
• 5.1 Overview of fitting locations - electrical components
  6
• 6 Repair instructions
  7
• 6.1 General repair instructions
  7
• Clutch
  9
• 1 Clutch operation
  9
• 1.1 Overview of fitting locations – clutch mechanism
  9
• 1.2 Assembly overview - pedal cluster
  11
• 1.3 Assembly overview - clutch hydraulics
  13
• 1.4 Removing and installing bearing bush
  15
• 1.5 Checking clutch master cylinder and clutch slave cylinder
  16
• 1.6 Removing and installing clutch position sender G476
  16
• 1.7 Removing and installing return spring
  16
• 1.8 Removing and installing over-centre spring
  19
• 1.9 Removing and installing clutch pedal
  21
• 1.10 Removing and installing mounting bracket
  23
• 1.11 Removing and installing clutch master cylinder
  27
• 1.12 Removing and installing clutch slave cylinder
  27
• 1.13 Removing and installing lines for clutch mechanism
  30
• 1.14 Bleeding clutch mechanism
  32
• 2 Clutch
  34
• Controls, housing
  35
• 1 Selector mechanism
  35
• 1.1 Installation position - selector mechanism
  35
• 1.2 Assembly overview - gear knob and cover
  36
• 1.3 Assembly overview - selector mechanism
  37
• 1.4 Removing and installing gear knob
  38
• 1.5 Removing and installing selector mechanism
  40
• 1.6 Repairing selector mechanism
  43
• 1.7 Adjusting selector mechanism
  45
• 1.8 Checking selector mechanism
  48
• 2 Removing and installing gearbox
  49
• 2.1 Removing gearbox
  49
• 2.2 Installing gearbox
  82
• 2.3 Specified torques for gearbox
  103
• 3 Assembly mountings
  105
• 3.1 Assembly overview - assembly mountings
  105
• 4 Gear oil
  107
• 4.1 Checking gear oil level
  107
• 4.2 Draining and filling gear oil
  107
• 5 Dismantling and assembling gearbox
  110
• 5.1 Assembly overview - selector unit
  110
• 5.2 Removing and installing selector unit with gearbox installed
  111
• 5.3 Repairing selector unit
  113
• 5.4 Renewing selector shaft seal
  115
• 6 Gearbox housing, clutch housing
  117
• Gears, shafts
  118
• 1 Input shaft
  118
• 2 Output shaft
  119
• 3 Reverse shaft
  120
• Final drive - differential
  121
• 1 Oil seals
  121
• 1.1 Overview of fitting locations - seals
  121
• 1.2 Renewing left seal
  122
• 1.3 Renewing right oil seal
  124
• 2 Differential
  127