Manual Transmission System (Controls & Housing - Service Information)

• Selector Mechanism
  • Notes
  • Selector Mechanism Installation Position
  • Overview - Gearshift Knob and Cover
  • Overview - Gearshift Lever and Gearshift Housing
    • Notes
    • Removing and Installing the Lock Washer
  • Overview - Operating Cables
    • Notes
    • Cable Retainer Allocation
    • Selector Lever/Relay Lever Installed Position
    • Cable Tie Installation Locations
  • Gearshift Knob, Removing and Installing
    • Notes
    • Removing
    • Installing
    • Installation location, Noise Insulation
  • Selector Mechanism, Removing and Installing
    • Notes
    • Removing
    • Disconnecting the Cable Retainer from the Selector Cable
      • Notes
      • Remove the Relay Lever and the Cable Retainer.
    • Installing
    • Installing the Selector Cable Retainer on the Relay Lever
    • Cable retainer allocation.
    • Installing the Transmission Shift Lever
    • Install the Relay Lever and the Cable Retainer Together
    • Tightening Specifications
  • Selector Mechanism, Adjusting
    • Notes
    • Adjusting Requirements
    • Procedure
  • Gearshift Mechanism, Checking
  • Gearshift Cable and Selector Cable, Removing and Installing
    • Notes
    • Removing
    • Installing
  • Selector Shaft Seal, Replacing
  • Selector Mechanism, Disassembling and Assembling
    • Notes
    • Disassembling
    • Assembling
      • Notes
      • Attach the Base Plate to the Gearshift Housing
• Transmission, Removing and Installing
  • Notes
  • Transmission Tightening Specifications
    • Notes
    • Transmission Tightening Specifications, Vehicles with 2.0L - 85 kW Engine
    • Transmission Tightening Specifications, Vehicles with 1.4L and 1.8L Engine
    • Transmission Tightening Specifications, Vehicles with 2.5L - 125 kW Engine
    • Transmission Tightening Specifications, Vehicles with Turbo Diesel Engine
  • Transmission, Removing
    • Notes
    • Transmission, Removing, 2.0L 85 kW Engine
      • Notes
      • For vehicles with the Start/Stop System
      • Vehicles with Hydraulic Power Steering
      • Tightening Specifications
    • Transmission, Removing, Vehicles with 1.4L and 1.8L Engine
      • Notes
      • Tightening Specifications
    • Transmission, Removing, Vehicles with 2.5L - 125 kW Engine
      • Notes
      • For vehicles with the Start/Stop System
      • Vehicles with Hydraulic Power Steering
      • Tightening Specifications
    • Transmission, Removing, Vehicles with Turbo Diesel Engine
      • Notes
      • Tightening Specifications
  • Transmission, Installing
    • Notes
    • Transmission, Installing, 2.0L - 85 kW Engine
    • Transmission, Installing, Vehicles with 1.4L and 1.8L Engine
    • Transmission, Installing, Vehicles with 2.5L - 125 kW Engine
    • Transmission, Installing, Vehicles with Turbo Diesel Engine
• Subframe Mount
  • Notes
  • Overview - Subframe Mount
    • Notes
    • Attaching the Transmission Mount to the Transmission Bracket
    • Transmission Support to Transmission Bracket and Transmission
    • Transmission Bracket -A- to Transmission.
• Transmission, Transporting
• Transmission, Disassembling and Assembling
  • Notes
  • Schematic Overview - Transmission
  • Overview - Transmission Housing Cover and 5th Gear
    • Notes
    • Transmission Housing Cover with a Magnet -A-
  • Overview - Transmission Housing and Gearshift Mechanism
  • Overview - Shift Unit
  • Overview - Input Shaft, Output Shafts, Differential, Gearshift Rods
  • Overview - Shift Forks
  • Shift Unit, Servicing
    • Notes
    • Removing the Locking Elbow -A- from the Shift Cover
    • Pressing the Locking Elbow -A- into Selector Cover
  • Shift Forks, Servicing
    • Notes
    • Shift Segment Identification
    • Removing the Lock Washer
    • Installing the Lock Washer
    • Removing the Angular Contact Ball Bearing
    • Installing the Angular Contact Ball Bearing Inner Race -A- into the Outer Race
    • Installing the Angular Contact Ball Bearing into the Shift Fork
    • Shift fork with the Shift Segments Installed
  • Transmission Housing Cover and 5th Gear, Removing
    • Notes
    • Under the Output Shaft Bracket
    • 5th Gear, Removing Separately
  • Transmission, Disassembling and Assembling
    • Notes
    • Transmission, Disassembling
      • Notes
      • Under the Input Shaft:
      • Under the Output Shaft Bracket
    • Transmission, Assembling
    • Reverse gear location
    • Tightening sequence:
    • Tightening Specifications
  • Transmission Housing Cover and 5th Gear, Installing
    • Notes
    • Installed Position, 5th Gear Wheel
    • Checking 5th Gear Synchronizer Ring
    • Installed Position of 5th Gear Synchronizer Hub/Locking Collar
    • 5th Gear Synchronizer Ring with Cast Locking Pieces -arrows-.
    • Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Gear Securing Bolts
    • 5th Gear Shift Fork, Mounting
    • 5th Gear Locking Collar, Adjusting
    • Tightening Specifications
• Transmission Housing and Clutch Housing
  • Notes
  • Overview - Transmission Housing
    • Notes
    • Differentiation of Output Shaft Bearings
      • Notes
      • Roller Sleeve -1- with Circlip
    • Roller Sleeve -1- without Circlip
    • Insert the Oil Catch Tray -A- into the Transmission
  • Overview - Clutch Housing
  • Transmission Housing, Servicing
    • Notes
    • Bearing/Input Shaft in Transmission Housing, Removing and Installing
      • Notes
      • Removing the Outer Race/Tapered Roller Bearing
      • Installing the Outer Race/Tapered Roller Bearing
    • Bearing/Output Shaft in Transmission Housing, Removing and Installing
      • Notes
      • Drive Out the Roller Sleeve without Circlip
      • Drive in the Roller Sleeve without Circlip all the Way
      • Roller Sleeve with Circlip, Removing
      • Roller Sleeve with Circlip, Installing
    • Bearing/Differential in Transmission Housing, Removing and Installing
      • Notes
      • Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
      • Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing.
  • Clutch Housing, Servicing
    • Notes
    • Bearing/Input Shaft in Clutch Housing, Removing and Installing
      • Notes
      • Removing the Outer Race/Tapered Roller Bearing
      • Installing the Outer Race/Tapered Roller Bearing
    • Bearing/Output Shaft in Clutch Housing, Removing and Installing
      • Notes
      • Outer Race/Tapered Roller Bearing -C-, Removing
      • Installing the Outer Race/Tapered Roller Bearing
    • Bearing/Differential in Clutch Housing, Removing and Installing
      • Notes
      • Removing the Outer Race/Tapered Roller Bearing
      • Installing the Outer Race/Tapered Roller Bearing
• Securing on Engine and Transmission Holder
• Transmission Fluid
  • Notes
  • Transmission Fluid Level, Checking
  • Transmission Fluid, Draining and Filling
    • Notes
    • Transmission Fluid, Draining
    • Transmission Fluid, Filling
    • Tightening Specifications
• Special Tools