5-speed manual gearbox 0A4

Kapitelübersicht

• 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
  4
• 3.3 Calculation of gear ratios
  4
• 4 Overview - power transmission
  5
• 5 Electrical components
  7
• 5.1 Overview of fitting locations - electrical components
  7
• 6 Repair instructions
  8
• 6.1 General repair instructions
  8
• Clutch
  11
• 1 Clutch operation
  11
• 1.1 Overview of fitting locations – clutch mechanism
  11
• 1.2 Assembly overview - pedal cluster
  13
• 1.3 Assembly overview - clutch hydraulics
  15
• 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
  19
• 1.7 Removing and installing clutch position sender G476
  20
• 1.8 Removing and installing over-centre spring
  21
• 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
  33
• 1.15 Bleeding clutch mechanism
  35
• 1.16 Repairing clutch release mechanism
  36
• 2 Clutch
  38
• 2.1 Assembly overview - clutch
  38
• 2.2 Removing and installing clutch
  41
• Controls, housing
  53
• 1 Selector mechanism
  53
• 1.1 Installation position - selector mechanism
  53
• 1.2 Assembly overview - gear knob and cover
  55
• 1.3 Assembly overview - selector mechanism
  56
• 1.4 Removing and installing gear knob
  57
• 1.5 Removing and installing selector mechanism
  59
• 1.6 Repairing selector mechanism
  62
• 1.7 Adjusting selector mechanism
  64
• 1.8 Checking selector mechanism
  67
• 2 Removing and installing gearbox
  68
• 2.1 Removing gearbox
  68
• 2.2 Install gearbox
  78
• 2.3 Specified torques for gearbox
  84
• 3 Assembly mountings
  85
• 3.1 Assembly overview - assembly mountings
  85
• 4 Transporting gearbox
  87
• 5 Gear oil
  88
• 5.1 Checking gear oil level
  88
• 5.2 Draining and filling gear oil
  88
• 6 Installing to engine and gearbox support
  91
• 7 Dismantling and assembling gearbox
  92
• 7.1 Schematic overview - gearbox
  92
• 7.2 Assembly overview - gearbox
  94
• 7.3 Assembly overview - cover for gearbox housing and 5th gear
  95
• 7.4 Assembly overview - gearbox housing and selector mechanism
  97
• 7.5 Assembly overview - selector unit
  98
• 7.6 Assembly overview - shafts, differential, selector mechanism
  99
• 7.7 Assembly overview - selector forks
  100
• 7.8 Removing and installing selector unit with gearbox installed
  101
• 7.9 Repairing selector unit
  103
• 7.10 Renewing oil seal for selector shaft
  104
• 7.11 Repairing selector forks
  105
• 7.12 Removing cover for gearbox housing and 5th gear
  109
• 7.13 Dismantling and assembling gearbox
  115
• 7.14 Installing cover for gearbox housing and 5th gear
  126
• 8 Gearbox housing, clutch housing
  130
• 8.1 Assembly overview - gearbox housing and clutch housing
  130
• 8.2 Repairing gearbox housing
  132
• 8.3 Repairing clutch housing
  137
• Gears, shafts
  139
• 1 Input shaft
  139
• 1.1 Assembly overview - input shaft
  139
• 1.2 Dismantling and assembling input shaft
  141
• 1.3 Adjusting input shaft
  146
• 1.4 Renewing input shaft seal
  151
• 2 Output shaft
  153
• 2.1 Assembly overview - output shaft
  153
• 2.2 Dismantling and assembling output shaft
  156
• 2.3 Adjusting output shaft
  166
• 3 Reverse shaft
  170
• 3.1 Assembly overview - reverse shaft
  170
• 3.2 Dismantling and assembling reverse shaft
  171
• Final drive - differential
  174
• 1 Oil seals
  174
• 1.1 Overview of fitting locations - seals
  174
• 1.2 Renewing left oil seal
  175
• 1.3 Renewing right oil seal
  177
• 2 Differential
  181
• 2.1 Assembly overview - differential
  181
• 2.2 Dismantling and assembling differential
  182
• 2.3 Adjusting differential
  187
• 3 Adjustment overview
  191