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
  17
• 1.5 Removing and installing bearing bush
  18
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  19
• 1.7 Removing and installing clutch position sender G476
  19
• 1.8 Removing and installing return spring
  20
• 1.9 Removing and installing over-centre spring
  22
• 1.10 Removing and installing clutch pedal
  25
• 1.11 Removing and installing mounting bracket
  26
• 1.12 Removing and installing clutch master cylinder
  31
• 1.13 Removing and installing clutch slave cylinder
  31
• 1.14 Removing and installing lines for clutch mechanism
  34
• 1.15 Bleeding clutch mechanism
  36
• 1.16 Repairing clutch release mechanism
  37
• 2 Clutch
  39
• 2.1 Assembly overview - clutch
  39
• 2.2 Removing and installing clutch
  42
• Controls, housing
  54
• 1 Selector mechanism
  54
• 1.1 Installation position - selector mechanism
  54
• 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
  63
• 1.7 Adjusting selector mechanism
  65
• 1.8 Checking selector mechanism
  68
• 2 Removing and installing gearbox
  69
• 2.1 Removing gearbox
  69
• 2.2 Install gearbox
  79
• 2.3 Specified torques for gearbox
  86
• 3 Assembly mountings
  87
• 3.1 Assembly overview - assembly mountings
  87
• 4 Transporting gearbox
  89
• 5 Gear oil
  90
• 5.1 Checking gear oil level
  90
• 5.2 Draining and filling gear oil
  90
• 6 Installing to engine and gearbox support
  93
• 7 Dismantling and assembling gearbox
  94
• 7.1 Schematic overview - gearbox
  94
• 7.2 Assembly overview - gearbox
  96
• 7.3 Assembly overview - cover for gearbox housing and 5th gear
  97
• 7.4 Assembly overview - gearbox housing and selector mechanism
  99
• 7.5 Assembly overview - selector unit
  100
• 7.6 Assembly overview - shafts, differential, selector mechanism
  101
• 7.7 Assembly overview - selector forks
  102
• 7.8 Repairing selector unit
  103
• 7.9 Renewing oil seal for selector shaft
  104
• 7.10 Repairing selector forks
  105
• 7.11 Removing cover for gearbox housing and 5th gear
  109
• 7.12 Dismantling and assembling gearbox
  115
• 7.13 Installing cover for gearbox housing and 5th gear
  127
• 8 Gearbox housing, clutch housing
  131
• 8.1 Assembly overview - gearbox housing and clutch housing
  131
• 8.2 Repairing gearbox housing
  133
• 8.3 Repairing clutch housing
  138
• Gears, shafts
  140
• 1 Input shaft
  140
• 1.1 Assembly overview - input shaft
  140
• 1.2 Dismantling and assembling input shaft
  142
• 1.3 Adjusting input shaft
  147
• 1.4 Renewing input shaft seal
  152
• 2 Output shaft
  154
• 2.1 Assembly overview - output shaft
  154
• 2.2 Dismantling and assembling output shaft
  157
• 2.3 Adjusting output shaft
  167
• 3 Reverse shaft
  171
• 3.1 Assembly overview - reverse shaft
  171
• 3.2 Dismantling and assembling reverse shaft
  172
• Final drive - differential
  175
• 1 Oil seals
  175
• 1.1 Overview of fitting locations - seals
  175
• 1.2 Renewing left oil seal
  176
• 1.3 Renewing right oil seal
  178
• 2 Differential
  182
• 2.1 Assembly overview - differential
  182
• 2.2 Dismantling and assembling differential
  183
• 2.3 Adjusting differential
  188
• 3 Adjustment overview
  192