5-speed manual gearbox 012/01W/0A9

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Identification code, assembly allocation, ratios, capacities
  1
• 2 Overview - power transmission
  9
• 3 Calculating overall gear ratio "i"
  11
• 4 General repair notes
  12
• 4.1 Components
  12
• Clutch
  15
• 1 Functional check of clutch master and slave cylinders
  15
• 2 Distinguishing clutch control mechanisms
  17
• 3 Repairing clutch control mechanism (master cylinder secured to clutch pedal with a pin)
  18
• 3.1 Overview
  18
• 3.2 Assembly overview - pedal cluster (LHD vehicles)
  19
• 3.3 Removing and installing clutch pedal and over-centre spring
  20
• 3.4 Assembly overview - pedal cluster (RHD vehicles)
  21
• 3.5 Assembly overview - hydraulic system
  23
• 3.6 Removing and installing master cylinder
  24
• 4.1 Overview
  28
• 4.2 Assembly overview - pedal cluster (LHD vehicles)
  29
• 4.3 Removing and installing clutch pedal and over-centre spring
  30
• 4.4 Assembly overview - pedal cluster (RHD vehicles)
  31
• 4.5 Assembly overview - hydraulic system
  33
• 4.6 Removing and installing master cylinder
  35
• 5 Clutch pedal switch
  40
• 5.2 Checking and adjusting clutch pedal switch F36
  40
• 6 Bleeding clutch system
  43
• 7 Repairing clutch release mechanism
  44
• 7.1 Removing and installing slave cylinder
  46
• 8 Repairing clutch
  50
• Controls, housing
  53
• 1 Repairing selector mechanism (gear lever must be pressed down to engage reverse gear)
  53
• 1.1 Installation position of selector mechanism
  53
• 1.2 Repairing gear lever, gear lever mounting, push rod and selector rod
  53
• 1.3 Removing and installing selector mechanism
  56
• 1.4 Adjusting selector mechanism
  57
• 2.1 Installation position of selector mechanism
  60
• 2.2 Repairing gear lever and gear lever mounting
  62
• 2.3 Repairing selector rod and push rod
  63
• 2.4 Removing and installing gear lever with gear lever mounting
  65
• 2.5 Removing and installing selector mechanism
  65
• 2.6 Adjusting selector mechanism
  67
• 3 Removing and installing gearbox
  69
• 3.1 Removing gearbox
  70
• 3.2 Transporting gearbox
  74
• 3.3 Installing gearbox
  75
• 4 Checking gear oil
  82
• 5 Dismantling and assembling gearbox
  83
• 5.1 Overview - gearbox
  83
• 5.2 Assembly overview
  84
• 5.3 Removing and installing input shaft ball bearing and multifunction sender
  85
• 5.5 Dismantling and assembling procedure
  89
• 6 Dismantling and assembling selector mechanism on gearbox side
  96
• 6.1 Checking and renewing locking unit for 5th gear and reverse gear
  100
• Gears, shafts
  102
• 1 Input shaft
  102
• 1.1 Dismantling and assembling input shaft
  102
• 1.2 Modified synchronisation of 3rd and 4th gear from gearbox date 23 06 3
  112
• 1.3 Adjusting input shaft
  112
• 2 Dismantling and assembling pinion shaft through gearbox date 22 06 3
  116
• 2.1 Reinforcement from gearbox date 17 08 8 in vicinity of for 4th gear wheel
  130
• 3 Dismantling and assembling pinion shaft from gearbox date 23 06 3
  132
• 4 Removing and installing reverse gear wheel
  147
• Final drive - differential
  148
• 1 Renewing oil seals for flange shafts
  148
• 2 Renewing speedometer sender and drive wheel
  151
• 2.1 Replacing speedometer sender
  151
• 2.2 Renewing speedometer drive wheel
  151
• 3 Removing and installing differential
  154
• 4 Dismantling and assembling differential
  159
• 5 Adjusting drive pinion and crown wheel
  167
• 5.1 Adjustment and marking of final drive gear sets
  167
• 5.2 Position of shims
  168
• 5.3 Adjustment overview
  168
• 5.4 Recommended sequence for readjusting final drive gear set
  169
• 5.5 Adjusting drive pinion
  169
• 5.6 Determining shim "S4" thickness when renewing gearbox cover
  177
• 5.7 Adjusting crown wheel
  177