5-speed manual gearbox 0A4

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 2 Identification code, assembly allocation, capacities
  2
• 2.5 Identification codes, assembly allocation and capacities, Passat 2006 ►
  7
• 2.6 Calculating overall gear ratio “i”
  8
• 3 Overview - power transmission
  9
• 4 General repair instructions
  11
• 5 Safety precautions
  14
• 5.1 Safety precautions for vehicles with a start-stop system
  14
• Clutch
  15
• 1 Clutch operation
  15
• 1.1 Overview - clutch actuation
  15
• 1.2 Assembly overview - pedal cluster
  17
• 1.3 Removing and installing over-centre spring
  19
• 1.4 Removing and installing clutch pedal
  38
• 1.5 Removing and installing mounting bracket
  41
• 1.6 Removing and installing master cylinder
  65
• 1.7 Removing and installing clutch position sender G476
  67
• 1.8 Assembly overview - hydraulics (LHD)
  70
• 1.9 Assembly overview - hydraulics (RHD)
  73
• 1.10 Removing and installing slave cylinder
  74
• 1.11 Bleeding clutch system
  76
• 2 Clutch release mechanism
  79
• 2.1 Assembly overview - clutch release mechanism
  79
• 2.2 Repairing clutch release mechanism
  80
• 3 Clutch
  81
• 3.1 Clutch in connection with dual mass flywheel
  81
• 3.2 Clutch in connection with simple flywheel
  89
• Controls, housing
  93
• 1 Selector mechanism
  93
• 1.1 Installation position of selector mechanism
  93
• 1.2 Overview - selector mechanism
  94
• 1.3 Assembly overview - gear knob and cover
  94
• 1.4 Removing and installing gear knob with gaiter and noise insulation
  96
• 1.5 Assembly overview - Gear lever and selector housing
  101
• 1.6 Dismantling and assembling selector mechanism (from 11.06)
  104
• 1.7 Assembly overview - Selector cables
  109
• 1.8 Removing and installing selector mechanism
  116
• 1.9 Adjusting selector mechanism
  121
• 2 Removing and installing gearbox
  125
• 2.1 Removing and installing gearbox, Golf 2004 ►
  125
• 2.2 Removing and installing gearbox, Golf 2009 ► with turbo diesel engine
  138
• 2.3 Removing and installing gearbox, Golf 2009 ► with petrol engine
  153
• 2.4 Removing and installing gearbox, Golf Plus
  170
• 2.5 Removing and installing gearbox, Passat
  188
• 3 Transporting gearbox
  202
• 4 Assembly overview - assembly mountings
  203
• 5 Gear oil
  205
• 5.1 Checking and topping up gear oil
  205
• 6 Dismantling and assembling gearbox
  208
• 6.1 Overview - gearbox
  208
• 6.2 Assembly overview - dismantling and assembling gearbox
  209
• 6.7 Assembly sequence - Dismantling and assembling gearbox completely
  220
• 7 Gearbox housing and clutch housing
  235
• 7.1 Assembly overview - gearbox housing and clutch housing
  235
• 7.2 Repairing gearbox housing and clutch housing
  237
• 8 Selector unit
  242
• 8.1 Assembly overview - selector unit
  242
• 8.2 Repairing selector unit
  244
• 9 Selector forks
  246
• 9.1 Assembly overview - selector forks
  246
• 9.2 Repairing selector forks
  247
• Gears, shafts
  251
• 1 Input shaft
  251
• 1.1 Assembly overview - input shaft
  251
• 1.2 Dismantling and assembling input shaft
  253
• 1.3 Adjusting input shaft
  258
• 1.4 Renewing input shaft seal
  263
• 2 Output shaft
  265
• 2.1 Assembly overview - output shaft
  265
• 2.2 Dismantling and assembling output shaft
  268
• 2.3 Adjusting output shaft
  278
• 3 Reverse shaft
  281
• 3.1 Assembly overview - reverse shaft
  281
• 3.2 Dismantling and assembling reverse shaft
  282
• Final drive - differential
  285
• 1 Oil seals
  285
• 1.1 Renewing left flange shaft oil seal with gearbox installed
  285
• 1.2 Distinguishing seals for right flange shaft
  287
• 2 Adjustment overview
  294
• 3 Differential
  295
• 3.1 Assembly overview - differential
  295
• 3.2 Dismantling and assembling differential
  297
• 3.3 Adjusting differential
  302