5-speed manual gearbox 0A4

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation and capacities
  2
• 2 Overview - power transmission
  6
• 3 Calculating overall gear ratio “i”
  8
• 4 General repair instructions
  9
• 4.1 Components
  9
• 5 Safety precautions
  13
• 5.1 Safety precautions for vehicles with a start-stop system
  13
• Clutch
  14
• 1 Repairing clutch mechanism
  14
• 1.1 Overview
  14
• 1.2 Assembly overview - pedal cluster
  15
• 1.3 Removing and installing over-centre spring
  16
• 1.4 Removing and installing clutch pedal
  21
• 1.5 Removing and installing mounting bracket
  26
• 1.6 Removing and installing clutch master cylinder
  32
• 1.7 Removing and installing clutch position sender G476
  34
• 1.8 Assembly overview - hydraulics (LHD)
  37
• 1.9 Assembly overview - hydraulics (RHD)
  40
• 1.10 Removing and installing clutch slave cylinder
  41
• 1.11 Bleeding clutch system
  44
• 2 Repairing clutch release mechanism
  46
• 3 Repairing clutch, in conjunction with dual-mass flywheel
  48
• 3.1 Determining clutch manufacturer
  48
• 3.2 Removing and installing Sachs clutch
  50
• 3.3 Repairing Sachs clutch
  51
• 3.4 Removing and installing LuK clutch
  52
• 3.5 Repairing LuK clutch
  54
• 4 Repairing clutch, in conjunction with one-piece flywheel
  56
• Controls, housing
  59
• 1 Repairing selector mechanism
  59
• 1.1 Installation position of selector mechanism
  59
• 1.2 Overview of selector mechanism
  60
• 1.3 Removing and installing gear knob and cover
  61
• 1.4 Removing and installing gaiter with gear knob and noise insulation
  62
• 1.5 Repairing gear lever and selector housing (through 10.06)
  63
• 1.6 Repairing gear lever and selector housing (from 11.06)
  66
• 1.7 Assembly overview - removing and installing selector cables
  72
• 1.8 Plastic relay lever
  76
• 1.9 Removing and installing selector mechanism
  79
• 1.10 Removing and installing gear selector cable and gate selector cable
  82
• 1.11 Adjusting selector mechanism
  84
• 2.1 Removing gearbox
  89
• 2.2 Install gearbox
  96
• 3 Removing and installing gearbox, Jetta 2011 ►
  103
• 3.1 Removing gearbox, Jetta 2011 with 2.0 l - 85 kW engine
  103
• 3.2 Installing gearbox, Jetta 2011 with 2.0 l - 85 kW engine
  113
• 3.3 Removing gearbox, Jetta 2011 with 2.5 l - 125 kW engine
  120
• 3.4 Installing gearbox, Jetta 2011 with 2.5 l - 125 kW engine
  131
• 3.5 Removing gearbox, Jetta 2011 with 1.8 l - 125 kW engine
  138
• 3.6 Installing gearbox, Jetta 2011 with 1.8 l - 125 kW engine
  151
• 3.7 Removing gearbox, Jetta 2011 with turbo diesel engine
  160
• 3.8 Installing gearbox, Jetta 2011 with turbo diesel engine
  170
• 4 Assembly mountings
  178
• 4.1 Assembly overview - assembly mountings
  178
• 5 Transporting gearbox
  180
• 6 Checking and topping up gear oil
  181
• 6.1 Preparing
  181
• 6.2 Drain gear oil
  182
• 6.3 Fill with gear oil
  183
• 7 Dismantling and assembling gearbox
  184
• 7.1 Overview - gearbox
  184
• 7.2 Assembly overview
  185
• 7.3 Removing and installing cover for gearbox housing and 5th gear
  186
• 7.4 Removing and installing gearbox housing and selector mechanism
  187
• 7.5 Removing and installing input shaft, output shaft, differential and selector forks
  189
• 7.7 Assembly sequence - Dismantling and assembling gearbox completely
  196
• 8 Repairing gearbox housing and clutch housing
  211
• 9 Repairing selector unit
  217
• 10 Dismantling and assembling selector forks
  220
• Gears, shafts
  225
• 1 Input shaft
  225
• 1.1 Dismantling and assembling input shaft
  225
• 1.2 Adjusting input shaft
  233
• 1.3 Renewing input shaft seal
  237
• 2 Output shaft
  240
• 2.1 Dismantling and assembling output shaft
  240
• 2.2 Adjusting output shaft
  253
• 3 Reverse shaft
  258
• 3.1 Dismantling and assembling reverse shaft
  258
• Final drive - differential
  261
• 1 Oil seals
  261
• 1.1 Overview of fitting locations - seals
  261
• 1.2 Renewing oil seal for left flange shaft
  261
• 1.3 Distinguishing seals for right flange shaft
  263
• 1.4 Renewing seal (two-part seal and sleeve for right flange shaft)
  264
• 2 Adjustment overview
  270
• 3 Differential
  271
• 3.1 Dismantling and assembling differential
  271
• 3.2 Adjusting differential
  279