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  • Examplepage for repair manual 5-speed manual gearbox 0A4
  • Examplepage for repair manual 2 5-speed manual gearbox 0A4
  • Examplepage for repair manual 3 5-speed manual gearbox 0A4

5-speed manual gearbox 0A4

For New Beetle Cabrio / New Beetle

Original Volkswagen repair manual


12,83 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

7.926 KB

148 Sites

Detailed technical data

Immediately readable

This repair manual contains: Repairing clutch mechanism, Removing and installing gearbox, Input shaft, Adjustment overview and Differential. Show more
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Repair manual New Beetle Cabrio / New Beetle 5-speed manual gearbox 0A4 PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Gearbox identification
    1
  • 1.1 Location on gearbox
    1
  • 1.2 Identification code, assembly allocation and capacities
    1
  • 2 Overview - power transmission
    3
  • 3 Calculating overall gear ratio “i”
    5
  • 4 General repair instructions
    6
  • 4.1 Components
    6
  • Clutch
    9
  • 1 Repairing clutch mechanism
    9
  • 1.1 Overview
    9
  • 1.2 Pedal cluster - Assembly overview
    10
  • 1.3 Removing and installing over-centre spring
    11
  • 1.4 Removing and installing clutch pedal
    12
  • 1.5 Removing and installing clutch pedal switch F36
    13
  • 1.6 Hydraulic system - Assembly overview
    14
  • 1.7 Removing and installing master cylinder
    16
  • 1.8 Removing and installing slave cylinder
    20
  • 1.9 Bleeding clutch system
    22
  • 2 Repairing clutch release mechanism
    24
  • 3 Repairing clutch
    26
  • 3.1 Determining clutch manufacturer
    26
  • 3.2 Repairing Sachs clutch
    28
  • 3.3 Removing and installing Sachs clutch
    28
  • 3.4 Repairing LuK clutch
    30
  • 3.5 Removing and installing LuK clutch
    31
  • Controls, housing
    34
  • 1 Repairing selector mechanism
    34
  • 1.1 Installation position of selector mechanism
    34
  • 1.2 Removing and installing selector lever knob and cover - Assembly overview
    36
  • 1.3 Separating gaiter from selector lever and assembling with selector lever knob
    36
  • 1.4 Repairing selector lever and selector lever housing
    37
  • 1.5 Removing and installing selector cables - Assembly overview
    39
  • 1.6 Removing and installing selector mechanism
    40
  • 1.7 Adjusting selector mechanism
    44
  • 2 Removing and installing gearbox
    48
  • 2.1 Modifying support rail VW 457/1
    49
  • 2.2 Removing gearbox
    49
  • 2.3 Transporting gearbox
    55
  • 2.4 Installing gearbox
    55
  • 3 Checking and topping up gear oil
    62
  • 3.1 Preparation
    62
  • 3.2 Draining gear oil
    63
  • 3.3 Filling with gearbox oil
    64
  • 4 Dismantling and assembling gearbox
    65
  • 4.1 Overview - rear final drive
    65
  • 4.2 Assembly overview
    66
  • 4.3 Removing and installing cover for gearbox housing and 5th gear
    67
  • 4.4 Removing and installing gearbox housing and selector mechanism
    68
  • 4.5 Removing and installing input shaft, output shaft, differential and selector forks
    69
  • 4.6 Dismantling and assembling procedure
    70
  • 5 Repairing gearbox housing and clutch housing
    82
  • 6 Repairing selector unit
    88
  • 7 Dismantling and assembling selector forks
    91
  • Gears, shafts
    96
  • 1 Input shaft
    96
  • 1.1 Dismantling and assembling input shaft
    96
  • 1.3 Adjusting input shaft
    103
  • 2 Output shaft
    108
  • 2.1 Dismantling and assembling output shaft
    108
  • 2.2 Adjusting output shaft
    121
  • 3 Reverse shaft
    125
  • 3.1 Dismantling and assembling reverse shaft
    125
  • Final drive - differential
    128
  • 1 Renewing flange shaft oil seals with gearbox installed
    128
  • 1.1 Renewing oil seal for left flange shaft
    128
  • 1.2 Renewing seal for right flange shaft
    129
  • 2 Adjustment overview
    134
  • 3 Differential
    135
  • 3.1 Dismantling and assembling differential
    135
  • 3.2 Adjusting differential
    141
Manufacturer's designation 5-speed manual gearbox 0A4
Manufacturer Volkswagen
Suitable for New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007)
Suitable car types 1Y, 1C
Transmission designations 0A4
Transmission types FNE, GTB, GQR, HGN, GQQ, JVF, KCD, KJF, KPF, KQM, KRY, KWK, LEL, LFZ, LHP, LHW, LLL, LUB, MDZ, LEA, MDM, MUC, HDR, HGR, HJE, HNV, JCW, JCR, HJK, HQS, JCS, JCT, JCU, JCV, JCX, JCY, JQP, KBL, KBM, KBN, KBP
Category Reparaturanleitung

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