5-speed manual gearbox 0A4

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Technical data
  4
• 3.1 Allocation gearbox - engine, gear ratios and capacities
  4
• 3.2 Calculating overall gear ratio “i”
  7
• 4 Overview - power transmission
  8
• 4.1 Overview - power transmission - front-wheel drive
  8
• 5 Repair notes
  10
• 5.1 Gearbox
  10
• 5.2 Gaskets and seals
  10
• 5.3 Locking devices
  11
• 5.4 Sealant
  11
• 5.5 Nuts and bolts
  11
• 5.6 Bearings
  11
• 5.7 Shims
  11
• 5.8 Synchro-rings
  12
• 5.9 Gear wheels
  12
• 5.10 Synchromeshed gears
  12
• 5.11 Clutch
  12
• Clutch
  13
• 1 Clutch mechanism
  13
• 1.1 Assembly overview - pedal cluster
  13
• 1.2 Assembly overview - clutch hydraulics
  15
• 1.3 Assembly overview - clutch release mechanism
  17
• 1.4 Removing and installing clutch pedal
  18
• 1.5 Removing and installing over-centre spring
  21
• 1.6 Removing and installing mounting bracket
  23
• 1.7 Removing and installing clutch master cylinder
  28
• 1.8 Removing and installing clutch slave cylinder
  30
• 1.9 Removing and installing clutch position sender G476
  32
• 1.10 Bleeding clutch mechanism
  33
• 2 Clutch
  34
• 2.1 Assembly overview - clutch
  34
• 2.2 Determining make of clutch
  35
• 2.3 Removing and installing clutch
  36
• Controls, housing
  43
• 1 Selector mechanism
  43
• 1.1 Installation position - selector mechanism
  43
• 1.2 Assembly overview – gear knob and cover
  44
• 1.3 Assembly overview - Gear lever and selector housing
  45
• 1.4 Assembly overview – selector cables
  47
• 1.5 Assembly overview - selector unit
  49
• 1.6 Removing and installing gear knob
  50
• 1.7 Removing and installing selector mechanism
  52
• 1.8 Adjusting selector mechanism
  54
• 1.9 Repairing selector unit
  58
• 2 Removing and installing gearbox
  60
• 2.1 Specified torques for gearbox
  60
• 2.2 Removing gearbox
  60
• 2.3 Removing gearbox as of 08.2010►
  66
• 2.4 Installing gearbox
  72
• 3 Assembly mountings
  78
• 3.1 Assembly overview - assembly mountings
  78
• 4 Transporting gearbox
  80
• 5 Dismantling and assembling gearbox
  81
• 5.1 Schematic overview - gearbox
  81
• 5.2 Assembly overview - cover for gearbox housing and 5th gear
  82
• 5.3 Assembly overview - gearbox housing and selector mechanism
  83
• 5.4 Assembly overview - input shaft, output shafts, differential, selector rods
  85
• 5.5 Assembly overview - selector forks
  86
• 5.6 Repairing selector forks
  87
• 5.7 Dismantling and assembling gearbox
  91
• 5.8 Removing and installing gearbox housing cover and 5th gear
  104
• 6 Gearbox housing, clutch housing
  115
• 6.1 Assembly overview - gearbox housing
  115
• 6.2 Assembly overview - clutch housing
  117
• 6.3 Repairing gearbox housing
  118
• 6.4 Repairing clutch housing
  126
• 7 Securing to engine and gearbox support
  132
• 8 Gear oil
  133
• 8.1 Checking gear oil level
  133
• 8.2 Draining and filling gear oil
  133
• Gears, shafts
  136
• 1 Input shaft
  136
• 1.1 Assembly overview - input shaft
  136
• 1.2 Dismantling and assembling input shaft
  139
• 1.3 Adjusting input shaft
  145
• 2 Output shaft
  151
• 2.1 Assembly overview - output shaft
  151
• 2.2 Dismantling and assembling output shaft
  154
• 2.3 Adjusting output shaft
  165
• 3 Reverse shaft
  169
• 3.1 Assembly overview - reverse shaft
  169
• 3.2 Dismantling and assembling reverse shaft
  171
• Final drive - differential
  174
• 1 Oil seals
  174
• 1.1 Overview of fitting locations - seals
  174
• 1.2 Renewing left seal
  175
• 1.3 Renewing right oil seal
  177
• 1.4 Renewing input shaft seal
  182
• 2 Differential
  185
• 2.1 Assembly overview - differential
  185
• 2.2 Dismantling and assembling differential
  187
• 2.3 Adjusting differential
  193
• 3 Adjustment overview
  197