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
  2
• 2.1 Gearbox identification
  2
• 3 Repair notes
  3
• 3.1 General repair instructions
  3
• 4 Technical data
  7
• 4.1 Capacities
  7
• 4.2 Allocation gearbox - engine
  7
• 4.3 Calculation of gear ratios
  8
• 5 Overview - power transmission
  10
• 5.1 Overview - power transmission - front-wheel drive
  10
• 6 Electrical components
  12
• 6.1 Overview of fitting locations - electrical components
  12
• Clutch
  14
• 1 Clutch operation
  14
• 1.1 Assembly overview - pedal cluster
  14
• 1.2 Assembly overview - clutch hydraulics
  17
• 1.3 Assembly overview - clutch release mechanism
  20
• 1.4 Removing and installing clutch pedal
  21
• 1.5 Removing and installing over-centre spring
  23
• 1.6 Removing and installing mounting bracket
  25
• 1.7 Removing and installing clutch master cylinder
  32
• 1.8 Removing and installing clutch slave cylinder
  34
• 1.9 Bleeding clutch mechanism
  38
• 1.10 Checking clutch master cylinder and clutch slave cylinder
  39
• 1.11 Removing and installing clutch position sender G476
  39
• 1.12 Repairing clutch release mechanism
  43
• 2 Clutch
  44
• 2.1 Determining make of clutch
  44
• 2.2 Assembly overview - clutch
  45
• 2.3 Removing and installing clutch
  50
• Controls, housing
  61
• 1 Selector mechanism
  61
• 1.1 Installation position - selector mechanism
  61
• 1.2 Assembly overview - gear knob and cover
  63
• 1.3 Assembly overview - Gear lever and selector housing
  64
• 1.4 Assembly overview - Selector cables
  66
• 1.5 Removing and installing gear knob
  70
• 1.6 Removing and installing selector mechanism
  72
• 1.7 Adjusting selector mechanism
  78
• 1.8 Checking selector mechanism
  82
• 1.9 Removing and installing gear selector cable and gate selector cable
  82
• 1.10 Renewing selector shaft seal
  83
• 1.11 Dismantling and assembling selector mechanism
  84
• 2 Removing and installing gearbox
  91
• 2.1 Specified torques for gearbox
  91
• 2.2 Removing gearbox
  92
• 2.3 Installing gearbox
  142
• 3 Assembly mountings
  149
• 3.1 Assembly overview - assembly mountings
  149
• 4 Transporting gearbox
  151
• 5 Dismantling and assembling gearbox
  152
• 5.1 Schematic overview - gearbox
  152
• 5.2 Assembly overview - cover for gearbox housing and 5th gear
  154
• 5.3 Assembly overview - gearbox housing and selector mechanism
  155
• 5.4 Assembly overview - selector unit
  156
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  157
• 5.6 Assembly overview - selector forks
  158
• 5.7 Repairing selector unit
  159
• 5.8 Repairing selector forks
  160
• 5.9 Dismantling and assembling gearbox
  164
• 5.10 Removing cover for gearbox housing and 5th gear
  178
• 5.11 Installing cover for gearbox housing and 5th gear
  184
• 6 Gearbox housing, clutch housing
  188
• 6.1 Assembly overview - gearbox housing
  188
• 6.2 Assembly overview - clutch housing
  190
• 6.3 Repairing gearbox housing
  191
• 6.4 Repairing clutch housing
  198
• 7 Securing to engine and gearbox support
  204
• 8 Gear oil
  205
• 8.1 Checking gear oil level
  205
• 8.2 Draining and filling gear oil
  205
• Gears, shafts
  208
• 1 Input shaft
  208
• 1.1 Assembly overview - input shaft
  208
• 1.2 Dismantling and assembling input shaft
  211
• 1.3 Adjusting input shaft
  217
• 2 Output shaft
  222
• 2.1 Assembly overview - output shaft
  222
• 2.2 Dismantling and assembling output shaft
  225
• 2.3 Adjusting output shaft
  235
• 3 Reverse shaft
  242
• 3.1 Assembly overview - reverse shaft
  242
• 3.2 Dismantling and assembling reverse shaft
  244
• Final drive - differential
  247
• 1 Oil seals
  247
• 1.1 Overview of fitting locations - seals
  247
• 1.2 Renewing left seal
  248
• 1.3 Renewing right oil seal
  250
• 1.4 Renewing input shaft seal
  255
• 2 Differential
  258
• 2.1 Assembly overview - differential
  258
• 2.2 Dismantling and assembling differential
  260
• 2.3 Adjusting differential
  266
• 3 Adjustment overview
  270