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
  6
• 4.1 Capacities
  6
• 4.2 Allocation gearbox - engine
  6
• 4.3 Calculation of gear ratios
  6
• 5 Overview - power transmission
  8
• 5.1 Overview - power transmission - front-wheel drive
  8
• 6 Electrical components
  10
• 6.1 Overview of fitting locations - electrical components
  10
• Clutch
  11
• 1 Clutch operation
  11
• 1.1 Assembly overview - pedal cluster
  11
• 1.2 Assembly overview - clutch hydraulics
  14
• 1.3 Assembly overview - clutch release mechanism
  17
• 1.4 Removing and installing clutch pedal
  18
• 1.5 Removing and installing over-centre spring
  19
• 1.6 Removing and installing return spring
  21
• 1.7 Removing and installing mounting bracket
  24
• 1.8 Removing and installing bearing bush
  28
• 1.9 Removing and installing clutch master cylinder
  29
• 1.10 Removing and installing clutch slave cylinder
  29
• 1.11 Removing and installing lines for clutch mechanism
  31
• 1.12 Bleeding clutch mechanism
  33
• 1.13 Checking clutch master cylinder and clutch slave cylinder
  34
• 1.14 Removing and installing clutch position sender G476
  34
• 1.15 Repairing clutch release mechanism
  35
• 2 Clutch
  37
• 2.1 Assembly overview - clutch
  37
• 2.2 Removing and installing clutch
  40
• Controls, housing
  52
• 1 Selector mechanism
  52
• 1.1 Installation position - selector mechanism
  52
• 1.2 Assembly overview - gear knob and cover
  53
• 1.3 Assembly overview - selector mechanism
  54
• 1.4 Removing and installing gear knob
  55
• 1.5 Removing and installing selector mechanism
  57
• 1.6 Adjusting selector mechanism
  63
• 1.7 Checking selector mechanism
  66
• 1.8 Renewing oil seal for selector shaft
  66
• 2 Removing and installing gearbox
  68
• 2.1 Specified torques for gearbox
  68
• 2.2 Removing gearbox
  68
• 2.3 Installing gearbox
  84
• 3 Assembly mountings
  93
• 3.1 Assembly overview - assembly mountings
  93
• 4 Transporting gearbox
  95
• 5 Dismantling and assembling gearbox
  96
• 5.1 Schematic overview - gearbox
  96
• 5.2 Assembly overview - cover for gearbox housing and 5th gear
  98
• 5.3 Assembly overview - gearbox housing and selector mechanism
  99
• 5.4 Assembly overview - selector unit
  100
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  101
• 5.6 Assembly overview - selector forks
  102
• 5.7 Repairing selector unit
  103
• 5.8 Repairing selector forks
  104
• 5.9 Removing cover for gearbox housing and 5th gear
  108
• 5.10 Dismantling and assembling gearbox
  114
• 5.11 Installing cover for gearbox housing and 5th gear
  126
• 6 Gearbox housing, clutch housing
  130
• 6.1 Assembly overview - gearbox housing
  130
• 6.2 Assembly overview - clutch housing
  132
• 6.3 Repairing gearbox housing
  133
• 6.4 Repairing clutch housing
  140
• 7 Installing to engine and gearbox support
  146
• 8 Gear oil
  147
• 8.1 Checking gear oil level
  147
• 8.2 Draining and filling gear oil
  147
• Gears, shafts
  150
• 1 Input shaft
  150
• 1.1 Assembly overview - input shaft
  150
• 1.2 Dismantling and assembling input shaft
  153
• 1.3 Adjusting input shaft
  159
• 2 Output shaft
  164
• 2.1 Assembly overview - output shaft
  164
• 2.2 Dismantling and assembling output shaft
  167
• 2.3 Adjusting output shaft
  177
• 3 Reverse shaft
  184
• 3.1 Assembly overview - reverse shaft
  184
• 3.2 Dismantling and assembling reverse shaft
  185
• Final drive - differential
  188
• 1 Oil seals
  188
• 1.1 Overview of fitting locations - seals
  188
• 1.2 Renewing left oil seal
  189
• 1.3 Renewing right oil seal
  191
• 1.4 Renewing input shaft seal
  195
• 2 Differential
  197
• 2.1 Assembly overview - differential
  197
• 2.2 Dismantling and assembling differential
  198
• 2.3 Adjusting differential
  203
• 3 Adjustment overview
  207