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 instructions
  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
  7
• 5.1 Overview - power transmission - front-wheel drive
  7
• 6 Electrical components
  9
• 6.1 Overview of fitting locations - electrical components
  9
• Clutch
  10
• 1 Clutch operation
  10
• 1.1 Assembly overview - pedal cluster
  10
• 1.2 Assembly overview - clutch hydraulics
  13
• 1.3 Assembly overview - clutch release mechanism
  16
• 1.4 Removing and installing clutch pedal
  17
• 1.5 Removing and installing over-centre spring
  18
• 1.6 Removing and installing return spring
  20
• 1.7 Removing and installing mounting bracket
  23
• 1.8 Removing and installing bearing bush
  27
• 1.9 Removing and installing clutch master cylinder
  28
• 1.10 Removing and installing clutch slave cylinder
  28
• 1.11 Removing and installing lines for clutch mechanism
  30
• 1.12 Bleeding clutch mechanism
  32
• 1.13 Checking clutch master cylinder and clutch slave cylinder
  33
• 1.14 Removing and installing clutch position sender G476
  33
• 1.15 Repairing clutch release mechanism
  34
• 2 Clutch
  36
• 2.1 Assembly overview - clutch
  36
• 2.2 Removing and installing clutch
  39
• Controls, housing
  51
• 1 Selector mechanism
  51
• 1.1 Installation position - selector mechanism
  51
• 1.2 Assembly overview - gear knob and cover
  52
• 1.3 Assembly overview - selector mechanism
  53
• 1.4 Removing and installing gear knob
  54
• 1.5 Removing and installing selector mechanism
  56
• 1.6 Adjusting selector mechanism
  62
• 1.7 Checking selector mechanism
  65
• 1.8 Renewing oil seal for selector shaft
  65
• 2 Removing and installing gearbox
  67
• 2.1 Specified torques for gearbox
  67
• 2.2 Removing gearbox
  67
• 2.3 Install gearbox
  83
• 3 Assembly mountings
  92
• 3.1 Assembly overview - assembly mountings
  92
• 4 Transporting gearbox
  94
• 5 Dismantling and assembling gearbox
  95
• 5.1 Schematic overview - gearbox
  95
• 5.2 Assembly overview - cover for gearbox housing and 5th gear
  97
• 5.3 Assembly overview - gearbox housing and selector mechanism
  98
• 5.4 Assembly overview - selector unit
  99
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  100
• 5.6 Assembly overview - selector forks
  101
• 5.7 Repairing selector unit
  102
• 5.8 Repairing selector forks
  103
• 5.9 Removing cover for gearbox housing and 5th gear
  107
• 5.10 Dismantling and assembling gearbox
  113
• 5.11 Installing cover for gearbox housing and 5th gear
  125
• 6 Gearbox housing, clutch housing
  129
• 6.1 Assembly overview - gearbox housing
  129
• 6.2 Assembly overview - clutch housing
  131
• 6.3 Repairing gearbox housing
  132
• 6.4 Repairing clutch housing
  139
• 7 Installing to engine and gearbox support
  145
• 8 Gear oil
  146
• 8.1 Checking gear oil level
  146
• 8.2 Draining and filling gear oil
  146
• Gears, shafts
  149
• 1 Input shaft
  149
• 1.1 Assembly overview - input shaft
  149
• 1.2 Dismantling and assembling input shaft
  152
• 1.3 Adjusting input shaft
  158
• 2 Output shaft
  163
• 2.1 Assembly overview - output shaft
  163
• 2.2 Dismantling and assembling output shaft
  166
• 2.3 Adjusting output shaft
  176
• 3 Reverse shaft
  183
• 3.1 Assembly overview - reverse shaft
  183
• 3.2 Dismantling and assembling reverse shaft
  184
• Final drive - differential
  187
• 1 Oil seals
  187
• 1.1 Overview of fitting locations - seals
  187
• 1.2 Renewing left oil seal
  188
• 1.3 Renewing right oil seal
  190
• 1.4 Renewing input shaft seal
  194
• 2 Differential
  196
• 2.1 Assembly overview - differential
  196
• 2.2 Dismantling and assembling differential
  197
• 2.3 Adjusting differential
  202
• 3 Adjustment overview
  206