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 Repair instructions
  5
• 3.1 General repair instructions
  5
• 4 Technical data
  10
• 4.1 Capacities
  10
• 4.2 Allocation gearbox - engine
  10
• 4.3 Calculation of gear ratios
  14
• 5 Overview - power transmission
  15
• 5.1 Overview - power transmission - front-wheel drive
  15
• 6 Electrical components
  17
• 6.1 Overview of fitting locations - electrical components
  17
• Clutch
  19
• 1 Clutch mechanism
  19
• 1.1 Assembly overview - pedal cluster
  19
• 1.2 Assembly overview - clutch hydraulics
  21
• 1.3 Assembly overview - clutch release mechanism
  24
• 1.4 Removing and installing clutch pedal
  26
• 1.5 Removing and installing over-centre spring
  31
• 1.6 Removing and installing mounting bracket
  35
• 1.7 Removing and installing clutch master cylinder
  43
• 1.8 Removing and installing clutch slave cylinder
  46
• 1.9 Removing and installing lines for clutch mechanism
  49
• 1.10 Bleeding clutch mechanism
  51
• 1.11 Checking clutch master cylinder
  53
• 1.12 Removing and installing clutch position sender G476
  53
• 1.13 Repairing clutch release mechanism
  55
• 2 Clutch
  57
• 2.1 Assembly overview - clutch
  57
• 2.2 Removing and installing clutch
  60
• Controls, housing
  76
• 1 Selector mechanism
  76
• 1.1 Installation position - selector mechanism
  76
• 1.2 Assembly overview – gear knob and cover
  77
• 1.3 Assembly overview - Gear lever and selector housing
  78
• 1.4 Assembly overview – selector cables
  80
• 1.5 Removing and installing gear knob
  82
• 1.6 Removing and installing selector mechanism
  84
• 1.7 Dismantling and assembling selector mechanism
  93
• 1.8 Removing and installing gear selector cable
  99
• 1.9 Adjusting selector mechanism
  102
• 1.10 Checking selector mechanism
  105
• 1.11 Renewing selector shaft seal
  105
• 2 Removing and installing gearbox
  108
• 2.1 Specified torques for gearbox
  108
• 2.2 Removing gearbox
  108
• 2.3 Installing gearbox
  119
• 3 Assembly mountings
  128
• 3.1 Assembly overview - assembly mountings
  128
• 4 Transporting gearbox
  132
• 5 Dismantling and assembling gearbox
  134
• 5.1 Schematic overview - gearbox
  134
• 5.2 Assembly overview - cover for gearbox housing and 5th gear
  135
• 5.3 Assembly overview - gearbox housing and selector mechanism
  137
• 5.4 Assembly overview - selector unit
  139
• 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
  139
• 5.6 Assembly overview - selector forks
  140
• 5.7 Repairing selector unit
  141
• 5.8 Repairing selector forks
  142
• 5.9 Dismantling and assembling gearbox
  147
• 5.10 Removing cover for gearbox housing and 5th gear
  161
• 5.11 Installing cover for gearbox housing and 5th gear
  168
• 6 Gearbox housing, clutch housing
  174
• 6.1 Assembly overview - gearbox housing
  174
• 6.2 Assembly overview - clutch housing
  177
• 6.3 Repairing gearbox housing
  179
• 6.4 Repairing clutch housing
  186
• 7 Securing to engine and gearbox support
  192
• 8 Gear oil
  193
• 8.1 Checking gear oil level
  193
• 8.2 Draining and filling gear oil
  193
• Gears, shafts
  196
• 1 Input shaft
  196
• 1.1 Assembly overview - input shaft
  196
• 1.2 Dismantling and assembling input shaft
  198
• 1.3 Adjusting input shaft
  204
• 2 Output shaft
  210
• 2.1 Assembly overview - output shaft
  210
• 2.2 Dismantling and assembling output shaft
  213
• 2.3 Adjusting output shaft
  225
• 3 Reverse shaft
  231
• 3.1 Assembly overview - reverse shaft
  231
• 3.2 Dismantling and assembling reverse shaft
  231
• Final drive - differential
  235
• 1 Oil seals
  235
• 1.1 Overview of fitting locations - seals
  235
• 1.2 Renewing left seal
  235
• 1.3 Renewing right seal
  238
• 1.4 Renewing input shaft seal
  245
• 2 Differential
  247
• 2.1 Assembly overview - differential
  247
• 2.2 Dismantling and assembling differential
  249
• 2.3 Adjusting differential
  255
• 3 Adjustment overview
  261