5-speed manual gearbox 0AF

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
  4
• 3.1 General repair instructions
  4
• 4 Technical data
  9
• 4.1 Allocation gearbox - engine
  9
• 4.2 Capacities
  9
• 4.3 Calculation of gear ratios
  9
• 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 mechanism
  14
• 1.1 Overview of fitting locations – clutch mechanism
  14
• 1.2 Assembly overview - pedal cluster
  15
• 1.3 Assembly overview - clutch hydraulics
  17
• 1.4 Assembly overview - clutch release mechanism
  22
• 1.5 Removing and installing over-centre spring
  23
• 1.6 Removing and installing clutch pedal
  30
• 1.7 Removing and installing mounting bracket
  37
• 1.8 Removing and installing clutch master cylinder
  44
• 1.9 Removing and installing clutch slave cylinder
  47
• 1.10 Checking clutch master cylinder and clutch slave cylinder
  50
• 1.11 Removing and installing clutch position sender G476
  50
• 1.12 Bleeding clutch mechanism
  53
• 1.13 Repairing clutch release mechanism
  55
• 2 Clutch
  57
• 2.1 Assembly overview - clutch
  57
• 2.2 Removing and installing clutch
  57
• Controls, housing
  63
• 1 Selector mechanism
  63
• 1.1 Installation position - selector mechanism
  63
• 1.2 Assembly overview - selector mechanism
  64
• 1.3 Assembly overview – gear knob and cover
  65
• 1.4 Assembly overview - Gear lever and selector housing
  66
• 1.5 Assembly overview – selector cables
  68
• 1.6 Removing and installing gear knob
  72
• 1.7 Dismantling and assembling selector mechanism
  74
• 1.8 Removing and installing selector mechanism
  81
• 1.9 Removing and installing gear selector cable and gate selector cable
  89
• 1.10 Adjusting selector mechanism
  91
• 1.11 Checking selector mechanism
  94
• 1.12 Renewing selector shaft seal
  94
• 2 Removing and installing gearbox
  96
• 2.1 Removing gearbox
  96
• 2.2 Installing gearbox
  107
• 2.3 Specified torques for gearbox
  114
• 3 Assembly mountings
  117
• 3.1 Assembly overview - assembly mountings
  117
• 4 Transporting gearbox
  121
• 5 Gear oil
  123
• 5.1 Checking gear oil level
  123
• 6 Securing to engine and gearbox support
  125
• 7 Dismantling and assembling gearbox
  127
• 7.1 Schematic overview - gearbox
  127
• 7.2 Assembly overview - gearbox
  128
• 7.3 Assembly overview - cover for gearbox housing and 5th gear
  128
• 7.4 Assembly overview - clutch housing
  129
• 7.5 Assembly overview - input shaft, output shafts, differential, selector rods
  130
• 7.6 Assembly overview - selector unit
  132
• 7.7 Assembly overview - selector forks
  133
• 7.8 Repairing selector forks
  134
• 7.9 Repairing selector unit
  139
• 7.10 Dismantling and assembling gearbox
  140
• 8 Gearbox housing, clutch housing
  153
• 8.1 Assembly overview - gearbox housing and clutch housing
  153
• 8.2 Repairing gearbox housing
  155
• 8.3 Repairing clutch housing
  156
• Gears, shafts
  159
• 1 Input shaft
  159
• 1.1 Assembly overview - input shaft
  159
• 1.2 Dismantling and assembling input shaft
  161
• 1.3 Renewing input shaft seal
  173
• 2 Output shaft
  176
• 2.1 Assembly overview - output shaft
  176
• 2.2 Dismantling and assembling output shaft
  178
• Final drive - rear differential
  187
• 1 Seals
  187
• 1.1 Overview of fitting locations - seals
  187
• 1.2 Renewing left seal
  187
• 1.3 Renewing right seal
  190
• 2 Differential
  193
• 2.1 Assembly overview - differential
  193
• 2.2 Dismantling and assembling differential
  195
• 2.3 Adjusting differential
  204