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
  8
• 4.1 Allocation gearbox - engine
  8
• 4.2 Capacities
  8
• 4.3 Calculation of gear ratios
  8
• 5 Overview - power transmission
  9
• 5.1 Overview - power transmission - front-wheel drive
  9
• 6 Electrical components
  11
• 6.1 Overview of fitting locations - electrical components
  11
• Clutch
  13
• 1 Clutch mechanism
  13
• 1.1 Overview of fitting locations – clutch mechanism
  13
• 1.2 Assembly overview - pedal cluster
  14
• 1.3 Assembly overview - clutch hydraulics
  16
• 1.4 Assembly overview - clutch release mechanism
  19
• 1.5 Removing and installing clutch pedal
  20
• 1.6 Removing and installing bearing bush
  21
• 1.7 Removing and installing over-centre spring
  23
• 1.8 Removing and installing return spring
  26
• 1.9 Removing and installing mounting bracket
  29
• 1.10 Checking clutch master cylinder and clutch slave cylinder
  35
• 1.11 Removing and installing clutch master cylinder
  35
• 1.12 Removing and installing clutch slave cylinder
  36
• 1.13 Removing and installing lines for clutch mechanism
  38
• 1.14 Bleeding clutch mechanism
  40
• 1.15 Removing and installing clutch position sender G476
  43
• 1.16 Repairing clutch release mechanism
  43
• 2 Clutch
  46
• 2.1 Assembly overview - clutch
  46
• 2.2 Removing and installing clutch
  46
• 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
  60
• 1.5 Removing and installing selector mechanism
  62
• 1.6 Adjusting selector mechanism
  65
• 1.7 Checking selector mechanism
  68
• 1.8 Renewing selector shaft seal
  68
• 2 Removing and installing gearbox
  71
• 2.1 Removing gearbox
  71
• 2.2 Installing gearbox
  85
• 2.3 Specified torques for gearbox
  93
• 3 Assembly mountings
  94
• 3.1 Assembly overview - assembly mountings
  94
• 4 Transporting gearbox
  98
• 5 Dismantling and assembling gearbox
  100
• 5.1 Schematic overview - gearbox
  100
• 5.2 Assembly overview - gearbox
  101
• 5.3 Assembly overview - cover for gearbox housing and 5th gear
  101
• 5.4 Assembly overview - clutch housing
  103
• 5.6 Assembly overview - selector unit
  105
• 5.7 Assembly overview - selector forks
  106
• 5.8 Repairing selector forks
  107
• 5.9 Repairing selector unit
  112
• 5.10 Dismantling and assembling gearbox
  114
• 6 Gearbox housing, clutch housing
  128
• 6.1 Assembly overview - gearbox housing and clutch housing
  128
• 6.2 Repairing clutch housing
  130
• 7 Securing to engine and gearbox support
  133
• 8 Gear oil
  135
• 8.1 Checking gear oil level
  135
• Gears, shafts
  137
• 1 Input shaft
  137
• 1.1 Assembly overview - input shaft
  137
• 1.2 Dismantling and assembling input shaft
  139
• 1.3 Renewing input shaft seal
  151
• 2 Output shaft
  154
• 2.1 Assembly overview - output shaft
  154
• 2.2 Dismantling and assembling output shaft
  156
• Final drive - differential
  165
• 1 Seals
  165
• 1.1 Overview of fitting locations - seals
  165
• 1.2 Renewing left seal
  165
• 1.3 Renewing right seal
  168
• 2 Differential
  173
• 2.1 Assembly overview - differential
  173
• 2.2 Dismantling and assembling differential
  175
• 2.3 Adjusting differential
  183