5-speed manual gearbox 0AH

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Code letters, assembly allocation and capacities - Touran 2003 ►
  2
• 1.3 Identification codes, assembly allocation, capacities, Passat 2006 ►
  3
• 1.4 Identification codes, assembly allocation, capacities, Golf 2009 ►
  3
• 1.5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ►
  4
• 2 Overview - power transmission
  5
• 3 Calculating overall gear ratio “i”
  7
• 4 General repair instructions
  8
• 4.1 Gearbox
  8
• 4.2 Gaskets and seals
  8
• 4.3 Sealant
  8
• 4.4 Locking devices
  9
• 4.5 Nuts and bolts
  9
• 4.6 Bearings
  9
• 4.7 Shims
  9
• 4.8 Synchro-rings
  10
• 4.9 Gear wheels
  10
• 4.10 Synchromeshed gears
  10
• 4.11 Clutch
  10
• 5 Safety precautions for vehicles with a start-stop system
  11
• Clutch
  12
• 1 Repairing clutch mechanism, Touran
  12
• 1.1 Overview
  12
• 1.2 Assembly overview - pedal cluster with clutch pedal switch F36 to 05.03
  13
• 1.3 Removing and installing clutch pedal switch F36
  14
• 1.4 Removing and installing mounting bracket (all Tourans)
  15
• 1.5 Removing and installing master cylinder with mounting bracket removed (through 05.03)
  23
• 1.8 Removing and installing over-centre spring with mounting bracket installed
  28
• 1.9 Removing and installing clutch pedal with mounting bracket installed
  31
• 1.11 Removing and installing clutch position sender G476 (from 06. 03)
  36
• 1.12 Assembly overview - hydraulics (LHD)
  38
• 1.13 Assembly overview - hydraulics (RHD)
  41
• 1.14 Removing and installing slave cylinder
  42
• 2 Repairing clutch mechanism, Passat, Golf and Golf Plus
  45
• 2.1 Overview
  45
• 2.2 Assembly overview - pedal cluster
  46
• 2.3 Removing and installing over-centre spring, Golf 2009 ► LHD
  47
• 2.4 Removing and installing over-centre spring - Golf 2009 ► right-hand drive
  52
• 2.5 Removing and installing over-centre spring, Golf Plus
  57
• 2.6 Removing and installing over-centre spring, Passat
  62
• 2.7 Removing and installing clutch pedal, Golf 2009 ► LHD
  63
• 2.8 Removing and installing clutch pedal - Golf 2009 ► right-hand drive
  69
• 2.9 Removing and installing clutch pedal, Golf Plus
  74
• 2.10 Removing and installing clutch pedal, Passat
  80
• 2.11 Removing and installing mounting bracket, Golf 2009 ► LHD
  82
• 2.13 Removing and installing mounting bracket, Golf Plus left-hand drive
  93
• 2.14 Removing and installing mounting bracket, Passat
  98
• 2.15 Removing and installing master cylinder
  102
• 2.16 Removing and installing clutch position sender G476
  103
• 2.17 Assembly overview - hydraulics (LHD)
  106
• 2.18 Assembly overview - hydraulics (RHD)
  108
• 2.19 Removing and installing slave cylinder
  109
• 3 Bleeding clutch system
  112
• 4 Repairing clutch release mechanism
  114
• 5 Repairing clutch
  116
• Controls, housing
  119
• 1 Repairing selector mechanism, Touran
  119
• 1.1 Installation position of selector mechanism
  119
• 1.2 Removing and installing gear knob and cover
  120
• 1.3 Removing and installing gaiter with gear knob
  121
• 1.4 Repairing gear lever and selector housing (through 10.06)
  123
• 1.5 Repairing gear lever and selector housing (from 11.06)
  125
• 1.6 Assembly overview - removing and installing selector cables
  130
• 1.7 Removing and installing selector mechanism
  134
• 2 Repairing selector mechanism, Passat, Golf and Golf Plus
  138
• 2.1 Installation position of selector mechanism
  138
• 2.2 Removing and installing gear knob and cover
  139
• 2.3 Removing and installing gaiter with gear knob and noise insulation, Golf
  140
• 2.4 Removing and installing gaiter with gear knob and noise insulation, Golf Plus
  142
• 2.5 Removing and installing gaiter with gear knob, Passat
  144
• 2.6 Repairing gear lever and selector housing (through 10.06)
  145
• 2.7 Repairing gear lever and selector housing (from 11.06)
  148
• 2.8 Attaching base plate
  153
• 2.9 Assembly overview - removing and installing selector cables
  153
• 2.10 Removing and installing selector mechanism
  156
• 3 Adjusting selector mechanism
  161
• 3.1 Checking selector mechanism
  163
• 5.1 Removing gearbox
  169
• 5.2 Installing gearbox
  174
• 6 Removing and installing gearbox, Passat
  182
• 6.1 Removing gearbox
  183
• 6.2 Installing gearbox
  187
• 7 Removing and installing gearbox, Golf
  194
• 7.1 Removing gearbox
  197
• 7.2 Installing gearbox
  202
• 8 Removing and installing gearbox, Golf Plus
  209
• 8.1 Removing gearbox
  211
• 8.2 Installing gearbox
  216
• 9 Transporting gearbox
  223
• 10 Securing to engine and gearbox support
  224
• 11 Checking gearbox oil
  226
• 12 Dismantling and assembling gearbox
  228
• 12.1 Overview - gearbox
  228
• 12.2 Assembly overview
  229
• 12.3 Removing and installing cover for gearbox housing and 5th gear
  230
• 12.4 Removing and installing clutch housing
  231
• 12.6 Dismantling and assembling procedure
  233
• 13 Repairing gearbox housing and clutch housing
  244
• 14 Repairing selector unit
  247
• 15 Dismantling and assembling selector forks
  250
• Gears, shafts
  255
• 1 Input shaft
  255
• 1.1 Dismantling and assembling input shaft
  255
• 2 Output shaft
  266
• 2.1 Dismantling and assembling output shaft
  266
• Final drive - differential
  274
• 1 Renewing flange shaft oil seals with gearbox installed, Touran
  274
• 1.1 Renewing oil seal for left flange shaft
  274
• 1.2 Renewing seal for right flange shaft
  276
• 2 Renewing flange shaft oil seals with gearbox installed, Passat, Golf and Golf Plus
  279
• 2.1 Renewing oil seal for left flange shaft
  279
• 2.2 Renewing seal for right flange shaft
  280
• 3 Differential
  283
• 3.1 Dismantling and assembling differential
  283
• 3.2 Adjusting differential
  290