5-speed manual gearbox 0AH

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 2 Overview - power transmission
  3
• 2.1 Overview - power transmission
  3
• 3 Technical data
  5
• 3.1 Calculating overall gear ratio “i”
  5
• 3.2 Allocation gearbox - engine/capacities
  5
• 4 Repair instructions
  9
• 4.1 General repair instructions
  9
• Clutch
  13
• 1 Clutch mechanism
  13
• 1.1 Assembly overview - pedal cluster
  13
• 1.2 Assembly overview - clutch hydraulics
  15
• 1.3 Assembly overview - clutch release mechanism
  17
• 1.4 Removing and installing over-centre spring
  18
• 1.5 Removing and installing clutch pedal
  22
• 1.6 Removing and installing mounting bracket
  25
• 1.7 Removing and installing clutch master cylinder
  32
• 1.8 Removing and installing clutch position sender G476
  34
• 1.9 Removing and installing clutch slave cylinder
  35
• 1.10 Bleeding clutch mechanism
  37
• 1.11 Repairing clutch release mechanism
  38
• 2 Clutch
  41
• 2.1 Assembly overview - clutch
  41
• 2.2 Removing and installing clutch
  42
• Controls, housing
  46
• 1 Selector mechanism
  46
• 1.1 Installation position - selector mechanism
  46
• 1.2 Assembly overview – selector cables
  47
• 1.3 Assembly overview – gear knob and cover
  51
• 1.4 Assembly overview - Selector lever and selector housing, ►06.2010
  52
• 1.5 Assembly overview - Selector lever and selector housing, 07.2010►
  55
• 1.6 Dismantling and assembling selector mechanism, 07.2010►
  57
• 1.7 Removing and installing gear knob
  62
• 1.8 Removing and installing selector mechanism
  63
• 1.9 Adjusting selector mechanism
  67
• 1.10 Removing and installing relay lever
  71
• 2 Removing and installing gearbox
  74
• 2.1 Specified torques for gearbox
  74
• 2.2 Removing gearbox, vehicles ►07.2010
  76
• 2.3 Removing gearbox, from 08.2010►
  85
• 2.4 Installing gearbox
  94
• 3 Transporting gearbox
  102
• 3.1 Transporting gearbox
  102
• 4 Gear oil
  104
• 4.1 Checking gear oil level
  104
• 5 Dismantling and assembling gearbox
  106
• 5.1 Schematic overview - gearbox
  106
• 5.2 Assembly overview - selector unit
  106
• 5.3 Assembly overview - selector forks
  107
• 5.4 Assembly overview - gearbox housing/5th gear
  108
• 5.5 Assembly overview - input shaft, output shafts, differential, selector unit
  109
• 5.6 Repairing selector unit
  111
• 5.7 Repairing selector forks
  113
• 5.8 Dismantling and assembling gearbox
  117
• 6 Gearbox housing, clutch housing
  128
• 6.1 Assembly overview - gearbox housing/clutch housing
  128
• 6.2 Assembly overview - clutch housing
  130
• 6.3 Repairing gearbox housing/clutch housing
  131
• Gears, shafts
  133
• 1 Input shaft
  133
• 1.1 Assembly overview - input shaft
  133
• 1.2 Dismantling and assembling input shaft
  135
• 2 Output shaft
  147
• 2.1 Assembly overview - output shaft
  147
• 2.2 Dismantling and assembling output shaft
  149
• Final drive - differential
  158
• 1 Oil seals
  158
• 1.1 Renewing left seal
  158
• 1.2 Renewing right seal
  160
• 2 Differential
  163
• 2.1 Assembly overview - differential
  163
• 2.2 Dismantling and assembling differential
  165
• 2.3 Adjusting differential
  173