5-speed manual gearbox 0AH

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation and capacities
  2
• 2 Overview - power transmission
  3
• 3 Calculating overall gear ratio “i”
  5
• 4 General repair instructions
  6
• 4.1 Components
  6
• Clutch
  10
• 1 Repairing clutch mechanism
  10
• 1.1 Overview
  10
• 1.2 Assembly overview - pedal cluster
  11
• 1.3 Removing and installing over-centre spring, LHD
  13
• 1.4 Removing and installing over-centre spring, RHD
  19
• 1.5 Removing and installing clutch pedal, LHD
  25
• 1.6 Removing and installing clutch pedal, RHD
  31
• 1.7 Removing and installing mounting bracket, left-hand drive vehicles
  37
• 1.8 Removing and installing mounting bracket, right-hand drive vehicles
  44
• 1.9 Removing and installing master cylinder
  51
• 1.10 Removing and installing clutch position sender G476
  53
• 1.11 Assembly overview - hydraulics, left-hand drive vehicles
  56
• 1.12 Assembly overview - hydraulics (RHD)
  58
• 1.13 Removing and installing slave cylinder
  60
• 2 Bleeding clutch system
  64
• 3 Repairing clutch release mechanism
  66
• 4 Repairing clutch
  69
• Controls, housing
  72
• 1 Repairing selector mechanism
  72
• 1.1 Installation position of selector mechanism
  72
• 1.2 Removing and installing gear knob and cover
  73
• 1.3 Removing and installing gaiter with gear knob and noise insulation
  74
• 1.4 Repairing gear lever and selector housing (to 10.06)
  77
• 1.5 Repairing gear lever and selector housing (from 11.06)
  80
• 1.6 Assembly overview - removing and installing selector cables
  87
• 1.7 Removing and installing selector mechanism
  91
• 1.8 Adjusting selector mechanism
  96
• 2 Plastic relay lever
  99
• 3 Removing and installing gearbox
  102
• 3.1 Removing gearbox
  105
• 3.2 Installing gearbox
  113
• 3.3 Specified torques
  119
• 4 Transporting gearbox
  121
• 5 Checking gearbox oil
  122
• 6 Securing to engine and gearbox support
  124
• 7 Dismantling and assembling gearbox
  126
• 7.1 Overview - gearbox
  126
• 7.2 Assembly overview
  126
• 7.3 Removing and installing cover for gearbox housing and 5th gear
  127
• 7.4 Removing and installing clutch housing
  128
• 7.6 Assembly sequence
  131
• 8 Repairing gearbox housing and clutch housing
  144
• 9 Repairing selector unit
  147
• 10 Dismantling and assembling selector forks
  150
• Gears, shafts
  156
• 1 Input shaft
  156
• 1.1 Dismantling and assembling input shaft
  156
• 2 Output shaft
  168
• 2.1 Dismantling and assembling output shaft
  168
• Final drive - differential
  178
• 1 Renewing flange shaft oil seals with gearbox installed
  178
• 1.1 Renewing oil seal for left flange shaft
  178
• 1.2 Renewing seal for right flange shaft
  180
• 2 Differential
  183
• 2.1 Dismantling and assembling differential
  183
• 2.2 Adjusting differential
  190