5-speed manual gearbox 0AH

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 instructions
  4
• 3.1 General repair instructions
  4
• 4 Technical data
  9
• 4.1 Allocation gearbox - engine
  9
• 4.2 Capacities
  10
• 4.3 Calculation of gear ratios
  10
• 5 Overview - power transmission
  11
• 5.1 Overview - power transmission - front-wheel drive
  11
• 6 Electrical components
  13
• 6.1 Overview of fitting locations - electrical components
  13
• Clutch
  15
• 1 Clutch mechanism
  15
• 1.1 Assembly overview - pedal cluster
  15
• 1.2 Assembly overview - clutch hydraulics
  17
• 1.3 Assembly overview - clutch release mechanism
  19
• 1.4 Removing and installing clutch pedal
  20
• 1.5 Removing and installing over-centre spring
  26
• 1.6 Removing and installing mounting bracket
  30
• 1.7 Removing and installing clutch master cylinder
  39
• 1.8 Removing and installing clutch slave cylinder
  41
• 1.9 Bleeding clutch mechanism
  44
• 1.10 Checking clutch master cylinder and clutch slave cylinder
  46
• 1.11 Removing and installing clutch position sender G476
  46
• 1.12 Repairing clutch release mechanism
  49
• 2 Clutch
  51
• 2.1 Assembly overview - clutch
  51
• 2.2 Removing and installing clutch
  51
• Controls, housing
  57
• 1 Selector mechanism
  57
• 1.1 Installation position - selector mechanism
  57
• 1.2 Assembly overview - selector mechanism
  58
• 1.3 Assembly overview – gear knob and cover
  59
• 1.4 Assembly overview - Gear lever and selector housing
  60
• 1.5 Assembly overview – selector cables
  62
• 1.6 Removing and installing gear knob
  67
• 1.7 Removing and installing selector mechanism
  68
• 1.8 Dismantling and assembling selector mechanism
  75
• 1.9 Removing and installing gear selector cable
  81
• 1.10 Adjusting selector mechanism
  84
• 1.11 Checking selector mechanism
  87
• 1.12 Renewing selector shaft seal
  87
• 1.13 Removing and installing gearbox neutral position sender G701
  88
• 1.14 Reversing light switch F4
  90
• 2 Removing and installing gearbox
  91
• 2.1 Specified torques for gearbox
  91
• 2.2 Removing gearbox
  92
• 2.3 Installing gearbox
  100
• 3 Assembly mountings
  108
• 3.1 Assembly overview - assembly mountings
  108
• 4 Transporting gearbox
  111
• 5 Dismantling and assembling gearbox
  113
• 5.1 Schematic overview - gearbox
  113
• 5.2 Assembly overview - gearbox
  113
• 5.3 Assembly overview - cover for gearbox housing and 5th gear
  114
• 5.4 Assembly overview - input shaft, output shafts, differential, selector rods
  115
• 5.5 Assembly overview - selector unit
  117
• 5.6 Assembly overview - selector forks
  118
• 5.7 Repairing selector unit
  119
• 5.8 Repairing selector forks
  120
• 5.9 Dismantling and assembling gearbox
  125
• 6 Gearbox housing, clutch housing
  139
• 6.1 Assembly overview - clutch housing
  139
• 6.2 Assembly overview - gearbox housing and clutch housing
  139
• 6.3 Repairing gearbox housing
  141
• 7 Securing to engine and gearbox support
  143
• 8 Gear oil
  144
• 8.1 Checking gear oil level
  144
• Gears, shafts
  146
• 1 Input shaft
  146
• 1.1 Assembly overview - input shaft
  146
• 1.2 Dismantling and assembling input shaft
  148
• 1.3 Renewing input shaft seal
  160
• 2 Output shaft
  163
• 2.1 Assembly overview - output shaft
  163
• 2.2 Dismantling and assembling output shaft
  165
• Final drive - differential
  174
• 1 Oil seals
  174
• 1.1 Overview of fitting locations - seals
  174
• 1.2 Renewing left seal
  174
• 1.3 Renewing right seal
  177
• 2 Differential
  181
• 2.1 Assembly overview - differential
  181
• 2.2 Dismantling and assembling differential
  183
• 2.3 Adjusting differential
  190