5-speed manual gearboxes 0DF and 0D0, installed

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 Technical data
  3
• 3.1 Allocation gearbox - engine
  3
• 3.2 Capacities
  3
• 4 Overview - power transmission
  4
• 5 Electrical components
  6
• 5.1 Overview of fitting locations - electrical components
  6
• 6 Repair notes
  8
• 6.1 General repair instructions
  8
• Clutch
  11
• 1 Clutch mechanism
  11
• 1.1 Overview of fitting locations – clutch mechanism
  11
• 1.2 Assembly overview - pedal cluster
  12
• 1.3 Assembly overview - clutch hydraulics
  14
• 1.4 Removing and installing bearing bush
  16
• 1.5 Checking clutch master cylinder and clutch slave cylinder
  17
• 1.6 Removing and installing clutch position sender G476
  18
• 1.7 Removing and installing over-centre spring
  20
• 1.8 Removing and installing clutch pedal
  22
• 1.9 Removing and installing mounting bracket
  25
• 1.10 Removing and installing master cylinder
  28
• 1.11 Removing and installing clutch slave cylinder
  29
• 1.12 Removing and installing lines for clutch mechanism
  32
• 1.13 Bleeding clutch mechanism
  35
• 2 Clutch
  37
• Controls, housing
  38
• 1 Selector mechanism
  38
• 1.1 Installation position - selector mechanism
  38
• 1.2 Assembly overview – gear knob and cover
  39
• 1.3 Assembly overview - selector mechanism
  39
• 1.4 Removing and installing gear knob
  41
• 1.5 Removing and installing selector mechanism
  43
• 1.6 Repairing selector mechanism
  46
• 1.7 Adjusting selector mechanism
  50
• 1.8 Checking selector mechanism
  53
• 2 Removing and installing gearbox
  55
• 2.1 Specified torques for gearbox
  55
• 2.2 Removing gearbox
  55
• 2.3 Installing gearbox
  64
• 3 Transporting gearbox
  68
• 4 Assembly mountings
  69
• 4.1 Assembly overview - assembly mountings
  69
• 5 Gear oil
  72
• 5.1 Checking gear oil level
  72
• 5.2 Draining and filling gear oil
  73
• 6 Dismantling and assembling gearbox
  75
• 6.1 Assembly overview - selector unit
  75
• 6.2 Removing and installing selector unit with gearbox installed
  76
• 6.3 Repairing selector unit
  79
• 6.4 Renewing selector shaft seal
  80
• 7 Gearbox housing, clutch housing
  81
• Gears, shafts
  82
• 1 Input shaft
  82
• 2 Output shaft
  83
• Final drive - differential
  84
• 1 Oil seals
  84
• 1.1 Overview of fitting locations - seals
  84
• 1.2 Renewing left seal
  84
• 1.3 Renewing right seal
  87
• 2 Differential
  90