5 - Speed manual gearbox 0AF

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 2 Technical data
  3
• 2.1 Correspondence (gearbox / engine)
  3
• 2.2 Supply capacity (gearbox oil)
  3
• 2.3 Gear ratio calculation “i”
  3
• 3 Transmission assembly scheme
  4
• 4 Electric components
  6
• 4.1 Electrical components - assembly overview
  6
• 5 General repair instructions
  8
• Clutch
  13
• 1 Clutch control
  13
• 1.1 Clutch drive system - assembly locations overview
  13
• 1.2 Clutch drive pedal - assembly overview
  14
• 1.3 Hydraulic clutch system - assembly overview
  16
• 1.4 Clutch release mechanism - assembly overview
  18
• 1.5 Support shell - remove and install
  19
• 1.6 Clutch position sender G476 - remove and install
  20
• 1.7 Pedal return spring - remove and install
  22
• 1.8 Clutch drive pedal - remove and install
  24
• 1.9 Clutch drive pedal support - remove and install
  25
• 1.10 Clutch transmitter cylinder - remove and install
  28
• 1.11 Clutch slave cylinder - remove and install
  29
• 1.12 Clutch drive system line - remove and install
  32
• 1.13 Hydraulic clutch mechanism - bleed
  34
• 1.14 Clutch release mechanism - repair
  36
• 2 Clutch
  38
• 2.1 Clutch - assembly overview
  38
• 2.2 Clutch - remove and install
  39
• Controls, housing
  44
• 1 Gearshift mechanism
  44
• 1.1 Gearshift mechanism - installation position
  44
• 1.2 Gear lever - assembly overview
  45
• 1.3 Handle and boot on the gear lever - assembly overview
  47
• 1.4 Gear knob - remove and install
  48
• 1.5 Gearshift mechanism - remove and install
  50
• 1.6 Gearshift mechanism - repair
  54
• 1.7 Gearshift mechanism - adjust
  58
• 1.8 Gearshift mechanism - check operation
  61
• 1.9 Gearshift lever and mechanism - remove and install
  62
• 1.10 Selector cables - remove and install
  67
• 1.11 Selector rod - replace seal
  69
• 1.12 Selector rod and the selector mechanism cover - assembly overview
  71
• 1.13 Selector rod and selector mechanism cover - remove and install with the gearbox installed
  72
• 2 Gearbox - remove and install
  78
• 2.1 Gearbox - remove
  78
• 2.2 Gearbox - installation
  89
• 2.3 Gearbox torques
  94
• 3 Auxiliary frame
  95
• 3.1 Assembly mountings - assembly overview
  95
• 4 Gearbox - transport
  98
• 4.1 Gearbox - transport
  98
• 5 Gearbox oil
  100
• 5.1 Gearbox oil - check level
  100
• 6 Transmission - fasten to support
  102
• 6.1 Transmission - fasten to support
  102
• 7 Gearbox - disassemble and assemble
  104
• 7.1 Gearbox - schematic overview
  104
• 7.2 gearbox - assembly overview
  104
• 7.3 Transmission housing cover and 5th gear - assembly overview
  105
• 7.4 Gearbox housing Cover and 5th gear - remove and install (gearbox installed)
  107
• 7.5 Clutch housing - assembly overview
  109
• 7.6 Input shaft, output shaft, differential, selection mechanism and selector forks
  109
• 8 Gearbox and clutch housings
  124
• 8.1 Transmission housing and transmission housing - assembly overview
  124
• 8.2 Gearbox housing - repair
  126
• 8.3 Clutch housing - repair
  127
• 9 Selector forks
  131
• 9.1 Selector forks - assembly overview
  131
• 9.2 Selector forks - repair
  131
• Gears, shafts
  136
• 1 Input shaft
  136
• 1.1 Input shaft - general overview of assembly
  136
• 1.2 Input shaft - remove and install
  138
• 1.3 Input shaft - replace seal
  151
• 2 Output shaft
  154
• 2.1 Output shaft - general overview of assembly
  154
• 2.2 Output shaft- remove and install
  157
• Final drive - differential
  165
• 1 Retainer seals
  165
• 1.1 Seals - assembly overview
  165
• 1.2 Seal (left-hand side) - replace
  165
• 1.3 Seal (right-hand side) - replace
  168
• 2 Differential
  171
• 2.1 Differential - general overview of assembly
  171
• 2.2 Differential - remove and install
  173
• 2.3 Adjust the differential
  181