5 and 6-speed manual gearbox 01E, 0A1

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation, capacities
  2
• 2 Overview - power transmission
  5
• 3 Calculating overall gear ratio „i“
  7
• 4 General repair notes
  8
• 4.1 Components
  8
• Clutch
  11
• 1 Functional check of clutch master and slave cylinders
  11
• 2 Distinguishing clutch control mechanisms
  13
• 3 Repairing clutch control mechanism (master cylinder secured to clutch pedal with a pin)
  14
• 3.1 Overview
  14
• 3.2 Assembly overview - pedal cluster (LHD vehicles)
  15
• 3.3 Removing and installing clutch pedal and over-centre spring
  16
• 3.4 Assembly overview - pedal cluster (RHD vehicles)
  17
• 3.5 Assembly overview - hydraulic system
  19
• 3.6 Removing and installing master cylinder
  20
• 4.1 Overview
  24
• 4.2 Assembly overview - pedal cluster (LHD vehicles)
  25
• 4.3 Removing and installing clutch pedal and over-centre spring
  26
• 4.4 Assembly overview - pedal cluster (RHD vehicles)
  27
• 4.5 Assembly overview - hydraulic system
  29
• 4.6 Removing and installing master cylinder
  31
• 5 Clutch pedal switch
  36
• 5.4 Bleeding clutch system
  38
• 6 Repairing clutch release mechanism
  40
• 6.1 Removing and installing slave cylinder
  43
• 7 Repairing clutch
  47
• Controls, housing
  53
• 1 Repairing selector mechanism
  53
• 1.1 Installation position of selector mechanism
  53
• 1.2 Repairing gear lever and gear lever mounting
  55
• 1.3 Repairing selector rod, connecting rod and push rod
  57
• 1.4 Removing and installing gear lever with gear lever mounting
  59
• 1.5 Removing and installing selector mechanism
  60
• 1.6 Adjusting selector mechanism
  64
• 2 Removing and installing gearbox
  68
• 2.1 Removing gearbox
  68
• 2.2 Installing gearbox
  72
• 3 Checking gear oil
  78
• 4 Dismantling and assembling gearbox
  79
• 4.1 Removing and installing manual gearbox and end cover
  80
• 4.2 Removing and installing 5th and 6th gear
  81
• 4.4 Dismantling and assembling procedure
  84
• 5 Repairing end cover
  101
• 6 Repairing bearing plate
  107
• 6.1 Redetermining shim S4
  111
• 7 Repairing gearbox housing
  113
• 7.1 Dismantling and assembling selector shaft complete
  120
• Gears, shafts
  123
• 1 Dismantling and assembling input shaft
  123
• 2 Dismantling and assembling pinion shaft
  129
• Final drive - differential
  139
• 1 Renewing oil seals for flange shafts
  139
• 1.1 Removing and installing flange shaft seals
  139
• 2 Renewing speedometer sender and drive wheel
  142
• 2.1 Renewing speedometer sender G22
  142
• 2.2 Renewing speedometer drive wheel
  143
• 3 Differential
  145
• 3.1 Removing and installing differential
  145
• 3.2 Dismantling and assembling differential
  146
• 4 Adjusting drive pinion and crown wheel
  155
• 4.1 General notes
  155
• 4.2 Adjustment and marking of final drive gear sets
  155
• 4.3 Position of shims
  156
• 4.4 Adjustment overview
  156
• 4.5 Recommended sequence for new adjustment of final drive gear set
  157
• 4.6 Adjusting drive pinion
  157
• 4.7 Adjusting crown wheel
  166