6-speed manual gearbox 0A5, four-wheel drive

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Code letters, allocation, ratios, capacities
  1
• 2 Identifying rear final drive
  5
• 2.1 Location on final drive
  5
• 2.2 Identification code, assembly allocation, capacities
  5
• 3 Overview - power transmission
  8
• 4 Calculating overall gear ratio “i”
  10
• 4.1 Notes on performance test
  10
• 5 General repair instructions
  11
• 5.1 Components
  11
• Clutch
  14
• 1 Repairing clutch mechanism
  14
• 1.1 Overview
  14
• 1.2 Assembly overview - pedal cluster
  15
• 1.3 Removing, installing and adjusting clutch pedal switch F36
  16
• 1.4 Removing and installing mounting bracket for clutch pedal
  16
• 1.6 Removing and installing clutch master cylinder
  20
• 1.7 Removing and installing clutch pedal with mounting bracket removed
  22
• 1.8 Assembly overview - hydraulic system
  23
• 1.9 Removing and installing master cylinder with mounting bracket removed
  24
• 1.10 Bleeding clutch system
  25
• 2 Repairing clutch release mechanism
  27
• 3 Repairing clutch
  30
• Controls, housing
  34
• 1 Electrical/electronic components and fitting locations
  34
• 1.1 Removing and installing four-wheel drive control unit J492
  36
• 1.2 Removing and installing all-wheel drive coupling pump V181
  41
• 2 Repairing selector mechanism
  45
• 2.1 Installation position of selector mechanism
  45
• 2.2 I - Removing and installing gear knob and cover
  47
• 2.3 II - Assembly overview - Repairing gear lever and selector housing
  48
• 2.4 III - Assembly overview - Selector cables
  50
• 2.5 Removing and installing selector mechanism
  52
• 3 Adjusting selector mechanism
  55
• 3.1 Distinguishing between selector mechanisms
  55
• 3.2 Adjusting selector mechanism in neutral gate for 1st /2nd gear
  55
• 3.3 Adjusting selector mechanism with 2nd gear engaged
  58
• 4 Removing and installing gearbox
  63
• 4.1 Removing gearbox
  64
• 4.2 Transporting gearbox
  71
• 4.3 Installing gearbox
  71
• 5 Checking gear oil in gearbox
  78
• 6 Removing and installing bevel box
  80
• 6.1 Removing bevel box
  80
• 6.2 Installing bevel box
  83
• 7 Checking gear oil in bevel box
  85
• 8 Dismantling and assembling gearbox
  86
• 8.1 Overview - gearbox
  86
• 8.2 Assembly overview
  87
• 8.3 Removing and installing gearbox housing and selector unit
  88
• 8.4 Removing and installing input shaft, output shafts, differential, bevel box and selector rods
  89
• 8.5 Assembly sequence
  91
• 9 Repairing gearbox housing
  102
• 10 Repairing clutch housing
  106
• 11 Repairing selector unit
  110
• 11.1 Renewing selector shaft seal
  110
• 12 Dismantling and assembling selector forks
  113
• Gears, shafts
  114
• 1 Input shaft
  114
• 1.1 Dismantling and assembling input shaft
  114
• 2 Output shaft for 1st and 2nd gear
  121
• 2.1 Dismantling and assembling output shaft for 1st and 2nd gear
  121
• 2.2 Adjusting output shaft for 1st and 2nd gear
  132
• 3 Output shaft for 3rd and 4th gear
  133
• 3.1 Dismantling and assembling output shaft for 3rd and 4th gear
  133
• 3.2 Adjusting output shaft for 3rd and 4th gear
  143
• 4 Output shaft for reverse gear
  144
• 4.1 Dismantling and assembling reverse gear output shaft
  144
• 4.2 Adjusting reverse gear output shaft
  153
• Final drive - rear differential
  154
• 1 Propshafts
  154
• 1.1 Assembly overview - two section propshaft
  154
• 1.2 Assembly overview - multi-part propshaft
  156
• 1.3 Removing and installing front propshaft tube
  158
• 1.4 Removing and installing middle and rear propshaft tubes
  161
• 1.5 Repairing propshaft
  166
• 2 Checking function of all-wheel drive coupling
  174
• 2.1 Checking function of open all-wheel drive coupling
  174
• 2.2 Checking function of closed all-wheel drive coupling
  174
• 3 Oil seal for propshaft flange on rear final drive
  176
• 3.1 Renewing propshaft flange oil seal on rear final drive (final drive removed)
  176
• 4 Renewing oil seals for flange shafts (rear final drive installed)
  181
• 4.1 Renewing seal for right flange shaft
  181
• 4.2 Renewing oil seal for left flange shaft
  183
• 5 Renewing O-ring for all-wheel drive coupling housing
  187
• 5.1 Renewing O-ring for all-wheel drive coupling cover (final drive removed)
  187
• 6 Removing and installing rear final drive
  191
• 6.1 Removing
  191
• 6.2 Installing
  193
• 7 Checking gear oil in rear final drive
  196
• 8 Checking oil level, topping up oil or changing oil in all-wheel drive coupling
  197
• 8.1 Checking oil level in all-wheel drive coupling
  197
• 8.2 Topping up oil in all-wheel drive coupling
  198
• 8.3 Changing oil in all-wheel drive coupling
  200
• 9 Pressing bonded rubber bush out of and into final drive
  201
• 9.1 Removing and installing front bonded rubber bush
  201
• 9.2 Pressing rear bonded rubber bush out and in
  202
• Final drive - front differential
  204
• 1 Renewing stub shaft oil seals with gearbox installed
  204
• 1.1 Renewing left stub shaft oil seal with gearbox installed
  204
• 1.2 Renewing right stub shaft oil seal with gearbox and bevel box installed
  206
• 2 Renewing seal between gearbox and bevel box with gearbox installed
  210
• 3 Renewing bevel box output flange oil seal (bevel box removed)
  212
• 3.1 Removing seal
  213
• 3.2 Installing seal
  214
• 4 Adjustment overview
  215
• 5 Differential
  216
• 5.1 Dismantling and assembling differential
  216
• 5.2 Adjusting differential
  225
• 6 Dismantling and assembling bevel box
  229
• 6.1 Renewing seal for bevel box stub shaft to gearbox (bevel box removed)
  229
• 6.2 Renewing seal for bevel box lay shaft to gearbox
  230