6-speed manual gearbox 0A5

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 2 Overview - power transmission
  3
• 2.1 Overview - power transmission
  3
• 2.2 Overview - power transmission - all-wheel drive
  4
• 3 Technical data
  7
• 3.1 Allocation gearbox - engine, gear ratios and capacities
  7
• 3.2 Allocation gearbox - engine, gear ratios and capacities, four-wheel drive
  9
• 3.3 Calculating overall gear ratio “i”
  13
• 4 Repair notes
  15
• 4.1 Gearbox
  15
• 4.2 Gaskets and seals
  15
• 4.3 Locking devices
  16
• 4.4 Nuts and bolts
  16
• 4.5 Bearings
  16
• 4.6 Shims
  17
• 4.7 Synchro-rings
  17
• 4.8 Gear wheels
  17
• 4.9 Synchromeshed gears
  17
• 4.10 Clutch
  17
• Clutch
  18
• 1 Clutch mechanism
  18
• 1.1 Assembly overview - pedal cluster
  18
• 1.2 Assembly overview - clutch hydraulics
  20
• 1.3 Assembly overview - clutch release mechanism
  22
• 1.4 Removing and installing clutch pedal
  23
• 1.5 Removing and installing mounting bracket
  24
• 1.6 Removing and installing over-centre spring
  27
• 1.7 Removing and installing clutch master cylinder
  28
• 1.8 Removing and installing clutch master cylinder with mounting bracket removed
  32
• 1.9 Removing and installing clutch pedal switch F36
  33
• 1.10 Bleeding clutch mechanism
  34
• 2 Clutch
  36
• 2.1 Assembly overview - clutch
  36
• 2.2 Removing and installing clutch
  38
• Controls, housing
  42
• 1 Bevel box
  42
• 1.1 Removing bevel box
  42
• 1.2 Installing bevel box
  46
• 1.3 Removing bevel boxes as of model year 2010
  49
• 1.4 Installing bevel boxes as of model year 2010
  52
• 2 Selector mechanism
  56
• 2.1 Installation position of selector mechanism
  56
• 2.2 Assembly overview – gear knob and cover
  57
• 2.3 Assembly overview - Gear lever and selector housing
  58
• 2.4 Assembly overview – gear levers and selector housings as of model year 2007
  61
• 2.5 Assembly overview – selector cables
  63
• 2.6 Assembly overview – selector cables as of model year 2009
  65
• 2.7 Assembly overview - selector unit
  67
• 2.8 Assembly overview - selector forks
  67
• 2.9 Removing and installing selector mechanism
  68
• 2.10 Distinguishing between selector mechanisms
  71
• 2.11 Adjusting selector mechanism, vehicles with retaining pin on selector unit
  72
• 2.12 Adjusting selector mechanism, vehicles with no retaining pin on selector unit
  76
• 2.13 Renewing selector shaft seal
  81
• 3 Removing and installing gearbox
  84
• 3.1 Specified torques for gearbox
  84
• 3.2 Removing gearbox
  86
• 3.3 Removing gearbox, vehicles as of model year 2010
  96
• 3.4 Removing gearbox, four-wheel drive
  105
• 3.5 Removing gearbox, vehicles with all-wheel drive as of model year 2010
  116
• 3.6 Installing gearbox
  125
• 3.7 Installing gearbox, vehicles as of model year 2010
  131
• 3.8 Installing gearbox, four-wheel drive
  138
• 3.9 Installing gearbox, vehicles with all-wheel drive as of model year 2010
  145
• 4 Transporting gearbox
  153
• 4.1 Transporting gearbox
  153
• 4.2 Transporting gearbox, four-wheel drive
  153
• 4.3 Converting adapter 10 - 222 A /23 with adapter 10 - 222 A /23-1
  154
• 5 Gear oil
  156
• 5.1 Checking gear oil level, manual gearbox
  156
• 5.2 Checking gear oil level, bevel box
  158
• 5.3 Checking gear oil level – bevel boxes as of model year 2010
  159
• 6 Dismantling and assembling gearbox
  161
• 6.1 Schematic overview - gearbox
  161
• 6.2 Schematic overview - four-wheel drive
  162
• 6.3 Assembly overview - input shaft, output shafts, differential and selector rods
  163
• 6.5 Dismantling and assembling gearbox
  167
• 7 Gearbox housing, clutch housing
  187
• 7.1 Assembly overview - gearbox housing
  187
• 7.2 Assembly overview - clutch housing
  189
• 7.3 Assembly overview - gearbox housing and clutch housing
  191
• 7.4 Repairing gearbox housing
  193
• 7.5 Repairing clutch housing
  195
• Gears, shafts
  199
• 1 Input shaft
  199
• 1.1 Assembly overview - input shaft
  199
• 1.2 Dismantling and assembling input shaft
  201
• 1.3 Renewing input shaft seal
  207
• 2 Output shaft
  209
• 2.1 Assembly overview - output shaft for 1st and 2nd gear
  209
• 2.2 Assembly overview - output shaft for 3rd and 4th gear
  212
• 2.3 Assembly overview - output shaft for reverse gear
  214
• 2.4 Dismantling and assembling output shaft for 1st and 2nd gear
  216
• 2.5 Dismantling and assembling output shaft for 3rd and 4th gear
  227
• 2.6 Dismantling and assembling reverse gear output shaft
  240
• 2.8 Adjusting output shaft
  250
• Final drive - differential
  251
• 1 Oil seals
  251
• 1.1 Assembly overview - seals
  251
• 1.2 Renewing seal on left of gearbox
  252
• 1.3 Renewing seal on right of gearbox, front-wheel drive vehicles
  256
• 1.4 Renewing seal on right of gearbox, vehicles with all-wheel drive
  260
• 1.5 Renewing seal on right of bevel box, vehicles up to 2010
  262
• 1.6 Renewing seal on right of bevel box, vehicles as of model year 2010
  267
• 1.8 Renewing seal between output flange bevel box, vehicles as of model year 2010
  275
• 2 Differential
  293
• 2.1 Assembly overview - differential
  293
• 2.2 Assembly overview - differential, four-wheel drive
  295
• 2.3 Dismantling and assembling differential
  298
• 2.4 Dismantling and assembling differential - all-wheel drive
  305
• 2.5 Adjusting differential
  313
• 2.6 Removing and installing stub shaft
  318
• 3 Adjustment overview
  321
• 3.1 Adjustment overview
  321