6-speed manual gearbox 0A5

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 General safety provisions
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 2.2 Identification of bevel box
  4
• 3 Repair notes
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Special tool
  5
• 3.3 Gearbox
  5
• 3.4 Clutch
  6
• 3.5 Bolts and nuts
  6
• 3.6 Gaskets and seals
  6
• 3.7 Routing and attachment of lines
  7
• 3.8 Locking devices
  7
• 3.9 Bearings
  8
• 3.10 Shims
  8
• 3.11 Synchro-rings
  9
• 3.12 Gears and synchro-hubs
  9
• 3.13 Synchromeshed gears
  9
• 4 Technical data
  10
• 4.1 Capacities
  10
• 4.2 Allocation gearbox - engine
  10
• 4.3 Calculation of gear ratios
  11
• 5 Overview - power transmission
  12
• 5.1 Overview - power transmission - front-wheel drive
  12
• 5.2 Overview - power transmission - all-wheel drive
  13
• 6 Electrical components
  16
• 6.1 Overview of fitting locations - electrical components
  16
• Clutch
  17
• 1 Clutch mechanism
  17
• 1.1 Assembly overview - pedal cluster
  17
• 1.2 Assembly overview - clutch hydraulics
  19
• 1.3 Assembly overview - clutch release mechanism
  20
• 1.4 Removing and installing clutch pedal
  21
• 1.5 Removing and installing over-centre spring
  26
• 1.6 Removing and installing mounting bracket
  29
• 1.7 Removing and installing bearing bush
  38
• 1.8 Checking clutch master cylinder and clutch slave cylinder
  39
• 1.9 Removing and installing clutch position sender G476
  40
• 1.10 Removing and installing clutch master cylinder
  41
• 1.11 Removing and installing clutch slave cylinder together with release bearing
  42
• 1.12 Removing and installing bleeder
  45
• 1.13 Bleeding clutch mechanism
  46
• 1.14 Checking clutch master cylinder and clutch slave cylinder
  48
• 2 Clutch
  49
• 2.1 Assembly overview - clutch
  49
• 2.2 Removing and installing clutch
  49
• Controls, housing
  54
• 1 Bevel box
  54
• 1.1 Assembly overview - bevel box
  54
• 1.2 Removing bevel box
  56
• 1.3 Installing bevel box
  61
• 1.4 Checking gear oil level in bevel box
  64
• 1.5 Installing repair kit for stub shaft
  66
• 2 Selector mechanism
  70
• 2.1 Installation position - selector mechanism
  70
• 2.2 Assembly overview - Gear lever and selector housing
  71
• 2.3 Removing and installing selector mechanism
  73
• 2.4 Adjusting selector mechanism
  74
• 2.5 Removing and installing selector cable
  77
• 2.6 Removing and installing selector lever handle
  80
• 2.7 Renewing selector shaft seal
  82
• 2.8 Checking selector mechanism
  83
• 2.9 Removing and installing mounting for cable support bracket
  84
• 2.10 Removing and installing relay lever
  84
• 3 Removing and installing gearbox
  86
• 3.1 Specified torques for gearbox
  86
• 3.2 Removing gearbox
  87
• 3.3 Installing gearbox
  107
• 4 Assembly mountings
  125
• 4.1 Assembly overview – assembly mountings
  125
• 5 Transporting gearbox
  127
• 6 Dismantling and assembling gearbox
  130
• 6.1 Schematic overview - gearbox
  130
• 6.2 Differentiating between gearboxes
  132
• 6.3 Assembly overview - gearbox housing and selector mechanism
  133
• 6.4 Assembly overview - selector unit
  137
• 6.5 Assembly overview - input shaft, output shafts, differential, selector rods
  137
• 6.6 Assembly overview - selector forks
  139
• 6.7 Dismantling and assembling gearbox
  140
• 7 Gearbox housing, clutch housing
  180
• 7.1 Assembly overview - gearbox housing
  180
• 7.2 Assembly overview - clutch housing
  182
• 7.3 Repairing gearbox housing
  184
• 7.4 Repairing clutch housing
  187
• 8 Securing to engine and gearbox support
  191
• 9 Gear oil
  193
• 9.1 Checking gear oil level
  193
• Gears, shafts
  196
• 1 Input shaft
  196
• 1.1 Assembly overview - input shaft
  196
• 1.2 Dismantling and assembling input shaft
  200
• 2 Output shaft
  216
• 2.1 Assembly overview - output shaft
  216
• 2.2 Dismantling and assembling output shaft
  223
• 2.3 Adjusting output shaft
  256
• Final drive - differential
  257
• 1 Oil seals
  257
• 1.1 Overview of fitting locations - oil seals
  257
• 1.2 Renewing left seal
  257
• 1.3 Renewing right seal
  262
• 1.4 Renewing input shaft seal
  267
• 2 Differential
  270
• 2.1 Assembly overview - differential
  270
• 2.2 Dismantling and assembling differential
  272
• 2.3 Adjusting differential
  281
• 3 Components of bevel box
  287
• 3.1 Renewing bevel box seals
  287