6-speed manual gearbox 0A6

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  2
• 1.3 Notes on performance test
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Technical data
  4
• 3.1 Allocation gearbox - engine
  4
• 3.2 Capacities
  4
• 3.3 Calculation of gear ratios
  5
• 4 Overview - power transmission
  6
• 5 Electrical components
  8
• 5.1 Overview of fitting locations - electrical components
  8
• 6 Repair instructions
  9
• 6.1 General repair instructions
  9
• Clutch
  13
• 1 Clutch mechanism
  13
• 1.1 Overview of fitting locations – clutch mechanism
  13
• 1.2 Assembly overview - pedal cluster
  15
• 1.3 Assembly overview - clutch hydraulics
  17
• 1.4 Assembly overview - clutch release mechanism
  20
• 1.5 Removing and installing bearing bush
  21
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  22
• 1.7 Removing and installing clutch position sender G476
  23
• 1.8 Removing and installing return spring
  23
• 1.9 Removing and installing over-centre spring
  26
• 1.10 Removing and installing clutch pedal
  28
• 1.11 Removing and installing mounting bracket
  30
• 1.12 Removing and installing clutch master cylinder
  33
• 1.13 Removing and installing bleeder
  34
• 1.14 Removing and installing lines for clutch mechanism
  35
• 1.15 Removing and installing clutch slave cylinder together with release bearing
  38
• 1.16 Bleeding clutch mechanism
  40
• 1.17 Repairing clutch release mechanism
  41
• 2 Clutch
  43
• 2.1 Assembly overview - clutch
  43
• 2.2 Removing and installing clutch
  46
• Controls, housing
  59
• 1 Selector mechanism
  59
• 1.1 Installation position - selector mechanism
  59
• 1.2 Assembly overview – gear knob and cover
  61
• 1.3 Assembly overview - selector mechanism
  62
• 1.4 Removing and installing gear knob
  63
• 1.5 Removing and installing selector mechanism
  65
• 1.6 Repairing selector mechanism
  67
• 1.7 Adjusting selector mechanism
  71
• 1.8 Checking selector mechanism
  73
• 2 Removing and installing gearbox
  74
• 2.1 Removing gearbox
  74
• 2.2 Installing gearbox
  83
• 2.3 Specified torques for gearbox
  92
• 3 Assembly mountings
  93
• 3.1 Assembly overview - assembly mountings
  93
• 4 Bevel box
  95
• 4.1 Assembly overview - bevel box
  95
• 4.2 Distinguishing between different types of bevel boxes
  96
• 4.3 Removing bevel box
  97
• 4.4 Installing bevel box
  103
• 5 Transporting gearbox
  108
• 6 Gear oil
  109
• 6.1 Checking gear oil level
  109
• 7 Securing to engine and gearbox support
  110
• 7.1 Installing manual gearbox to engine and gearbox support
  110
• 7.2 Installing bevel box to engine and gearbox support
  111
• 8 Dismantling and assembling gearbox
  113
• 8.1 Schematic overview - gearbox
  113
• 8.2 Assembly overview - gearbox
  114
• 8.3 Assembly overview - gearbox housing and selector mechanism
  115
• 8.4 Assembly overview - selector unit
  117
• 8.5 Assembly overview - shafts, differential, selector mechanism
  119
• 8.6 Assembly overview - selector forks
  121
• 8.7 Repairing selector unit
  122
• 8.8 Renewing selector shaft seal
  123
• 8.9 Dismantling and assembling gearbox
  124
• 9 Gearbox housing, clutch housing
  136
• 9.1 Assembly overview - gearbox housing
  136
• 9.2 Assembly overview - clutch housing
  138
• 9.3 Repairing gearbox housing
  140
• 9.4 Repairing clutch housing
  143
• Gears, shafts
  145
• 1 Input shaft
  145
• 1.1 Assembly overview - input shaft
  145
• 1.2 Dismantling and assembling input shaft
  147
• 1.3 Renewing input shaft seal
  153
• 2 Output shaft
  156
• 2.1 Assembly overview - output shaft
  156
• 2.2 Dismantling and assembling output shaft
  162
• Final drive - differential
  193
• 1 Oil seals
  193
• 1.1 Overview of fitting locations - seals
  193
• 1.2 Renewing left seal
  194
• 1.3 Renewing right oil seal
  197
• 2 Differential
  203
• 2.1 Assembly overview - differential
  203
• 2.2 Dismantling and assembling differential
  205
• 2.3 Adjusting differential
  209
• 3 Components of bevel box
  215
• 3.1 Assembly overview - components of bevel box
  215
• 3.2 Renewing bevel box seals
  219
• 3.3 Renewing needle bearing (polygon bearing) on stub shaft of bevel box
  232
• 4 Gear oil
  238
• 4.1 Checking gear oil level
  238
• 4.2 Draining and filling gear oil
  241