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
  5
• 3.1 Allocation gearbox - engine
  5
• 3.2 Capacities
  5
• 3.3 Calculation of gear ratios
  6
• 4 Overview - power transmission
  7
• 5 Electrical components
  9
• 5.1 Overview of fitting locations - electrical components
  9
• 6 Repair instructions
  11
• 6.1 General repair instructions
  11
• Clutch
  16
• 1 Clutch mechanism
  16
• 1.1 Overview of fitting locations – clutch mechanism
  16
• 1.2 Assembly overview - pedal cluster
  17
• 1.3 Assembly overview - clutch hydraulics
  19
• 1.4 Assembly overview - clutch release mechanism
  23
• 1.5 Removing and installing bearing bush
  24
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  26
• 1.7 Removing and installing clutch position sender G476
  26
• 1.8 Removing and installing return spring
  27
• 1.9 Removing and installing over-centre spring
  30
• 1.10 Removing and installing clutch pedal
  33
• 1.11 Removing and installing mounting bracket
  35
• 1.12 Removing and installing clutch master cylinder
  41
• 1.13 Removing and installing bleeder
  41
• 1.14 Removing and installing lines for clutch mechanism
  43
• 1.15 Removing and installing clutch slave cylinder together with release bearing
  47
• 1.16 Bleeding clutch mechanism
  49
• 1.17 Repairing clutch release mechanism
  50
• 2 Clutch
  53
• 2.1 Assembly overview - clutch
  53
• 2.2 Removing and installing clutch
  56
• Controls, housing
  73
• 1 Selector mechanism
  73
• 1.1 Installation position - selector mechanism
  73
• 1.2 Assembly overview – gear knob and cover
  74
• 1.3 Assembly overview - selector mechanism
  76
• 1.4 Removing and installing gear knob
  78
• 1.5 Removing and installing selector mechanism
  80
• 1.6 Repairing selector mechanism
  87
• 1.7 Adjusting selector mechanism
  89
• 1.8 Checking selector mechanism
  92
• 2 Removing and installing gearbox
  93
• 2.1 Removing gearbox
  93
• 2.2 Installing gearbox
  110
• 2.3 Specified torques for gearbox
  122
• 3 Assembly mountings
  123
• 3.1 Assembly overview - assembly mountings
  123
• 4 Bevel box
  126
• 4.1 Assembly overview - bevel box
  126
• 4.2 Distinguishing between different types of bevel boxes
  128
• 4.3 Removing bevel box
  129
• 4.4 Installing bevel box
  138
• 5 Transporting gearbox
  145
• 6 Gear oil
  146
• 6.1 Checking gear oil level
  146
• 7 Securing to engine and gearbox support
  147
• 7.1 Installing manual gearbox to engine and gearbox support
  147
• 7.2 Installing bevel box to engine and gearbox support
  149
• 8 Dismantling and assembling gearbox
  151
• 8.1 Schematic overview - gearbox
  151
• 8.2 Assembly overview - gearbox
  152
• 8.3 Assembly overview - gearbox housing and selector mechanism
  153
• 8.4 Assembly overview - selector unit
  156
• 8.5 Assembly overview - shafts, differential, selector mechanism
  157
• 8.6 Assembly overview - selector forks
  159
• 8.7 Repairing selector unit
  160
• 8.8 Renewing selector shaft seal
  162
• 8.9 Dismantling and assembling gearbox
  163
• 9 Gearbox housing, clutch housing
  181
• 9.1 Assembly overview - gearbox housing
  181
• 9.2 Assembly overview - clutch housing
  183
• 9.3 Repairing gearbox housing
  185
• 9.4 Repairing clutch housing
  189
• Gears, shafts
  191
• 1 Input shaft
  191
• 1.1 Assembly overview - input shaft
  191
• 1.2 Dismantling and assembling input shaft
  193
• 1.3 Renewing input shaft seal
  201
• 2 Output shaft
  203
• 2.1 Assembly overview - output shaft
  203
• 2.2 Dismantling and assembling output shaft
  209
• Final drive - differential
  250
• 1 Seals
  250
• 1.1 Overview of fitting locations - seals
  250
• 1.2 Renewing left seal
  251
• 1.3 Renewing right seal
  256
• 2 Differential
  263
• 2.1 Assembly overview - differential
  263
• 2.2 Dismantling and assembling differential
  265
• 2.3 Adjusting differential
  272
• 3 Components of bevel box
  278
• 3.1 Assembly overview - components of bevel box
  278
• 3.2 Renewing bevel box seals
  283
• 3.3 Renewing needle bearing (polygon bearing) on stub shaft of bevel box
  299
• 4 Gear oil
  307
• 4.1 Checking gear oil level
  307
• 4.2 Draining and filling gear oil
  311