6-speed manual gearbox 0A8

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  3
• 3.1 Allocation gearbox - engine
  3
• 3.2 Capacities
  3
• 3.3 Calculation of gear ratios
  3
• 4 Overview - power transmission
  4
• 5 Electrical components
  6
• 5.1 Overview of fitting locations - electrical components
  6
• 6 Repair notes
  7
• 6.1 General repair instructions
  7
• Clutch
  10
• 1 Clutch operation
  10
• 1.1 Overview of fitting locations – clutch mechanism
  10
• 1.2 Assembly overview - pedal cluster
  12
• 1.3 Assembly overview - clutch hydraulics
  14
• 1.4 Assembly overview - clutch release mechanism
  18
• 1.5 Removing and installing bearing bush
  19
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  20
• 1.7 Removing and installing clutch position sender G476
  20
• 1.8 Removing and installing over-centre spring
  22
• 1.9 Removing and installing extension spring
  23
• 1.10 Removing and installing clutch pedal
  23
• 1.11 Removing and installing mounting bracket
  25
• 1.12 Removing and installing clutch master cylinder
  29
• 1.13 Removing and installing bleeder
  30
• 1.14 Removing and installing lines for clutch mechanism
  31
• 1.15 Removing and installing clutch slave cylinder together with release bearing
  34
• 1.16 Bleeding clutch mechanism
  35
• 1.17 Repairing clutch release mechanism
  36
• 2 Clutch
  38
• 2.1 Assembly overview - clutch
  38
• 2.2 Removing and installing clutch
  41
• Controls, housing
  54
• 1 Selector mechanism
  54
• 1.1 Installation position - selector mechanism
  54
• 1.2 Assembly overview - gear knob and cover
  56
• 1.3 Assembly overview - selector mechanism
  57
• 1.4 Removing and installing gear knob
  59
• 1.5 Removing and installing selector mechanism
  60
• 1.6 Repairing selector mechanism
  63
• 1.7 Adjusting selector mechanism
  65
• 1.8 Checking selector mechanism
  67
• 2 Removing and installing gearbox
  68
• 2.1 Removing gearbox
  68
• 2.2 Installing gearbox
  89
• 2.3 Specified torques for gearbox
  96
• 3 Assembly mountings
  97
• 3.1 Assembly overview - assembly mountings
  97
• 4 Transporting gearbox
  98
• 5 Gear oil
  99
• 5.1 Distinguishing between different manual gearbox types when filling oil
  99
• 5.2 Checking gear oil level
  99
• 6 Installing to engine and gearbox support
  103
• 7 Dismantling and assembling gearbox
  104
• 7.1 Schematic overview - gearbox
  104
• 7.2 Assembly overview - gearbox
  105
• 7.3 Assembly overview - gearbox housing and selector mechanism
  106
• 7.4 Assembly overview - selector unit
  108
• 7.5 Assembly overview - shafts, differential, selector mechanism
  109
• 7.6 Assembly overview - selector forks
  111
• 7.7 Renewing oil seal for selector shaft
  111
• 7.8 Removing and installing selector unit with gearbox installed
  113
• 7.9 Dismantling and assembling gearbox
  116
• 8 Gearbox housing, clutch housing
  131
• 8.1 Assembly overview - gearbox housing
  131
• 8.2 Assembly overview - clutch housing
  133
• 8.3 Repairing gearbox housing
  134
• 8.4 Repairing clutch housing
  142
• Gears, shafts
  144
• 1 Input shaft
  144
• 1.1 Assembly overview - input shaft
  144
• 1.2 Dismantling and assembling input shaft
  145
• 1.3 Renewing input shaft seal
  149
• 2 Output shaft
  151
• 2.1 Assembly overview - output shaft
  151
• 2.2 Dismantling and assembling output shaft
  156
• 2.3 Adjusting output shaft
  177
• Final drive - differential
  188
• 1 Seals
  188
• 1.1 Overview of fitting locations - seals
  188
• 1.2 Renewing left oil seal
  189
• 1.3 Renewing right oil seal
  191
• 2 Differential
  195
• 2.1 Assembly overview - differential
  195
• 2.2 Dismantling and assembling differential
  197
• 2.3 Adjusting differential
  201
• 3 Adjustment overview
  206