6-speed manual gearbox 0A8

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation and capacities
  1
• 2 Overview - power transmission
  4
• 3 Calculating overall gear ratio “i”
  6
• 4 General repair notes
  7
• 4.1 Contact corrosion!
  7
• 4.2 Repair instructions
  7
• Clutch
  10
• 1 Repairing clutch mechanism
  10
• 1.1 Overview
  10
• 1.2 Assembly overview - pedal cluster
  11
• 1.3 Distinguishing between clutch pedal switches F36
  12
• 1.4 Removing and installing clutch pedal switch F36 with rectangular housing
  12
• 1.5 Removing and installing clutch pedal switch F36 with round housing
  13
• 1.6 Removing and installing over-centre spring
  14
• 1.7 Removing and installing mounting bracket
  15
• 1.8 Removing and installing clutch pedal
  18
• 1.9 Assembly overview - hydraulics (LHD)
  20
• 1.10 Assembly overview - hydraulics (RHD)
  22
• 1.11 Removing and installing master cylinder
  24
• 1.12 Bleeding clutch system
  26
• 2 Repairing clutch release mechanism
  28
• 2.1 Removing pipe/hose line and bleeder from and installing on slave cylinder
  29
• 2.2 Removing and installing slave cylinder with release bearing
  29
• 2.3 Removing and installing pipe/hose line
  30
• 2.4 Renewing input shaft seal
  32
• 3 Repairing clutch
  35
• Controls, housing
  38
• 1 Repairing selector mechanism
  38
• 1.1 Installation position of selector mechanism
  38
• 1.2 Removing and installing gear knob and cover
  40
• 1.4 Repairing gear lever and selector housing (through 05.06)
  42
• 1.5 Repairing gear lever and selector housing (from 06.06)
  44
• 1.6 Assembly overview - removing and installing selector cables
  46
• 1.7 Removing and installing selector mechanism
  48
• 1.8 Adjusting selector mechanism
  51
• 1.9 Functional check
  53
• 2 Removing and installing gearbox
  55
• 2.1 Removing gearbox
  57
• 2.2 Installing gearbox
  62
• 3 Checking gear oil
  68
• 4 Dismantling and assembling gearbox
  70
• 4.1 Overview - gearbox
  70
• 4.2 Assembly overview
  70
• 4.3 Assembly overview - removing and installing gearbox housing and selector unit
  72
• 4.5 Installing to engine and gearbox support
  75
• 4.6 Assembly order, gearbox »without« retaining ring A for input shaft sealing cover
  76
• 4.7 Assembly order, gearbox »with« retaining ring A for input shaft sealing cover
  86
• 5 Repairing gearbox housing
  97
• 6 Repairing clutch housing
  108
• 7 Repairing selector unit
  112
• 8 Repairing selector forks
  115
• Gears, shafts
  118
• 1 Input shaft
  118
• 1.1 Dismantling and assembling input shaft
  118
• 2 Output shaft for 1st through 4th gears
  125
• 2.1 Dismantling and assembling output shaft for 1st through 4th gears
  125
• 2.2 Adjusting output shaft for 1st through 4th gears
  137
• 3 Output shaft for 5th, 6th and reverse gears
  143
• 3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears
  143
• 3.2 Adjusting output shaft for 5th, 6th and reverse gears
  153
• Final drive - differential
  159
• 1 Renewing flange shaft oil seals with gearbox installed
  159
• 1.1 Renewing oil seal for left flange shaft
  159
• 1.2 Renewing seal for right flange shaft
  160
• 2 Adjustment overview
  163
• 3 Differential
  164
• 3.1 Dismantling and assembling differential
  164
• 3.2 Adjusting differential
  169