6-speed manual gearbox 0AG

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Code letters, assembly allocation and capacities - Golf 2004 ►
  1
• 1.3 Identification codes, assembly allocation, capacities, Golf Plus 2005 ►
  2
• 2 Overview - power transmission
  4
• 3 Calculating overall gear ratio “i”
  6
• 4 General repair instructions
  7
• 4.1 Components
  7
• Clutch
  10
• 1 Repairing clutch mechanism
  10
• 1.1 Overview
  10
• 1.2 Assembly overview - pedal cluster
  11
• 1.3 Removing and installing over-centre spring, Golf
  12
• 1.4 Removing and installing over-centre spring, Golf Plus
  17
• 1.5 Removing and installing clutch pedal, Golf
  21
• 1.6 Removing and installing clutch pedal, Golf Plus
  26
• 1.7 Removing and installing mounting bracket, Golf
  31
• 1.8 Removing and installing mounting bracket, Golf Plus
  36
• 1.9 Removing and installing master cylinder
  41
• 1.10 Removing and installing clutch position sender G476
  43
• 1.11 Assembly overview - hydraulics (LHD vehicles)
  45
• 1.12 Assembly overview - hydraulics (RHD vehicles)
  48
• 1.13 Removing and installing slave cylinder
  49
• 1.14 Bleeding clutch system
  51
• 2 Repairing clutch release mechanism
  53
• 3 Repairing clutch
  55
• Controls, housing
  58
• 1 Repairing selector mechanism
  58
• 1.1 Installation position of selector mechanism
  58
• 1.2 Removing and installing gear knob and cover
  60
• 1.3 Removing and installing gaiter with gear knob and noise insulation, Golf
  60
• 1.4 Removing and installing gaiter with gear knob and noise insulation, Golf Plus
  62
• 1.5 Repairing gear lever and selector housing (to 10.06)
  63
• 1.6 Repairing gear lever and selector housing (from 11.06)
  66
• 1.7 Assembly overview - removing and installing selector cables
  71
• 1.8 Plastic relay lever
  75
• 1.9 Removing and installing selector mechanism
  77
• 1.10 Adjusting selector mechanism
  81
• 2 Removing and installing gearbox, Golf
  84
• 2.1 Removing gearbox
  85
• 2.2 Install gearbox
  89
• 3 Removing and installing gearbox, Golf Plus
  96
• 3.1 Removing gearbox
  98
• 3.2 Install gearbox
  102
• 4 Transporting gearbox
  109
• 5 Checking gear oil
  110
• 6 Dismantling and assembling gearbox
  112
• 6.1 Overview - gearbox
  112
• 6.2 Assembly overview
  113
• 6.4 Assembly overview - removing and installing clutch housing
  116
• 6.6 Dismantling and assembling procedure
  118
• 7 Repairing gearbox housing and clutch housing
  133
• 8 Repairing gearbox housing cover
  138
• 9 Repairing selector unit
  141
• 10 Dismantling and assembling selector forks
  144
• Gears, shafts
  149
• 1 Input shaft
  149
• 1.1 Dismantling and assembling input shaft
  149
• 2 Output shaft
  159
• 2.1 Dismantling and assembling output shaft
  159
• Final drive - differential
  167
• 1 Renewing flange shaft oil seals with gearbox installed
  167
• 1.1 Renewing oil seal for left flange shaft
  167
• 1.2 Renewing seal for right flange shaft
  169
• 2 Differential
  171
• 2.1 Dismantling and assembling differential
  171
• 2.2 Adjusting differential
  179