6-speed manual gearbox 0AG

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification codes, assembly allocation, capacities
  1
• 2 Overview - power transmission
  3
• 3 Calculating overall gear ratio “i”
  5
• 4 General repair notes
  6
• 4.1 Components
  6
• Clutch
  9
• 1 Fault finding, power transmission
  9
• 2 Repairing clutch mechanism
  10
• 2.1 Overview
  10
• 2.2 Assembly overview - pedal cluster
  11
• 2.3 Removing and installing over-centre spring
  12
• 2.4 Removing and installing clutch pedal
  14
• 2.5 Removing and installing mounting bracket
  16
• 2.6 Removing and installing master cylinder
  19
• 2.7 Removing and installing clutch position sender G476
  21
• 2.8 Assembly overview - hydraulic system
  23
• 2.9 Removing and installing slave cylinder
  25
• 2.10 Bleeding clutch system
  27
• 3 Repairing clutch release mechanism
  29
• 4 Repairing clutch
  31
• Controls, housing
  34
• 1 Fault finding, power transmission
  34
• 2 Repairing selector mechanism
  35
• 2.1 Installation position of selector mechanism
  35
• 2.2 Removing and installing selector lever knob and cover
  37
• 2.3 Removing and installing gaiter with selector lever knob and noise insulation
  38
• 2.4 Repairing selector lever and selector lever housing (through 10.06)
  39
• 2.5 Repairing selector lever and selector lever housing (from 11.06)
  42
• 2.6 Assembly overview - removing and installing selector cables
  46
• 2.7 Plastic relay lever
  49
• 2.8 Removing and installing selector mechanism
  51
• 2.9 Adjusting selector mechanism
  53
• 3 Removing and installing gearbox
  56
• 3.1 Removing gearbox
  57
• 3.2 Installing gearbox
  62
• 3.3 Torque settings
  67
• 4 Checking gear oil
  69
• 5 Dismantling and assembling gearbox
  71
• 5.1 Overview - gearbox
  71
• 5.2 Assembly overview
  72
• 5.4 Assembly overview - removing and installing clutch housing
  75
• 5.6 Dismantling and assembling procedure
  77
• 6 Repairing gearbox housing and clutch housing
  90
• 7 Repairing gearbox housing cover
  95
• 8 Repairing selector unit
  98
• 9 Dismantling and assembling selector forks
  101
• Gears, shafts
  106
• 1 Input shaft
  106
• 1.1 Dismantling and assembling input shaft
  106
• 2 Output shaft
  116
• 2.1 Dismantling and assembling output shaft
  116
• Final drive - differential
  124
• 1 Renewing flange shaft oil seals with gearbox installed
  124
• 1.1 Renewing oil seal for left flange shaft
  124
• 1.2 Renewing seal for right flange shaft
  125
• 2 Differential
  128
• 2.1 Dismantling and assembling differential
  128
• 2.2 Adjusting differential
  135