6-speed manual gearbox 0AJ

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Repair notes
  3
• 3.1 General repair instructions
  3
• 4 Technical data
  8
• 4.1 Capacities
  8
• 4.2 Allocation gearbox - engine
  8
• 4.3 Calculation of gear ratios
  9
• 5 Overview - power transmission
  10
• 5.1 Overview - power transmission - front-wheel drive
  10
• 6 Electrical components
  12
• 6.1 Overview of fitting locations - electrical components
  12
• Clutch
  14
• 1 Clutch mechanism
  14
• 1.1 Assembly overview - pedal cluster
  14
• 1.2 Assembly overview - clutch hydraulics
  16
• 1.3 Assembly overview - clutch release mechanism
  20
• 1.4 Removing and installing clutch pedal
  21
• 1.5 Removing and installing over-centre spring
  24
• 1.6 Removing and installing mounting bracket
  27
• 1.7 Removing and installing clutch master cylinder
  36
• 1.8 Removing and installing clutch slave cylinder
  39
• 1.9 Bleeding clutch mechanism
  43
• 1.10 Checking clutch master cylinder and clutch slave cylinder
  44
• 1.11 Removing and installing clutch position sender G476
  44
• 1.12 Repairing clutch release mechanism
  48
• 2 Clutch
  50
• 2.1 Assembly overview - clutch
  50
• 2.2 Removing and installing clutch
  50
• Controls, housing
  57
• 1 Selector mechanism
  57
• 1.1 Installation position - selector mechanism
  57
• 1.2 Assembly overview – gear knob and cover
  58
• 1.3 Assembly overview - Gear lever and selector housing
  59
• 1.4 Assembly overview – selector cables
  61
• 1.5 Removing and installing gear knob
  63
• 1.6 Removing and installing selector mechanism
  66
• 1.7 Adjusting selector mechanism
  75
• 1.8 Checking selector mechanism
  79
• 1.9 Removing and installing gear selector cable and gate selector cable
  80
• 1.10 Repairing selector mechanism
  82
• 1.11 Renewing selector shaft seal
  83
• 1.12 Dismantling and assembling selector mechanism
  85
• 2 Removing and installing gearbox
  93
• 2.1 Specified torques for gearbox
  93
• 2.2 Removing gearbox
  95
• 2.3 Installing gearbox
  109
• 3 Assembly mounting
  120
• 3.1 Assembly overview - assembly mountings
  120
• 4 Transporting gearbox
  124
• 5 Dismantling and assembling gearbox
  126
• 5.1 Schematic overview - gearbox
  126
• 5.2 Assembly overview - cover for gearbox housing and 5th/6th gear
  126
• 5.3 Assembly overview - selector unit
  128
• 5.4 Assembly overview - input shaft, output shafts, differential, selector rods
  130
• 5.5 Assembly overview - selector forks
  132
• 5.6 Repairing selector forks
  133
• 5.7 Dismantling and assembling gearbox
  138
• 6 Gearbox housing, clutch housing
  163
• 6.1 Assembly overview - clutch housing
  163
• 6.2 Assembly overview - gearbox housing and clutch housing
  163
• 6.3 Assembly overview - gearbox housing cover
  165
• 6.4 Repairing gearbox housing
  167
• 6.5 Repairing gearbox housing cover
  168
• 7 Securing to engine and gearbox support
  172
• 8 Gear oil
  174
• 8.1 Checking gear oil level
  174
• Gears, shafts
  176
• 1 Input shaft
  176
• 1.1 Assembly overview - input shaft
  176
• 1.2 Dismantling and assembling input shaft
  179
• 1.3 Renewing input shaft seal
  190
• 2 Output shaft
  192
• 2.1 Assembly overview - output shaft
  192
• 2.2 Dismantling and assembling output shaft
  195
• Final drive - differential
  203
• 1 Oil seals
  203
• 1.1 Overview of fitting locations - seals
  203
• 1.2 Renewing left seal
  203
• 1.3 Renewing right seal
  206
• 2 Differential
  211
• 2.1 Assembly overview - differential
  211
• 2.2 Dismantling and assembling differential
  213
• 2.3 Adjusting differential
  220