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 Technical data
  3
• 3.1 Allocation gearbox - engine
  3
• 3.2 Capacities
  6
• 3.3 Calculation of gear ratios
  6
• 4 Overview - power transmission
  7
• 5 Electrical components
  9
• 5.1 Overview of fitting locations - electrical components
  9
• 6 Repair instructions
  11
• 6.1 General repair instructions
  11
• Clutch
  14
• 1 Clutch mechanism
  14
• 1.1 Overview of fitting locations – clutch mechanism
  14
• 1.2 Assembly overview - pedal cluster
  16
• 1.3 Assembly overview - clutch hydraulics
  20
• 1.4 Assembly overview - clutch release mechanism
  25
• 1.5 Removing and installing bearing bush
  26
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  26
• 1.7 Removing and installing clutch position sender G476
  27
• 1.8 Removing and installing return spring
  30
• 1.9 Removing and installing over-centre spring
  32
• 1.10 Removing and installing clutch pedal
  36
• 1.11 Removing and installing mounting bracket
  40
• 1.12 Removing and installing clutch master cylinder
  48
• 1.13 Removing and installing clutch slave cylinder
  50
• 1.14 Removing and installing lines for clutch mechanism
  53
• 1.15 Bleeding clutch mechanism
  55
• 1.16 Repairing clutch release mechanism
  56
• 2 Clutch
  58
• 2.1 Assembly overview - clutch
  58
• 2.2 Removing and installing clutch
  59
• Controls, housing
  63
• 1 Selector mechanism
  63
• 1.1 Installation position - selector mechanism
  63
• 1.2 Assembly overview - gear knob and cover
  65
• 1.3 Assembly overview - selector mechanism
  67
• 1.4 Removing and installing gear knob
  69
• 1.5 Removing and installing selector mechanism
  73
• 1.6 Repairing selector mechanism
  76
• 1.7 Adjusting selector mechanism
  79
• 1.8 Checking selector mechanism
  82
• 2 Removing and installing gearbox
  83
• 2.1 Distinguishing between different types of engines, Scirocco
  83
• 2.2 Removing gearbox
  84
• 2.3 Installing gearbox
  128
• 2.4 Specified torques for gearbox
  146
• 3 Assembly mountings
  149
• 3.1 Assembly overview - assembly mountings
  149
• 4 Transporting gearbox
  151
• 5 Gear oil
  152
• 5.1 Checking gear oil level
  152
• 6 Securing to engine and gearbox support
  154
• 7 Dismantling and assembling gearbox
  156
• 7.1 Schematic overview - gearbox
  156
• 7.2 Assembly overview - cover for gearbox housing and 5th/6th gear
  158
• 7.3 Assembly overview - clutch housing
  160
• 7.4 Assembly overview - shafts, differential, selector mechanism
  161
• 7.5 Assembly overview - selector unit
  162
• 7.6 Assembly overview - selector forks
  164
• 7.7 Repairing selector forks
  165
• 7.8 Repairing selector unit
  168
• 7.9 Renewing selector shaft seal
  171
• 7.10 Dismantling and assembling gearbox
  171
• 8 Gearbox housing, clutch housing
  189
• 8.1 Assembly overview - gearbox housing and clutch housing
  189
• 8.2 Assembly overview - gearbox housing cover
  191
• 8.3 Repairing gearbox housing cover
  192
• Gears, shafts
  194
• 1 Input shaft
  194
• 1.1 Assembly overview - input shaft
  194
• 1.2 Dismantling and assembling input shaft
  197
• 1.3 Renewing input shaft seal
  205
• 2 Output shaft
  207
• 2.1 Assembly overview - output shaft
  207
• 2.2 Dismantling and assembling output shaft
  210
• Final drive - differential
  216
• 1 Oil seals
  216
• 1.1 Overview of fitting locations - seals
  216
• 1.2 Renewing left seal
  217
• 1.3 Renewing right oil seal
  219
• 2 Differential
  223
• 2.1 Assembly overview - differential
  223
• 2.2 Dismantling and assembling differential
  224
• 2.3 Adjusting differential
  229