6-speed manual gearbox 0AX

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
• 2.2 Identification of bevel box
  3
• 3 Repair notes
  4
• 3.1 Rules for cleanliness
  4
• 3.2 General repair instructions
  4
• 3.3 Contact corrosion
  4
• 3.4 Gaskets and seals
  5
• 3.5 Nuts and bolts
  5
• 3.6 Routing and attachment of lines
  6
• 4 Technical data
  7
• 4.1 Capacities
  7
• 4.2 Allocation gearbox - engine
  7
• Clutch
  9
• 1 Clutch mechanism
  9
• 1.1 Assembly overview - clutch mechanism
  9
• 1.2 Assembly overview - clutch release mechanism
  11
• 1.3 Removing and installing clutch pedal
  11
• 1.4 Removing and installing over-centre spring
  13
• 1.5 Removing and installing mounting bracket
  14
• 1.6 Removing and installing bearing bush
  14
• 1.7 Removing and installing clutch master cylinder
  14
• 1.8 Removing and installing clutch slave cylinder together with release bearing
  15
• 1.9 Removing and installing bleeder
  16
• 1.10 Bleeding clutch mechanism
  18
• 1.11 Checking clutch master cylinder and clutch slave cylinder
  19
• 1.12 Removing and installing clutch position sender G476
  20
• 2 Clutch
  21
• 2.1 Assembly overview - clutch
  21
• 2.2 Removing and installing clutch
  21
• Controls, housing
  25
• 1 Bevel box
  25
• 1.1 Assembly overview - bevel box
  25
• 1.2 Removing bevel box
  27
• 1.3 Installing bevel box
  29
• 1.4 Bevel box - checking gear oil level
  30
• 1.5 Fitting repair kit for stub shaft
  32
• 2 Selector mechanism
  36
• 2.1 Installation position - selector mechanism
  36
• 2.2 Assembly overview - selector mechanism
  36
• 2.3 Removing and installing mounting for cable support bracket
  38
• 2.4 Removing and installing selector mechanism
  38
• 2.5 Adjusting selector mechanism
  40
• 2.6 Checking selector mechanism
  43
• 2.7 Removing and installing gear selector cable
  44
• 2.8 Removing and installing selector lever handle
  47
• 2.9 Renewing selector shaft seal
  49
• 3 Removing and installing gearbox
  52
• 3.1 Specified torques for gearbox
  52
• 3.2 Removing gearbox
  54
• 3.3 Installing gearbox
  70
• 4 Assembly mountings
  71
• 4.1 Assembly overview - assembly mountings
  71
• 5 Transporting gearbox
  74
• 6 Dismantling and assembling gearbox
  76
• 6.1 Schematic overview - gearbox
  76
• 6.2 System overview of gearbox
  78
• 6.3 Assembly overview - gearbox housing and selector mechanism
  79
• 6.4 Assembly overview - selector unit
  83
• 6.5 Assembly overview - input shaft, output shafts, differential, selector rods
  83
• 6.6 Assembly overview - selector forks
  85
• 6.7 Dismantling and assembling gearbox
  86
• 7 Gearbox housing, clutch housing
  125
• 7.1 Assembly overview - gearbox housing
  125
• 7.2 Assembly overview - clutch housing
  127
• 7.3 Repairing gearbox housing
  129
• 7.4 Repairing clutch housing
  132
• 8 Securing to engine and gearbox support
  136
• 9 Gear oil
  137
• 9.1 Draining and filling gear oil
  137
• Gears, shafts
  139
• 1 Input shaft
  139
• 1.1 Assembly overview - input shaft
  139
• 1.2 Dismantling and assembling input shaft
  143
• 2 Output shaft
  159
• 2.1 Assembly overview - output shaft
  159
• 2.2 Dismantling and assembling output shaft
  165
• 2.3 Adjusting output shaft
  198
• Final drive - differential
  199
• 1 Oil seals
  199
• 1.1 Overview of fitting locations - oil seals
  199
• 1.2 Renewing input shaft seal
  200
• 1.3 Renewing left seal
  202
• 1.4 Renewing right seal
  205
• 2 Differential
  210
• 2.1 Assembly overview - differential
  210
• 2.2 Dismantling and assembling differential
  212
• 2.3 Adjusting differential
  221