6-speed manual gearbox 0DQ

Chapter overview

• Technical data
  1
• 1 Safety instructions
  1
• 1.1 Safety precautions when working on vehicles with a Start/Stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  4
• 3.1 Allocation gearbox - engine
  4
• 3.2 Capacities
  4
• 3.3 Calculation of gear ratios
  4
• 4 Overview - power transmission
  5
• 5 Electrical components
  7
• 5.1 Overview of fitting locations – electrical components
  7
• 6 Repair instructions
  9
• 6.1 General repair notes
  9
• Clutch
  13
• 1 Clutch operation
  13
• 1.1 Overview of fitting locations – clutch mechanism
  13
• 1.2 Assembly overview - pedal cluster
  14
• 1.3 Assembly overview - clutch hydraulics
  16
• 1.4 Assembly overview - clutch release mechanism
  21
• 1.5 Removing and installing bearing bush
  22
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  23
• 1.7 Removing and installing clutch position sender G476
  23
• 1.8 Removing and installing over-centre spring
  25
• 1.9 Removing and installing extension spring
  27
• 1.10 Removing and installing clutch pedal
  27
• 1.11 Removing and installing mounting bracket
  29
• 1.12 Removing and installing clutch master cylinder
  35
• 1.13 Removing and installing clutch slave cylinder
  36
• 1.14 Removing and installing lines for clutch mechanism
  38
• 1.15 Bleeding clutch mechanism
  41
• 1.16 Repairing clutch release mechanism
  42
• 2 Clutch
  45
• 2.1 Assembly overview - clutch
  45
• 2.2 Removing and installing clutch
  45
• Controls, housing
  51
• 1 Selector mechanism
  51
• 1.1 Installation position - selector mechanism
  51
• 1.2 Assembly overview - gear knob and cover
  52
• 1.3 Assembly overview - selector mechanism
  53
• 1.4 Removing and installing gear knob
  55
• 1.5 Removing and installing selector mechanism
  57
• 1.6 Repairing selector mechanism
  62
• 1.7 Adjusting selector mechanism
  65
• 1.8 Checking selector mechanism
  68
• 2 Removing and installing gearbox
  69
• 2.1 Removing gearbox
  69
• 2.2 Installing gearbox
  80
• 2.3 Specified torques for gearbox
  86
• 3 Assembly mountings
  87
• 3.1 Assembly overview - assembly mountings
  87
• 4 Transporting gearbox
  90
• 5 Gear oil
  91
• 5.1 Checking gear oil level
  91
• 6 Installing to engine and gearbox support
  93
• 7 Dismantling and assembling gearbox
  95
• 7.1 Schematic overview - gearbox
  95
• 7.2 Assembly overview - gearbox
  96
• 7.3 Assembly overview - cover for gearbox housing and 5th/6th gear
  96
• 7.4 Assembly overview - clutch housing
  98
• 7.5 Assembly overview - shafts, differential, selector mechanism
  98
• 7.6 Assembly overview - selector unit
  100
• 7.7 Assembly overview - selector forks
  101
• 7.8 Repairing selector forks
  102
• 7.9 Repairing selector unit
  107
• 7.10 Renewing oil seal for selector shaft
  110
• 7.11 Dismantling and assembling gearbox
  111
• 8 Gearbox housing, clutch housing
  131
• 8.1 Assembly overview - gearbox housing and clutch housing
  131
• 8.2 Assembly overview - gearbox housing cover
  133
• 8.3 Repairing gearbox housing cover
  134
• 8.4 Repairing clutch housing
  135
• Gears, shafts
  138
• 1 Input shaft
  138
• 1.1 Assembly overview - input shaft
  138
• 1.2 Dismantling and assembling input shaft
  141
• 1.3 Renewing input shaft seal
  152
• 2 Output shaft
  154
• 2.1 Assembly overview - output shaft
  154
• 2.2 Dismantling and assembling output shaft
  157
• Final drive - differential
  165
• 1 Oil seals
  165
• 1.1 Overview of fitting locations - seals
  165
• 1.2 Renewing left oil seal
  165
• 1.3 Renewing right oil seal
  169
• 2 Differential
  172
• 2.1 Assembly overview - differential
  172
• 2.2 Dismantling and assembling differential
  174
• 2.3 Adjusting differential
  182