6-speed manual gearbox 0FB Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety precautions when working on vehicles with a start/stop system
  2
• 1.3 All-wheel drive - notes on performance test
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Repair notes
  4
• 3.1 General repair instructions
  4
• 4 Technical data
  7
• 4.1 Allocation gearbox - engine
  7
• 4.2 Capacities
  7
• 4.3 Calculation of gear ratios
  7
• 5 Overview - power transmission
  9
• 5.1 Overview - power transmission - all-wheel drive
  9
• 6 Electrical components
  11
• 6.1 Overview of fitting locations - electrical components
  11
• Clutch
  12
• 1 Clutch operation
  12
• 1.1 Overview of fitting locations – clutch mechanism
  12
• 1.2 Assembly overview - pedal cluster
  14
• 1.3 Assembly overview - clutch hydraulics
  16
• 1.4 Assembly overview - clutch release mechanism
  18
• 1.5 Removing and installing bearing bush
  19
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  20
• 1.7 Removing and installing clutch position sender G476
  20
• 1.8 Removing and installing return spring
  20
• 1.9 Removing and installing over-centre spring
  23
• 1.10 Removing and installing clutch pedal
  25
• 1.11 Removing and installing mounting bracket
  26
• 1.12 Removing and installing clutch master cylinder
  30
• 1.13 Removing and installing bleeder
  31
• 1.14 Removing and installing lines for clutch mechanism
  31
• 1.15 Removing and installing clutch slave cylinder together with release bearing
  33
• 1.16 Bleeding clutch mechanism
  34
• 1.17 Repairing clutch release mechanism
  35
• 2 Clutch
  37
• 2.1 Assembly overview - clutch
  37
• 2.2 Removing and installing clutch
  40
• Controls, housing
  53
• 1 Selector mechanism
  53
• 1.1 Installation position - selector mechanism
  53
• 1.2 Overview - selector mechanism
  55
• 1.3 Assembly overview - gear knob and cover
  56
• 1.4 Assembly overview - Gear lever and selector housing
  57
• 1.5 Assembly overview - Selector cables
  59
• 1.6 Assembly overview - selector mechanism
  61
• 1.7 Removing and installing gear knob
  62
• 1.8 Dismantling and assembling selector mechanism
  64
• 1.9 Removing and installing selector mechanism
  68
• 1.10 Removing and installing gear selector cable and gate selector cable
  75
• 1.11 Adjusting selector mechanism
  77
• 1.12 Checking selector mechanism
  79
• 2 Removing and installing gearbox
  80
• 2.1 Removing gearbox
  80
• 2.2 Installing gearbox
  86
• 2.3 Specified torques for gearbox
  93
• 3 Assembly mountings
  94
• 3.1 Assembly overview - assembly mountings
  94
• 4 Bevel box
  97
• 4.1 Removing bevel box
  97
• 4.2 Installing bevel box
  102
• 5 Transporting gearbox
  106
• 5.1 Transporting gearbox
  106
• 6 Gear oil
  107
• 6.1 Checking gear oil level
  107
• 7 Installing to engine and gearbox support
  109
• 7.1 Installing manual gearbox to engine and gearbox support
  109
• 7.2 Installing bevel box to engine and gearbox support
  109
• 8 Dismantling and assembling gearbox
  111
• 8.1 Schematic overview - gearbox
  111
• 8.2 Overview - gearbox
  112
• 8.3 Assembly overview - gearbox housing and selector mechanism
  113
• 8.4 Assembly overview - selector unit
  115
• 8.5 Assembly overview - input shaft, output shafts, differential, selector rods
  116
• 8.6 Assembly overview - selector forks
  118
• 8.7 Renewing oil seal for selector shaft
  118
• 8.8 Dismantling and assembling gearbox
  120
• 9 Gearbox housing, clutch housing
  135
• 9.1 Assembly overview - gearbox housing
  135
• 9.2 Assembly overview - clutch housing
  137
• 9.3 Repairing gearbox housing
  138
• 9.4 Repairing clutch housing
  145
• Gears, shafts
  148
• 1 Input shaft
  148
• 1.1 Assembly overview - input shaft
  148
• 1.2 Dismantling and assembling input shaft
  149
• 1.3 Renewing input shaft seal
  153
• 2 Output shaft
  155
• 2.1 Assembly overview - output shaft
  155
• 2.2 Dismantling and assembling output shaft
  162
• 2.3 Adjusting output shaft
  184
• Final drive - front differential
  195
• 1 Oil seals
  195
• 1.1 Overview of fitting locations - seals
  195
• 1.2 Renewing left oil seal
  196
• 1.3 Renewing right oil seal
  198
• 2 Differential
  203
• 2.1 Assembly overview - differential
  203
• 2.2 Dismantling and assembling differential
  206
• 2.3 Adjusting differential
  211
• 3 Adjustment overview
  216
• 4 Bevel box
  217
• 4.1 Assembly overview - bevel box
  217
• 4.2 Renewing bevel box seals
  219
• 4.3 Renewing output flange and redetermining thickness of shim
  230
• 4.4 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  230
• 5 All-wheel drive coupling
  235
• 5.1 Checking function
  235
• 5.2 Removing and installing all-wheel drive coupling pump V181
  235
• 5.3 Removing and installing all-wheel drive coupling
  235
• 6 Gear oil
  236
• 6.1 Checking gear oil level
  236
• 7 High performance oil for all-wheel drive coupling
  241