Installed 5-speed manual gearbox 0A4

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
  3
• 3.3 Calculation of gear ratios
  3
• 4 Overview - power transmission
  4
• 5 Electrical components
  6
• 5.1 Overview of fitting locations - electrical components
  6
• 6 Repair instructions
  7
• 6.1 General repair instructions
  7
• Clutch
  9
• 1 Clutch mechanism
  9
• 1.1 Overview of fitting locations – clutch mechanism
  9
• 1.2 Assembly overview - pedal cluster
  11
• 1.3 Assembly overview - clutch hydraulics
  13
• 1.4 Removing and installing bearing bush
  15
• 1.5 Checking clutch master cylinder and clutch slave cylinder
  16
• 1.6 Removing and installing clutch position sender G476
  17
• 1.7 Removing and installing return spring
  17
• 1.8 Removing and installing over-centre spring
  20
• 1.9 Removing and installing clutch pedal
  22
• 1.10 Removing and installing mounting bracket
  24
• 1.11 Removing and installing clutch master cylinder
  28
• 1.12 Removing and installing clutch slave cylinder
  28
• 1.13 Removing and installing lines for clutch mechanism
  31
• 1.14 Bleeding clutch mechanism
  33
• 2 Clutch
  35
• Controls, housing
  36
• 1 Selector mechanism
  36
• 1.1 Installation position - selector mechanism
  36
• 1.2 Assembly overview - gear knob and cover
  37
• 1.3 Assembly overview - selector mechanism
  38
• 1.4 Removing and installing gear knob
  39
• 1.5 Removing and installing selector mechanism
  41
• 1.6 Repairing selector mechanism
  44
• 1.7 Adjusting selector mechanism
  46
• 1.8 Checking selector mechanism
  49
• 2 Removing and installing gearbox
  50
• 2.1 Removing gearbox
  50
• 2.2 Installing gearbox
  61
• 2.3 Specified torques for gearbox
  69
• 3 Assembly mountings
  70
• 3.1 Assembly overview - assembly mountings
  70
• 4 Gear oil
  72
• 4.1 Checking gear oil level
  72
• 4.2 Draining and filling gear oil
  72
• 5 Dismantling and assembling gearbox
  75
• 5.1 Assembly overview - selector unit
  75
• 5.2 Removing and installing selector unit with gearbox installed
  76
• 5.3 Repairing selector unit
  78
• 5.4 Renewing selector shaft seal
  79
• 6 Gearbox housing, clutch housing
  82
• Gears, shafts
  83
• 1 Input shaft
  83
• 2 Output shaft
  84
• 3 Reverse shaft
  85
• Final drive - differential
  86
• 1 Oil seals
  86
• 1.1 Overview of fitting locations - seals
  86
• 1.2 Renewing left seal
  87
• 1.3 Renewing right oil seal
  89
• 2 Differential
  93