Installed 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
  3
• 4 Overview - power transmission
  4
• 5 Electrical components
  6
• 5.1 Overview of fitting locations - electrical components
  6
• 6 Repair instructions
  8
• 6.1 General repair instructions
  8
• Clutch
  11
• 1 Clutch mechanism
  11
• 1.1 Overview of fitting locations – clutch mechanism
  11
• 1.2 Assembly overview - pedal cluster
  12
• 1.3 Assembly overview - clutch hydraulics
  14
• 1.4 Removing and installing bearing bush
  16
• 1.5 Checking clutch master cylinder and clutch slave cylinder
  17
• 1.6 Removing and installing clutch position sender G476
  18
• 1.7 Removing and installing over-centre spring
  20
• 1.8 Removing and installing clutch pedal
  22
• 1.9 Removing and installing mounting bracket
  25
• 1.10 Removing and installing master cylinder
  28
• 1.11 Removing and installing clutch slave cylinder
  29
• 1.12 Removing and installing lines for clutch mechanism
  32
• 1.13 Bleeding clutch mechanism
  34
• 2 Clutch
  37
• Controls, housing
  38
• 1 Selector mechanism
  38
• 1.1 Installation position - selector mechanism
  38
• 1.2 Assembly overview – gear knob and cover
  39
• 1.3 Assembly overview - selector mechanism
  40
• 1.4 Removing and installing gear knob
  42
• 1.5 Removing and installing selector mechanism
  44
• 1.6 Repairing selector mechanism
  52
• 1.7 Adjusting selector mechanism
  56
• 1.8 Checking selector mechanism
  60
• 2 Removing and installing gearbox
  61
• 2.1 Specified torques for gearbox
  61
• 2.2 Removing gearbox
  61
• 2.3 Installing gearbox
  71
• 3 Assembly mountings
  78
• 3.1 Assembly overview - assembly mountings
  78
• 4 Gear oil
  81
• 4.1 Checking gear oil level
  81
• 5 Dismantling and assembling gearbox
  83
• 5.1 Assembly overview - selector unit
  83
• 5.2 Removing and installing selector unit with gearbox installed
  84
• 5.3 Repairing selector unit
  89
• 5.4 Renewing selector shaft seal
  90
• 6 Gearbox housing, clutch housing
  92
• Gears, shafts
  93
• 1 Input shaft
  93
• 2 Output shaft
  94
• Final drive - differential
  95
• 1 Oil seals
  95
• 1.1 Overview of fitting locations - seals
  95
• 1.2 Renewing left seal
  95
• 1.3 Renewing right seal
  98
• 2 Differential
  102