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
  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
  8
• 6.1 General repair instructions
  8
• Clutch
  10
• 1 Clutch operation
  10
• 1.1 Assembly overview - pedal cluster
  10
• 1.2 Assembly overview - clutch hydraulics
  13
• 1.3 Removing and installing bearing bush
  14
• 1.4 Checking clutch master cylinder and clutch slave cylinder
  14
• 1.5 Removing and installing clutch position sender G476
  15
• 1.6 Removing and installing return spring
  15
• 1.7 Removing and installing over-centre spring
  18
• 1.8 Removing and installing clutch pedal
  20
• 1.9 Removing and installing mounting bracket
  22
• 1.10 Removing and installing clutch master cylinder
  26
• 1.11 Removing and installing clutch slave cylinder
  26
• 1.12 Removing and installing lines for clutch mechanism
  29
• 1.13 Bleeding clutch mechanism
  31
• 2 Clutch
  33
• Controls, housing
  34
• 1 Selector mechanism
  34
• 1.1 Installation position - selector mechanism
  34
• 1.2 Assembly overview - gear knob and cover
  35
• 1.3 Assembly overview - selector mechanism
  36
• 1.4 Removing and installing gear knob
  37
• 1.5 Removing and installing selector mechanism
  39
• 1.6 Repairing selector mechanism
  41
• 1.7 Adjusting selector mechanism
  44
• 1.8 Checking selector mechanism
  46
• 2 Removing and installing gearbox
  47
• 2.1 Removing gearbox
  47
• 2.2 Install gearbox
  69
• 2.3 Specified torques for gearbox
  81
• 3 Assembly mountings
  82
• 3.1 Assembly overview - assembly mountings
  82
• 4 Gear oil
  84
• 4.1 Checking gear oil level
  84
• 5 Dismantling and assembling gearbox
  86
• 5.1 Assembly overview - selector unit
  86
• 5.2 Removing and installing selector unit with gearbox installed
  87
• 5.3 Repairing selector unit
  91
• 5.4 Renewing oil seal for selector shaft
  91
• 6 Gearbox housing, clutch housing
  93
• Gears, shafts
  94
• 1 Input shaft
  94
• 2 Output shaft
  95
• Final drive - differential
  96
• 1 Oil seals
  96
• 1.1 Overview of fitting locations - seals
  96
• 1.2 Renewing left oil seal
  97
• 1.3 Renewing right oil seal
  99
• 2 Differential
  103