5-speed Manual Gearbox 0A4 Repair Manual

5-speed Manual Gearbox 0A4 Repair Manual PDF

5-speed Manual Gearbox 0A4 Repair Manual. 5-speed manual gearbox 0A4 is installed in following vehicles:

CONTENTS:

Technical data

  • Gearbox identification
  • Location on gearbox
  • Identification codes, assembly allocation, capacities, Golf 2004 ▸
  • Identification codes, assembly allocation, capacities, Golf 2009 ▸
  • Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸
  • Identification codes, assembly allocation, capacities, Golf Plus 2009 ▸
  • Identification codes, assembly allocation and capacities, Passat 2006 ▸
  • Overview – power transmission
  • Calculating overall gear ratio “i”
  • General repair notes
  • Components

Clutch

  • Repairing clutch mechanism
  • Overview
  • Assembly overview – pedal cluster
  • Removing and installing over-centre spring, Golf 2004 ▸
  • Removing and installing over-centre spring, Golf 2009 ▸ LHD
  • Removing and installing over-centre spring, Golf 2009 ▸ RHD
  • Removing and installing over-centre spring, Golf Plus
  • Removing and installing over-centre spring, Passat
  • Removing and installing clutch pedal, Golf 2004 ▸
  • Removing and installing clutch pedal, Golf 2009 ▸ LHD
  • Removing and installing clutch pedal, Golf 2009 ▸ RHD
  • Removing and installing clutch pedal, Golf Plus
  • Removing and installing clutch pedal, Passat
  • Removing and installing mounting bracket, Golf 2004 ▸
  • Removing and installing mounting bracket, Golf 2009 ▸ LHD
  • Removing and installing mounting bracket, Golf 2009 ▸ right-hand drive and Golf Plus righthand drive
  • Removing and installing mounting bracket, Golf Plus left-hand drive
  • Removing and installing mounting bracket, Passat
  • Removing and installing master cylinder
  • Removing and installing clutch position sender G476
  • Assembly overview – hydraulics (LHD)
  • Assembly overview – hydraulics (RHD)
  • Removing and installing slave cylinder
  • Removing
  • Installing
  • Torque settings
  • Bleeding clutch system
  • Repairing clutch release mechanism
  • Repairing clutch, in conjunction with dual-mass flywheel
  • Identifying make of clutch, vehicles with 1.9 l – 66 kW turbo diesel engine and vehicles with 1.9L – 77 kW turbo diesel engine
  • Removing and installing Sachs clutch
  • Repairing Sachs clutch
  • Removing and installing LuK clutch
  • Repairing LuK clutch
  • Repairing clutch, in conjunction with one-piece flywheel

Controls, housing

  • Repairing selector mechanism
  • Installation position of selector mechanism
  • Overview of selector mechanism
  • Removing and installing gear knob and cover
  • Removing and installing gaiter with gear knob and noise insulation, Golf
  • Removing and installing gaiter with gear knob and noise insulation, Golf Plus
  • Removing and installing gaiter with selector lever knob and noise insulation, Passat
  • Repairing gear lever and selector housing (through 10.06)
  • Repairing gear lever and selector housing (from 11.06)
  • Assembly overview – removing and installing selector cables
  • Plastic relay lever
  • Removing and installing selector mechanism
  • Adjusting selector mechanism
  • Removing and installing gearbox, Golf 2004 ▸
  • Removing gearbox
  • Installing gearbox
  • Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine
  • Removing gearbox
  • Installing gearbox
  • Removing and installing gearbox, Golf 2009 ▸ with petrol engine
  • Removing gearbox
  • Installing gearbox
  • Removing and installing gearbox, Golf Plus
  • Removing gearbox
  • Installing gearbox
  • Removing and installing gearbox, Passat
  • Removing gearbox
  • Installing gearbox
  • Transporting gearbox
  • Checking and topping up gear oil
  • Preparation
  • Draining gear oil
  • Fill with gear oil
  • Dismantling and assembling gearbox
  • Overview – gearbox
  • Assembly overview
  • Removing and installing cover for gearbox housing and 5th gear
  • Removing and installing gearbox housing and selector mechanism
  • Removing and installing input shaft, output shaft, differential and selector forks
  • Assembly sequence – removing and installing cover for gearbox housing and 5th gear
  • Assembly sequence – Dismantling and assembling gearbox completely
  • Repairing gearbox housing and clutch housing
  • Repairing selector unit
  • Dismantling and assembling selector forks

Gears, shafts

  • Input shaft
  • Dismantling and assembling input shaft
  • Adjusting input shaft
  • Output shaft
  • Dismantling and assembling output shaft
  • Adjusting output shaft
  • Reverse shaft
  • Dismantling and assembling reverse shaft

Final drive – differential

  • Renewing flange shaft oil seals with gearbox installed
  • Renewing oil seal for left flange shaft
  • Distinguishing seals for right flange shaft
  • Renewing seal (two-part seal and sleeve for right flange shaft)
  • Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft)
  • Adjustment overview
  • Differential
  • Dismantling and assembling differential
  • Adjusting differential

Edition 04.2010
Language: English
Format: PDF
Pages: 319
Size: 11.4 Mb
Free download 5-speed Manual Gearbox 0A4 Workshop Manual PDF
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