VW 5-speed Manual Gearbox 0A4 Repair Manual (Edition 04.2010 K0058990420)
5-speed Manual Gearbox 0A4 Repair Manual. 5-speed manual gearbox 0A4 is installed in following vehicles:
- Volkswagen Golf 2004-
- Volkswagen Golf 2009-
- Volkswagen Golf Plus 2005-
- Volkswagen Golf Plus 2009
- Volkswagen Passat 2006-
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
Language: English
Format: PDF
Pages: 319
VW 5-speed Manual Gearbox 0A4 Repair Manual (Edition 04.2010 K0058990420) PDF free online