Volkswagen 6-speed Manual Gearbox 0AJ Workshop Manual

Volkswagen 6-speed Manual Gearbox 0AJ Workshop Manual PDF

Volkswagen 6-speed Manual Gearbox 0AJ Workshop Manual. The 6-speed manual gearbox 0AJ is installed in the Jetta 2005 ▸, in the Golf Variant 2007 ▸ and in the Golf Variant 2010 ▸ in conjunction with a 4-cylinder injection engine.


Technical data

  • Gearbox identification
  • Location on gearbox
  • Identification code, assembly allocation and capacities
  • Overview – power transmission
  • Calculating overall gear ratio “i”
  • General repair notes
  • Components


  • Fault finding, power transmission
  • Repairing clutch mechanism
  • Overview
  • Assembly overview – pedal cluster
  • Removing and installing over-centre spring
  • Removing and installing clutch pedal
  • Removing and installing mounting bracket
  • Removing and installing master cylinder
  • Removing and installing clutch position sender G476
  • Assembly overview – hydraulics (LHD vehicles)
  • Assembly overview – hydraulics (RHD vehicles)
  • Removing and installing slave cylinder
  • Bleeding clutch system
  • Repairing clutch release mechanism
  • Assembly overview – clutch release mechanism
  • Removing and installing clutch release lever, release bearing and guide sleeve
  • Repairing clutch

Controls, housing

  • Repairing selector mechanism
  • Installation position of selector mechanism
  • Overview of selector mechanism
  • Assembly overview – gear knob and frame
  • Removing and installing gaiter with gear knob and noise insulation
  • Assembly overview – selector mechanism
  • Assembly overview – selector cables
  • Removing cable end-piece from relay lever and installing
  • Removing and installing selector mechanism
  • Removing and installing gear selector cable and gate selector cable
  • Adjusting selector mechanism
  • Removing and installing gearbox
  • Removing gearbox
  • Installing gearbox
  • Transporting gearbox
  • Checking gear oil
  • Dismantling and assembling gearbox
  • Overview – gearbox
  • Assembly overview
  • Removing and installing cover for gearbox housing and 5th and 6th gear
  • Removing and installing clutch housing
  • Removing and installing input shaft, output shaft, differential, selector mechanism and selector forks
  • Dismantling and assembling procedure
  • Repairing gearbox housing and clutch housing
  • Repairing gearbox housing cover
  • Repairing selector unit
  • Dismantling and assembling selector forks

Gears, shafts

  • Input shaft
  • Dismantling and assembling input shaft
  • Output shaft
  • Dismantling and assembling output shaft

Final drive – differential

  • Renewing flange shaft oil seals with gearbox installed
  • Renewing oil seal for left flange shaft
  • Renewing seal for right flange shaft
  • Differential
  • Dismantling and assembling differential
  • Adjusting differential

Edition 07.2009 (MEX5R009620)

Language: English
Format: Online PDF
Pages: 154
Size: 5.14 Mb

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