Volkswagen 6-speed Dual Clutch Gearbox 02E Workshop Manual

6-speed Dual Clutch Gearbox 02E Workshop Manual PDF

Volkswagen 6-speed Dual Clutch Gearbox 02E Workshop Manual. The 6-speed manual gearbox 09G is installed in the Golf Variant 2007 ➤, Golf Variant 2010 ➤,  Jetta 2005 ➤, Jetta 2011 ➤.

CONTENTS:

Technical data

  • General repair notes
  • Tools
  • Gearbox
  • Overview
  • O-rings, seals and gaskets
  • Dual clutch gearbox oil
  • Nuts and bolts
  • Electrical components
  • Fault finding
  • General notes on fault finding
  • Useful information about the „behaviour of the control unit in the event of a gearbox fault“
  • Special notes on fault finding
  • Gearbox identification
  • Reading gearbox code letters
  • Code – engine allocation
  • Identification code
  • Capacity

Clutch

  • Notes on clutch
  • Removing and installing clutch
  • Removing clutch cover (end cover)
  • Installing clutch cover (end cover)
  • Removing clutch
  • Preparing installation of multi-clutch
  • Installing and adjusting clutch

Controls, housing

  • Electrical and electronic components for the dual clutch gearbox and their locations
  • Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
  • Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
  • Removing and installing gearbox input speed sender G182 and oil temperature sender in
    multi-plate clutch G509
  • Removing and installing gearbox oil cooler
  • Removing gearbox oil cooler
  • Installing gearbox oil cooler
  • Removing and installing oil pump
  • Removing oil pump
  • Installing oil pump
  • Renew seal on selector shaft lever
  • Selector mechanism
  • Overview – selector mechanism in vehicles up to 02.2009
  • Removing and installing selector lever cable – vehicles up to 02.2009
  • Overview of selector mechanism – vehicles from 03.2009 onwards
  • Removing and installing selector mechanism with selector lever and selector lever cable – vehicles from 03.2009 onwards
  • Checking selector lever cable
  • Adjusting selector lever cable
  • Emergency release of selector lever
  • Removing and installing selector lever knob
  • Checking selector mechanism
  • Removing and installing gearbox
  • Removing gearbox
  • Installing gearbox
  • Torque settings
  • Transporting gearbox and securing to assembly stand
  • Changing oil and filter and adjusting oil level
  • Changing oil and filter

Gears, shafts

  • Currently, no repairs can be made to gears and shafts

Final drive – differential

  • Renewing seals for flange shaft or stub shaft
  • Renewing oil seal for left flange shaft
  • Renewing seals for right flange shaft or stub shaft

Edition 07.2010 (MEX5R006620)
Language: English
Format: PDF
Pages: 105
Size: 4.25 Mb
Free download Volkswagen 6-speed Dual Clutch Gearbox 02E Workshop Manual PDF
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