Volkswagen 6-speed Manual Gearbox 02Q Workshop Manual

Volkswagen 6-speed Manual Gearbox 02Q Workshop Manual PDF

Volkswagen 6-speed Manual Gearbox 02Q Workshop Manual. The 6-speed manual gearbox 02Q is installed in the Jetta 2005 ►, in the Golf Variant 2007 ►, in the Golf Variant 2010 ► and in the Jetta 2011 ► in conjunction with a 4-cylinder engine.

CONTENTS:

Technical data

  • Gearbox identification
  • Location on gearbox
  • Identification code, assembly allocation and capacities
  • Overview – power transmission
  • Calculating overall gear ratio „i“
  • General repair notes
  • Contact corrosion!
  • Special tools
  • Components

Clutch

  • 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)
  • Assembly overview – hydraulics (RHD)
  • Bleeding clutch system
  • Repairing clutch release mechanism
  • Removing pipe/hose line and bleeder from and installing on slave cylinder
  • Removing and installing slave cylinder with release bearing
  • Removing and installing pipe/hose line or plastic line
  • Renewing input shaft seal
  • Repairing clutch – vehicles with turbo diesel engine
  • Determining clutch manufacturer
  • Removing and installing „Sachs“ clutch
  • Repairing „Sachs“ clutch
  • Removing and installing „LuK“ clutch
  • Repairing „LuK“ clutch
  • Repairing clutch – vehicles with petrol engine
  • Repairing clutch
  • Removing and installing clutch

Controls, housing

  • Repairing selector mechanism
  • Installation position of selector mechanism
  • Overview of selector mechanism
  • Removing and installing gear knob and frame
  • Removing and installing gaiter with gear knob and noise insulation
  • 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
  • Removing and installing gear selector cable and gate selector cable
  • Adjusting selector mechanism
  • Removing and installing gearbox in vehicles with turbo diesel engine
  • Removing gearbox
  • Transporting gearbox
  • Installing gearbox
  • Specified torques
  • Removing and installing gearbox, vehicles with petrol engine
  • Removing gearbox
  • Transporting gearbox
  • Installing gearbox
  • Specified torques
  • Checking gearbox oil
  • Dismantling and assembling gearbox
  • Overview – rear final drive
  • Assembly overview
  • Removing and installing gearbox housing and selector mechanism
  • Removing and installing input shaft, output shafts, differential and selector rods
  • Assembly order, gearbox »without« retaining ring A for input shaft sealing cover
  • Assembly order, gearbox »with« retaining ring A for input shaft sealing cover
  • Repairing gearbox housing
  • Repairing clutch housing
  • Repairing selector unit
  • Renewing oil seal for selector shaft
  • Repairing selector forks

Gears, shafts

  • Input shaft
  • Dismantling and assembling input shaft
  • Output shaft for 1st through 4th gears
  • Assembly overview – output shaft for 1st through 4th gears
  • Dismantling and assembling output shaft for 1st through 4th gears
  • Adjusting output shaft for 1st through 4th gears
  • Output shaft for 5th, 6th and reverse gears
  • Dismantling and assembling output shaft for 5th, 6th and reverse gears
  • Adjusting output shaft for 5th, 6th and reverse gears

Final drive – differential

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

Edition 06.2010 (MEX5R006920)
Language: English
Format: PDF
Pages: 246
Size: 9.28 Mb
Free download Volkswagen 6-speed Manual Gearbox 02Q Workshop Manual PDF
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