Volkswagen 6-Speed Manual Gearbox 02S Workshop Manual

Volkswagen 6-Speed Manual Gearbox 02S Workshop Manual PDF

Volkswagen 6-Speed Manual Gearbox 02S Workshop Manual. The 6-speed manual gearbox 02S is installed in the Jetta 2005 ▸, in the Golf Variant 2007 ▸ and in the Golf Variant 2010 ▸ 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
  • 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 vehicles)
  • Assembly overview – hydraulics (RHD vehicles)
  • Removing and installing slave cylinder
  • Bleeding clutch system
  • Repairing clutch release mechanism
  • Repairing clutch, in conjunction with dual-mass flywheel
  • Determining clutch manufacturer
  • 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

  • Fault finding, power transmission
  • 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
  • Removing gearbox
  • Installing gearbox
  • Checking and topping up gear oil
  • Preparation
  • Draining gear oil
  • Filling with 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 gearbox housing and shift mechanism
  • Removing and installing input shaft, output shaft, differential and selector forks
  • Assembly sequence – Removing and installing cover for gearbox housing and 5th and 6th gear
  • Assembly sequence – Dismantling and assembling gearbox completely
  • 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
  • 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 07.2009 (MEX5R007520)
Language: English
Format: PDF
Pages: 206
Size: 10.7 Mb
Free download Volkswagen 6-Speed Manual Gearbox 02S Workshop Manual PDF
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