6-speed manual gearbox 02Q, 0BB and 0FB

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  2
• 1.3 All-wheel drive - notes on performance test
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Technical data
  6
• 3.1 Allocation gearbox - engine
  6
• 3.2 Capacities
  16
• 3.3 Calculation of gear ratios
  17
• 4 Overview - power transmission
  18
• 4.1 Overview - power transmission - front-wheel drive
  18
• 4.2 Overview - power transmission - all-wheel drive
  19
• 5 Electrical components
  22
• 5.1 Overview of fitting locations - electrical components
  22
• 6 Repair instructions
  25
• 6.1 General repair instructions
  25
• Clutch
  29
• 1 Clutch mechanism
  29
• 1.1 Overview of fitting locations – clutch mechanism
  29
• 1.2 Assembly overview - pedal cluster
  30
• 1.3 Assembly overview - clutch hydraulics
  36
• 1.4 Assembly overview - clutch release mechanism
  44
• 1.5 Removing and installing bearing bush
  46
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  47
• 1.7 Removing and installing clutch position sender G476
  48
• 1.8 Removing and installing return spring
  55
• 1.9 Removing and installing over-centre spring
  58
• 1.10 Removing and installing clutch pedal
  75
• 1.11 Removing and installing mounting bracket
  80
• 1.12 Removing and installing clutch master cylinder
  106
• 1.13 Removing and installing bleeder
  110
• 1.14 Removing and installing lines for clutch mechanism
  114
• 1.15 Removing and installing clutch slave cylinder together with release bearing
  118
• 1.16 Bleeding clutch mechanism
  120
• 1.17 Repairing clutch release mechanism
  121
• 2 Clutch
  123
• 2.1 Determining make of clutch
  123
• 2.2 Assembly overview - clutch
  124
• 2.3 Removing and installing clutch
  127
• Controls, housing
  143
• 1 Selector mechanism
  143
• 1.1 Installation position - selector mechanism
  143
• 1.2 Overview - selector mechanism
  144
• 1.3 Assembly overview – gear knob and cover
  145
• 1.5 Assembly overview - selector cables, CC, Scirocco, Golf Cabriolet, Passat
  149
• 1.6 Assembly overview - selector mechanism, Golf, Golf Estate
  151
• 1.7 Removing and installing gear knob
  153
• 1.8 Dismantling and assembling selector mechanism
  161
• 1.9 Removing and installing selector mechanism
  167
• 1.10 Removing and installing gear selector cable and gate selector cable
  173
• 1.11 Repairing selector mechanism
  176
• 1.12 Adjusting selector mechanism
  181
• 1.13 Checking selector mechanism
  186
• 2 Removing and installing gearbox
  187
• 2.1 Distinguishing between different types of turbo diesel engines
  187
• 2.2 Removing gearbox
  188
• 2.3 Installing gearbox
  295
• 2.4 Specified torques for gearbox
  369
• 3 Assembly mountings
  370
• 3.1 Assembly overview - assembly mountings
  370
• 4 Bevel box
  374
• 4.1 Assembly overview - bevel box
  374
• 4.2 Bevel box differences, Golf and Golf estate
  376
• 4.3 Removing bevel box
  377
• 4.4 Installing bevel box
  390
• 5 Front differential lock
  400
• 5.1 Assembly overview - front differential lock
  400
• 5.2 Allocation of front differential lock
  400
• 5.3 Removing front differential lock
  400
• 5.4 Installing front differential lock
  404
• 6 Transporting gearbox
  408
• 6.1 Transporting gearbox
  408
• 6.2 Transporting front differential lock
  409
• 7 Gear oil
  410
• 7.1 Distinguishing between different manual gearbox types when filling oil
  410
• 7.2 Checking gear oil level
  410
• 8 Securing to engine and gearbox support
  415
• 8.1 Installing manual gearbox to engine and gearbox support
  415
• 8.2 Installing bevel box or front differential lock to engine and gearbox support
  416
• 9 Dismantling and assembling gearbox
  418
• 9.1 Schematic overview - gearbox
  418
• 9.2 Assembly overview - gearbox
  421
• 9.3 Assembly overview - gearbox housing and selector mechanism
  423
• 9.4 Assembly overview - selector unit
  425
• 9.5 Assembly overview - shafts, differential, selector mechanism
  426
• 9.6 Assembly overview - selector forks
  430
• 9.7 Renewing selector shaft seal
  431
• 9.8 Dismantling and assembling gearbox
  433
• 10 Gearbox housing, clutch housing
  458
• 10.1 Assembly overview - gearbox housing
  458
• 10.2 Assembly overview - clutch housing
  460
• 10.3 Repairing gearbox housing
  462
• 10.4 Repairing clutch housing
  472
• Gears, shafts
  476
• 1 Input shaft
  476
• 1.1 Assembly overview - input shaft
  476
• 1.2 Dismantling and assembling input shaft
  477
• 1.3 Renewing input shaft seal
  483
• 2 Output shaft
  485
• 2.1 Assembly overview - output shaft
  485
• 2.2 Dismantling and assembling output shaft
  493
• 2.3 Adjusting output shaft
  554
• Final drive - differential
  566
• 1 Oil seals
  566
• 1.1 Overview of fitting locations - seals
  566
• 1.2 Renewing left seal
  568
• 1.3 Renewing right seal
  572
• 2 Differential
  587
• 2.1 Assembly overview - differential
  587
• 2.2 Dismantling and assembling differential
  592
• 2.3 Adjusting differential
  606
• 3 Adjustment overview
  612
• 4 Components of bevel box
  613
• 4.1 Assembly overview - components of bevel box
  613
• 4.2 Renewing bevel box seals
  619
• 4.3 Renewing output flange and redetermining thickness of shim
  646
• 4.4 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  647
• 5 Components of front differential lock
  652
• 5.1 Assembly overview - components of front differential lock
  652
• 5.2 Checking function
  654
• 5.3 Removing and installing pump V181
  654
• 5.4 Removing and installing coupling for front differential lock
  656
• 5.5 Removing and installing differential lock control unit J647
  656
• 5.6 Renewing seals for front differential lock
  657
• 5.7 Renewing ball bearing for flange shaft
  661
• 6 Gear oil
  664
• 6.1 Checking gear oil level
  664
• 7 Oil for front differential lock
  672
• 7.1 Checking oil level for front differential lock
  672
• 7.2 Draining and filling oil for front differential lock
  673