6-speed manual gearbox 02Q

Kapitelübersicht

• Technical data
  1
• 1 Front-wheel drive - gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Front-wheel drive - identification codes, assembly allocation, Golf 2004 ►
  2
• 1.3 Front-wheel drive - identification codes, assembly allocation, Golf 2009 ►
  4
• 1.4 Identification codes, assembly allocation, Golf Plus 2005 ►
  6
• 1.5 Identification codes, assembly allocation, Golf Plus 2009 ►
  7
• 1.6 Front-wheel drive - identification codes, assembly allocation, Passat 2006 ►
  8
• 1.7 Identification codes, engine allocation, Passat CC 2009 ►
  11
• 1.8 Front-wheel drive, identification codes, assembly allocation, CC 2010 ►
  12
• 1.9 Identification codes, assembly allocation, Eos 2006 ►
  14
• 1.10 Identification codes, engine allocation, Touran 2003 ►
  16
• 2 All-wheel drive - gearbox identification
  19
• 2.1 Location on gearbox
  19
• 2.2 All-wheel drive - identification codes, assembly allocation, Golf 2004 ►
  20
• 2.3 All-wheel drive - identification codes, assembly allocation, Golf 2009 ►
  23
• 2.4 All-wheel drive - identification codes, assembly allocation, Passat 2006 ►
  24
• 2.5 All-wheel drive, identification codes, assembly allocation, CC 2010 ►
  25
• 3 Capacities
  26
• 3.1 Capacity, manual gearbox
  26
• 3.2 Capacity, bevel box
  26
• 4 Front-wheel drive - Overview power transmission
  27
• 5 Overview - all-wheel drive power train
  29
• 6 Calculating overall gear ratio “i”
  31
• 7 All-wheel drive - notes on performance test
  32
• 8 General repair instructions
  33
• 8.1 Special tool
  33
• 8.2 Gearbox
  33
• 8.3 Gaskets and seals
  33
• 8.4 Sealant
  33
• 8.5 Locking devices
  34
• 8.6 Nuts and bolts
  34
• 8.7 Bearings
  34
• 8.8 Shims
  34
• 8.9 Synchro-rings
  35
• 8.10 Gear wheels
  35
• 8.11 Synchromeshed gears
  35
• 8.12 Clutch
  35
• 9 Safety precautions for vehicles with a start-stop system
  36
• Clutch
  37
• 1 Repairing clutch mechanism
  37
• 1.1 Overview
  37
• 1.4 Removing and installing over-centre spring
  41
• 1.6 Removing and installing clutch pedal
  63
• 1.7 Removing and installing mounting bracket, Golf 2004 ►
  66
• 1.8 Removing and installing mounting bracket, Golf 2009 ► LHD
  72
• 1.9 Removing and installing mounting bracket, Golf Plus left-hand drive
  77
• 1.11 Removing and installing master cylinder
  89
• 1.12 Assembly overview - hydraulics (LHD)
  91
• 1.13 Assembly overview - hydraulics (RHD)
  93
• 1.14 Touran: Removing and installing clutch pedal switch F36
  95
• 1.15 Removing and installing mounting bracket (all Tourans)
  96
• 1.16 Touran: removing and installing master cylinder with mounting bracket removed (to 05.03)
  104
• 1.17 Removing and installing mounting bracket, Passat, Passat CC and CC
  106
• 1.18 Removing and installing mounting bracket, Eos
  110
• 2 Removing and installing clutch position sender G476
  115
• 2.1 Removing
  115
• 2.2 Installing
  117
• 3 Bleeding clutch system
  119
• 4 Repairing clutch release mechanism
  121
• 4.1 Assembly overview
  121
• 4.2 Removing line and bleeder from and installing on slave cylinder
  122
• 4.3 Removing and installing slave cylinder with release bearing
  123
• 4.4 Removing and installing line for clutch mechanism
  124
• 5 Repairing clutch, in conjunction with dual-mass flywheel
  127
• 2.0 l - 103 kW turbo diesel engine)
  128
• 5.2 Removing and installing “Sachs” clutch
  129
• 5.3 Repairing “Sachs” clutch
  131
• 5.4 Removing and installing “LuK” clutch
  132
• 5.5 Repairing LuK clutch
  135
• 6 Repairing clutch, in conjunction with one-piece flywheel
  137
• Controls, housing
  140
• 1 Repairing selector mechanism
  140
• 1.1 Installation position of selector mechanism
  140
• 1.2 Overview of selector mechanism
  141
• 1.3 Assembly overview - gear knob and cover
  141
• 1.5 Removing and installing gaiter with gear knob and noise insulation, Golf Plus
  144
• 1.6 Removing and installing gaiter with gear knob, Touran
  146
• 1.8 Repairing gear lever and selector housing (to 10.06)
  149
• 1.9 Repairing gear lever and selector housing (from 11.06)
  151
• 1.10 Assembly overview - removing and installing selector cables
  156
• 1.11 Removing and installing selector mechanism
  161
• 1.12 Adjusting selector mechanism
  167
• 1.13 Checking selector mechanism
  169
• 3 Touran, identifying gearbox for removal and installation
  174
• 4.1 Removing gearbox
  177
• 4.2 Installing gearbox
  183
• 6.1 Removing gearbox
  194
• 6.2 Installing gearbox
  204
• 7.1 Removing gearbox
  215
• 7.2 Installing gearbox
  223
• 8 Removing and installing gearbox, Golf 2004 ► front-wheel drive
  233
• 8.1 Removing gearbox
  235
• 8.2 Installing gearbox
  243
• 9 Removing and installing gearbox, Golf 2009 ► front-wheel drive with turbo diesel engine
  252
• 9.1 Removing gearbox
  255
• 9.2 Installing gearbox
  263
• 10 Removing and installing gearbox, Golf 2009 ► front-wheel drive with petrol engine
  272
• 10.1 Removing gearbox
  275
• 10.2 Installing gearbox
  283
• 11 Removing and installing gearbox, Golf 2004 ► all-wheel drive
  292
• 11.1 Removing and installing gearbox in vehicles with turbo diesel engine
  292
• 11.2 Removing and installing gearbox, vehicles with 6-cylinder petrol engine
  311
• 12 Removing and installing gearbox, Golf 2009 ► all-wheel drive
  331
• 12.1 Removing gearbox
  334
• 12.2 Installing gearbox
  344
• 13 Removing and installing gearbox, Golf Plus 2005 ►
  355
• 13.1 Removing gearbox
  357
• 13.2 Installing gearbox
  366
• 14 Removing and installing gearbox, Golf Plus 2009 ►
  375
• 14.1 Removing gearbox
  378
• 14.2 Installing gearbox
  388
• 15 Removing and installing gearbox, Passat 2006 ► front-wheel drive
  397
• 15.1 Removing gearbox
  398
• 15.2 Installing gearbox
  407
• 16 Removing and installing gearbox, Passat 2006 ► all-wheel drive
  416
• 16.1 Removing gearbox
  417
• 16.2 Installing gearbox
  426
• 17.1 Removing gearbox
  439
• 17.2 Installing gearbox
  448
• 18.1 Removing gearbox
  458
• 18.2 Installing gearbox
  467
• 19 Removing and installing gearbox, CC all-wheel drive
  476
• 19.1 Removing gearbox
  479
• 19.2 Installing gearbox
  488
• 20 Removing and installing gearbox, Eos
  500
• 20.1 Removing gearbox
  502
• 20.2 Installing gearbox
  510
• 21 Transporting gearbox
  518
• 21.1 Front-wheel drive - transporting gearbox
  518
• 21.2 All-wheel drive - transporting gearbox
  518
• 22 Securing to engine and gearbox support
  520
• 23 Gear oil
  522
• 23.1 Distinguishing between different manual gearbox types when filling oil
  522
• 23.2 Checking gear oil level
  522
• 24.1 Removing bevel box
  527
• 24.2 Installing bevel box
  532
• 25.1 Removing bevel box
  538
• 25.2 Installing bevel box
  543
• 26.1 Removing bevel box
  546
• 26.2 Installing bevel box
  550
• 27 Checking or topping up gear oil in bevel box
  553
• 27.1 Checking gear oil in bevel box
  554
• 27.2 Topping up gear oil in bevel box
  554
• 28 Dismantling and assembling gearbox
  558
• 28.1 Overview - gearbox, front-wheel drive, Golf 2004 ► and Touran
  558
• 28.3 Overview - gearbox, all-wheel drive
  560
• 28.4 Assembly overview - front-wheel drive
  561
• 28.5 Assembly overview - all-wheel drive
  562
• 28.6 Assembly overview - removing and installing gearbox housing and selector unit
  563
• 28.10 Installation position of shafts and selector rods in gearbox
  570
• 28.11 Assembly order, gearbox »without« circlip A for input shaft cover made from sheet metal
  570
• 29 Repairing gearbox housing
  602
• 30 Front-wheel drive - repairing clutch housing
  613
• 31 four-wheel drive - repairing clutch housing
  617
• 32 Repairing selector unit
  621
• 32.1 Renewing selector shaft seal
  622
• 33 Repairing selector forks
  624
• Gears, shafts
  627
• 1 Input shaft
  627
• 1.1 Assembly overview - input shaft
  627
• 1.2 Dismantling and assembling input shaft
  629
• 1.3 Renewing input shaft seal
  634
• 2 Output shaft for 1st to 4th gears
  636
• 2.1 Assembly overview - output shaft for 1st to 4th gears
  636
• 2.2 Dismantling and assembling output shaft for 1st to 4th gears
  638
• 2.3 Adjusting output shaft for 1st to 4th gears
  660
• 3 Output shaft for 5th and 6th gears and reverse gear
  665
• 3.1 Assembly overview - output shaft for 5th, 6th and reverse gears
  665
• 3.2 Dismantling and assembling output shaft for 5th, 6th and reverse gears
  667
• 3.3 Adjusting output shaft for 5th, 6th and reverse gears
  676
• Final drive - differential
  682
• 1.1 Renewing oil seal for left flange shaft
  682
• 1.2 Identifying gearbox to renew right oil seal, Golf and Touran
  684
• 1.3 Renewing stub shaft seal - Golf and Touran to gearbox manufacture date 31 10 4
  685
• 01 11 4, Golf Plus, Passat, Passat CC, Eos
  686
• 2.1 Renewing oil seal for left flange shaft
  689
• 2.2 Renewing seal for right flange shaft
  689
• 3 Renewing seal between gearbox and bevel box, in gearbox
  692
• 5 Renewing seal between gearbox and bevel box with bevel box removed
  696
• 6 Renewing bevel box output flange oil seal (bevel box removed)
  698
• 7 Renewing output flange and redetermining thickness of shim (bevel box removed)
  708
• 8 Renewing polygon needle bearing and seal on right flange shaft
  709
• 8.1 Removing
  710
• 8.2 Installing
  711
• 9 Adjustment overview - manual gearbox
  713
• 10 Differential
  714
• 10.1 Front-wheel drive - dismantling and assembling differential
  714
• 10.2 All-wheel drive - dismantling and assembling differential
  721
• 10.3 Adjusting differential
  728