6-speed manual gearbox 02S

Kapitelübersicht

• Technical data
  1
• 1 Identification
  1
• 1.1 Gearbox identification
  1
• 2 Identification codes, assembly allocation, ratios and capacities
  2
• 2.1 Identification codes, assembly allocation, ratios and capacities, Golf 2004 ►
  2
• 2.2 Identification codes, assembly allocation, ratios and capacities, Golf 2009 ►
  5
• 2.5 Identification codes, assembly allocation and capacities, Passat 2006 ►
  9
• 2.6 Identification code, assembly allocation, transmission ratios and capacities, Passat 2011 ►
  10
• 2.7 Identification codes, assembly allocation, gear ratios and capacities, Passat CC 2009 ►
  11
• 2.8 Identification codes, assembly allocation, gear ratios and capacities, CC 2010 ►
  12
• 2.9 Identification codes, assembly allocation and capacities, Eos 2006 ►
  13
• 2.11 Calculating overall gear ratio “i”
  14
• 3 Overview - power transmission
  15
• 4 General repair instructions
  17
• 5 Safety precautions
  20
• 5.1 Safety precautions for vehicles with a start-stop system
  20
• Clutch
  21
• 1 Clutch operation
  21
• 1.1 Overview - clutch actuation
  21
• 1.2 Assembly overview - pedal cluster
  23
• 1.3 Removing and installing over-centre spring
  25
• 1.4 Removing and installing clutch pedal
  45
• 1.5 Removing and installing mounting bracket
  48
• 1.6 Removing and installing master cylinder
  77
• 1.7 Removing and installing clutch position sender G476
  79
• 1.8 Assembly overview - hydraulics (LHD)
  82
• 1.9 Assembly overview - hydraulics (RHD)
  84
• 1.10 Removing and installing slave cylinder
  85
• 1.11 Bleeding clutch system
  87
• 2 Clutch release mechanism
  89
• 2.1 Assembly overview - clutch release mechanism
  89
• 2.2 Repairing clutch release mechanism
  90
• 3 Clutch
  91
• 3.1 Clutch in connection with dual mass flywheel
  91
• 3.2 Clutch in connection with simple flywheel
  99
• Controls, housing
  103
• 1 Selector mechanism
  103
• 1.1 Installation position of selector mechanism
  103
• 1.2 Overview - selector mechanism
  104
• 1.3 Assembly overview - gear knob and cover
  104
• 1.4 Removing and installing gear knob with gaiter and noise insulation
  106
• 1.5 Assembly overview - Gear lever and selector housing
  111
• 1.6 Dismantling and assembling selector mechanism (from 11.06)
  114
• 1.7 Assembly overview - Selector cables
  119
• 1.8 Removing and installing selector mechanism
  127
• 1.9 Adjusting selector mechanism
  131
• 2 Removing and installing gearbox
  135
• 2.1 Removing and installing gearbox, Golf 2004 ►
  135
• 2.2 Removing and installing gearbox, Golf 2009 ► with 1.4 l engine
  149
• 2.3 Removing and installing gearbox, Golf 2009 ► with 1.8 l engine
  166
• 2.4 Removing and installing gearbox, Golf Plus 2005 ►
  184
• 2.5 Removing and installing gearbox, Golf Plus 2009 ►
  199
• 2.6 Removing and installing gearbox, Passat 2006 ►
  216
• 2.7 Removing and installing gearbox, Passat 2011 ► with turbo diesel engine
  231
• 2.10 Removing and installing gearbox, Eos
  280
• 2.11 Removing and installing gearbox - Scirocco
  294
• 3 Transporting gearbox
  312
• 4 Assembly overview - assembly mountings
  313
• 5 Gear oil
  315
• 5.1 Checking and topping up gear oil
  315
• 6 Dismantling and assembling gearbox
  318
• 6.1 Overview - gearbox
  318
• 6.2 Overview - dismantling and assembling gearbox
  319
• 6.7 Assembly sequence - Dismantling and assembling gearbox completely
  331
• 7 Gearbox housing and clutch housing
  352
• 7.1 Assembly overview - gearbox housing and clutch housing
  352
• 7.2 Repairing gearbox housing and clutch housing
  354
• 8 Gearbox housing cover
  363
• 8.1 Assembly overview - gearbox housing cover
  363
• 8.2 Repairing gearbox housing cover
  364
• 9 Selector unit
  367
• 9.1 Assembly overview - selector unit
  367
• 9.2 Repairing selector unit
  369
• 10 Selector forks
  371
• 10.1 Assembly overview - selector forks in connection with reverse synchromeshed gear arrow
  371
• 10.2 Assembly overview - selector forks in connection with reverse gear locking collar arrow
  372
• 10.3 Repairing selector forks
  374
• Gears, shafts
  378
• 1 Input shaft
  378
• 1.1 Assembly overview - input shaft
  378
• 1.2 Dismantling and assembling input shaft
  380
• 1.3 Adjusting input shaft
  386
• 1.4 Renewing input shaft seal
  391
• 2 Output shaft
  393
• 2.1 Assembly overview - output shaft
  393
• 2.2 Dismantling and assembling output shaft
  396
• 2.3 Adjusting output shaft
  406
• 3 Reverse shaft
  411
• 3.1 Assembly overview - reverse shaft with reverse synchromeshed gear arrow
  411
• 3.2 Assembly overview - reverse shaft with reverse gear locking collar arrow
  412
• 3.3 Dismantling and assembling reverse shaft
  414
• Final drive - differential
  417
• 1 Oil seals
  417
• 1.1 Renewing left flange shaft oil seal with gearbox installed
  417
• 1.2 Distinguishing seals for right flange shaft
  419
• 2 Adjustment overview
  426
• 3 Differential
  427
• 3.1 Assembly overview - differential
  427
• 3.2 Dismantling and assembling differential
  429
• 3.3 Adjusting differential
  434