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  • Examplepage for repair manual 4 and 5 speed manual gearbox 020/02K
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4 and 5 speed manual gearbox 020/02K

For Caddy Kasten/Kombi / Polo Classic / Polo Variant

Original Volkswagen repair manual


16,40 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

4.251 KB

197 Sites

Detailed technical data

Immediately readable

This repair manual contains: Servicing clutch control, Removing and installing gearbox, Servicing gearbox housing and selector shaft and Adjusting differential. Show more
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Repair manual Caddy Kasten/Kombi / Polo Classic / Polo Variant 4 and 5 speed manual gearbox 020/02K PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Gearbox identification
    1
  • 1.1 Gearbox identification
    1
  • 1.2 Code letters, assembly allocation, ratios, capacities
    2
  • 2 Calculating overall ratio "i"
    5
  • 2.1 Calculating overall ratio "i"
    5
  • 3 Transmission layout
    6
  • 3.1 Transmission layout
    6
  • 4 General repair instructions
    8
  • 4.1 General repair instructions
    8
  • Clutch
    10
  • 1 Servicing clutch control
    10
  • 1.1 Servicing clutch control
    10
  • 1.2 Assembly overview - Pedal cluster mechanical clutch control
    12
  • 1.3 Removing and installing over-centre spring
    15
  • 1.4 Removing and installing clutch pedal
    17
  • 1.5 Assembly overview - Mechanics
    19
  • 1.6 Checking function of clutch cable
    22
  • 1.7 Removing and installing clutch cable
    24
  • 1.8 Assembly overview - Pedal cluster for hydraulically operated clutch
    27
  • 1.9 Removing and installing clutch pedal
    31
  • 1.10 Assembly overview - Hydraulic system
    34
  • 1.11 Removing and installing master cylinder
    38
  • 1.12 Bleeding clutch system
    41
  • 2 Servicing clutch
    42
  • 2.1 Servicing clutch
    42
  • 2.2 Removing and installing clutch
    45
  • Controls, Housing
    48
  • 1 Servicing gear selector mechanism
    48
  • 1.1 Servicing gear selector mechanism
    48
  • 1.2 Installation position of gear selector mechanism
    48
  • 1.3 Assembly overview - Gearstick housing/gearstick
    50
  • 1.4 Installing gear stick gaiter to gear stick knob
    57
  • 1.5 Assembly overview - gear selector relay points at gearbox
    58
  • 1.6 Removing and installing gearstick/selector rod
    63
  • 1.7 Adjusting gear selector mechanism
    65
  • 2 Servicing gearbox housing cover
    69
  • 2.1 Servicing gearbox housing cover
    69
  • 3 Removing and installing gearbox
    75
  • 3.1 Removing and installing gearbox
    75
  • 4 Dismantling and assembling gearbox
    92
  • 4.1 Dismantling and assembling gearbox
    92
  • 4.2 Overview
    92
  • 4.3 Assembly overview
    94
  • 4.4 Removing and installing gearbox housing cover and 5th gear
    95
  • 4.5 Removing and installing gearbox housing and selector mechanism
    98
  • 4.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    101
  • 4.7 Dismantling and assembling sequence
    107
  • 5 Servicing gearbox housing and selector shaft
    127
  • 5.1 Servicing gearbox housing and selector shaft
    127
  • 6 Checking gearbox oil
    133
  • 6.1 Checking gearbox oil
    133
  • 7 Servicing clutch housing
    134
  • 7.1 Servicing clutch housing
    134
  • Gears, Shafts
    143
  • 1 Dismantling and assembling input shaft
    143
  • 1.1 Dismantling and assembling input shaft
    143
  • 2 Dismantling and assembling output shaft
    156
  • 2.1 Dismantling and assembling output shaft
    156
  • 2.2 Allocating output shafts
    169
  • 3 Adjusting output shaft
    170
  • 3.1 Adjusting output shaft
    170
  • Final drive, Differential
    174
  • 1 Removing and installing drive flange oil seal
    174
  • 1.1 Removing and installing drive flange oil seal
    174
  • 2 Dismantling and assembling differential
    177
  • 2.1 Dismantling and assembling differential
    177
  • 3 Adjusting differential
    190
  • 3.1 Adjusting differential
    190
  • 4 Adjustment overview
    193
  • 4.1 Adjustment overview
    193
Manufacturer's designation 4 and 5 speed manual gearbox 020/02K
Manufacturer Volkswagen
Suitable for Caddy Kasten/Kombi (1996 - 2003) / Polo Classic / Polo Variant (1996 - 2002)
Suitable car types 9K, 6V
Transmission designations 020, 02K, 02KA
Transmission types 2Y, 3R, 4R, 5B, AUG, ATH, APW, AON, AMC, AGS, AGB, 9A, EJP, DFN, DDR, CYY, CYX, CRY, CQB, CHE, CHD, CHC, CDJ, CBS, AWY, AVX, AEN, ACD, 4T, 4S, AVZ, CYW, CYZ, DGH, DDG, DGD, AOP, CHB, DFW, STD, DFZ, DFP, DFQ, DFR, DFX, DGE, DGK, DGT, DMM, DXY, EJR, EJS, EJT, HBN, FVW, EJH, EAZ, EAY, DUW, DUV, DUU, DUS, DSB, DRZ, ERT, DNZ, DLP, CZE, DRY, DUT, CZD, CHV, CZA, CZK, DGL, DGM, EJL, EJN, CHW, CJF, FFZ, DQF, MWN, DGF, DGG
Category Reparaturanleitung

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