THE CAR REPAIR SHOP
0
Home » Manuals » 5-Speed manual gearbox 02C four wheel drive
  • Examplepage for repair manual 5-Speed manual gearbox 02C four wheel drive
  • Examplepage for repair manual 2 5-Speed manual gearbox 02C four wheel drive
  • Examplepage for repair manual 3 5-Speed manual gearbox 02C four wheel drive
  • Examplepage for repair manual 5-Speed manual gearbox 02C four wheel drive
  • Examplepage for repair manual 2 5-Speed manual gearbox 02C four wheel drive
  • Examplepage for repair manual 3 5-Speed manual gearbox 02C four wheel drive

5-Speed manual gearbox 02C four wheel drive

For Golf / Golf Variant / Vento

Original Volkswagen repair manual


23,56 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

7.300 KB

298 Sites

Detailed technical data

Immediately readable

This repair manual contains: Servicing clutch control, Removing and installing gearbox, Adjusting input shaft, Renewing bevel box output flange oil seal (bevel box removed), Functional check of free-wheel, Checking rear final drive oil and Dismantling and assembling differential and freewheel (assembly overview). Show more
Secure Payment via PayPal, credit card, direct debit and more
PayPal Logo SEPA Lastschrift Logo Giropay Logo Sofort Überweisung Logo

Repair manual Golf / Golf Variant / Vento 5-Speed manual gearbox 02C four wheel drive 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 Rear final drive identification
    3
  • 2.1 Rear final drive identification
    3
  • 2.2 Code letters, assembly allocation, ratios, capacities
    4
  • 3 Transmission layout
    5
  • 3.1 Transmission layout
    5
  • 4 Calculating overall ratio (i)
    7
  • 4.1 Calculating overall ratio (i)
    7
  • 4.2 Notes on brake and performance tests and towing
    7
  • 5 General repair instructions
    7
  • 5.1 General repair instructions
    7
  • Clutch
    9
  • 1 Servicing clutch control
    9
  • 1.1 Servicing clutch control
    9
  • 1.2 Assembly overview - pedal cluster
    10
  • 1.3 Removing and installing over-centre spring
    14
  • 1.4 Removing and installing clutch pedal
    15
  • 1.5 Assembly overview - hydraulic system
    17
  • 1.6 Removing and installing master cylinder
    20
  • 1.7 Bleeding clutch system
    22
  • 2 Servicing clutch release mechanism
    24
  • 2.1 Servicing clutch release mechanism
    24
  • 3 Servicing clutch
    27
  • 3.1 Servicing clutch
    27
  • Controls, Housing
    32
  • 1 Servicing gear selector mechanism
    32
  • 1.1 Servicing gear selector mechanism
    32
  • 1.2 Installation position of gear selector mechanism
    32
  • 1.3 Removing and installing gear selector cables
    35
  • 1.4 Removing and installing gear stick housing
    41
  • 1.5 Servicing gear stick
    43
  • 1.6 Adjusting gear selector mechanism
    46
  • 2 Removing and installing gearbox
    48
  • 2.1 Removing and installing gearbox
    48
  • 2.2 Removing and installing gearbox and bevel box (Vehicles with 4 cylinder engine)
    48
  • 2.3 Removing and installing gearbox and bevel box (Vehicles with 6 cylinder fuel injection engine)
    59
  • 3 Removing and installing bevel box
    70
  • 3.1 Removing and installing bevel box
    70
  • 3.2 Removing and installing bevel box (Vehicles with 4-cylinder engine)
    70
  • 3.3 Removing and installing bevel box (Vehicles with 6-cylinder injection engine)
    75
  • 4 Checking oil in manual gearbox with bevel box
    80
  • 4.1 Checking oil in manual gearbox with bevel box
    80
  • 5 Dismantling and assembling gearbox
    82
  • 5.1 Dismantling and assembling gearbox
    82
  • 5.2 Removing and installing cover for gearbox housing and 5th gear
    83
  • 5.3 Removing and installing gearbox housing and selector mechanism
    86
  • 5.4 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    88
  • 5.5 Dismantling and assembling sequence
    90
  • 6 Servicing gearbox housing and clutch housing
    107
  • 6.1 Servicing gearbox housing and clutch housing
    107
  • 7 Dismantling and assembling gearbox selector mechanism
    116
  • 7.1 Dismantling and assembling gearbox selector mechanism
    116
  • 8 Dismantling and assembling selector forks
    121
  • 8.1 Dismantling and assembling selector forks
    121
  • Gears, Shafts
    127
  • 1 Dismantling and assembling input shaft
    127
  • 1.1 Dismantling and assembling input shaft
    127
  • 2 Adjusting input shaft
    138
  • 2.1 Adjusting input shaft
    138
  • 2.2 Table of adjustment shims
    139
  • 2.3 Carrying out check measurement
    141
  • 3 Dismantling and assembling output shaft (pinion shaft)
    142
  • 3.1 Dismantling and assembling output shaft (pinion shaft)
    142
  • 4 Adjusting output shaft
    166
  • 4.1 Adjusting output shaft
    166
  • 5 Dismantling and assembling reverse shaft
    169
  • 5.1 Dismantling and assembling reverse shaft
    169
  • Final drive, Differential rear
    173
  • 1.2 Renewing left-hand flange shaft oil seal
    173
  • 1.3 Renewing right-hand drive flange oil seal
    174
  • 2 Renewing bevel box output flange oil seal (bevel box removed)
    175
  • 2.1 Renewing bevel box output flange oil seal (bevel box removed)
    175
  • 3 Dismantling and assembling differential
    177
  • 3.1 Dismantling and assembling differential
    177
  • 4 Adjustment overview
    189
  • 4.1 Adjustment overview
    189
  • 5 Adjusting differential
    189
  • 5.1 Adjusting differential
    189
  • 6 Dismantling and assembling bevel box
    191
  • 6.1 Dismantling and assembling bevel box
    191
  • 6.2 Assembly overview
    192
  • 6.3 Dismantling and assembling sequence
    201
  • 7 Adjusting shaft bevel gear and bevel gear (gear set)
    212
  • 7.1 Adjusting shaft bevel gear and bevel gear (gear set)
    212
  • 7.2 General notes
    212
  • 7.3 Adjusting and marking of gear sets
    212
  • 7.4 Position of shims
    213
  • 7.5 Adjustment overview (bevel box)
    213
  • 7.6 Recommended sequence for adjusting gear set
    214
  • 7.7 Determining shim "S4" thickness when replacing output flange
    214
  • 7.8 Adjusting shaft bevel gear
    215
  • 7.9 Adjusting bevel gear
    221
  • 8 Removing and installing propshaft
    224
  • 8.1 Removing and installing propshaft
    224
  • 9 Servicing propshaft
    228
  • 9.1 Servicing propshaft
    228
  • 10 Checking function of viscous coupling
    236
  • 10.1 Checking function of viscous coupling
    236
  • 11 Removing and installing viscous coupling
    236
  • 11.1 Removing and installing viscous coupling
    236
  • 12 Removing and installing viscous coupling seal
    238
  • 12.1 Removing and installing viscous coupling seal
    238
  • 13 Removing and installing drive flange oil seal (rear final drive)
    238
  • 13.1 Removing and installing drive flange oil seal (rear final drive)
    238
  • 14 Functional check of free-wheel
    240
  • 14.1 Functional check of free-wheel
    240
  • 15 Functional check of free-wheel lock
    240
  • 15.1 Functional check of free-wheel lock
    240
  • 16 Removing and installing rear final drive
    241
  • 16.1 Removing and installing rear final drive
    241
  • 17 Checking rear final drive oil
    244
  • 17.1 Checking rear final drive oil
    244
  • 18 Dismantling and assembling rear final drive
    245
  • 18.1 Dismantling and assembling rear final drive
    245
  • 18.2 Removing viscous coupling and rear axle housing from bevel gear housing
    257
  • 18.3 Servicing shaft bevel gear bearings
    259
  • 18.4 Pressing bevel gear off and on input shaft
    263
  • 18.5 Servicing bevel gear/input shaft bearings
    264
  • 18.6 Servicing differential bearings
    268
  • 18.7 Installing rear axle housing on bevel gear housing and building on viscous coupling
    270
  • 19 Dismantling and assembling differential and freewheel (assembly overview)
    275
  • 19.1 Dismantling and assembling differential and freewheel (assembly overview)
    275
  • 20 Dismantling and assembling differential (sequence)
    279
  • 20.1 Dismantling and assembling differential (sequence)
    279
  • 21 Removing and installing freewheel (sequence)
    280
  • 21.1 Removing and installing freewheel (sequence)
    280
  • 22 Dismantling and assembling freewheel (sequence)
    281
  • 22.1 Dismantling and assembling freewheel (sequence)
    281
  • 23 Adjusting bevel gear and shaft bevel gear (gear set)
    282
  • 23.1 Adjusting bevel gear and shaft bevel gear (gear set)
    282
  • 23.2 General notes
    282
  • 23.3 Adjusting and marking of gear sets
    283
  • 23.4 Position of shims
    284
  • 23.5 Adjustment overview (rear final drive)
    284
  • 23.6 Recommended sequence for adjusting gear set
    285
  • 23.7 Adjusting shaft bevel gear
    285
  • 23.8 Adjusting bevel gear
    289
Manufacturer's designation 5-Speed manual gearbox 02C four wheel drive
Manufacturer Volkswagen
Suitable for Golf / Golf Variant / Vento (1992 - 1999)
Suitable car types 1H
Transmission designations 02C, 02CA
Transmission types AMF, AWR, DDP, CTT, CSR, CDH, CBC, CBB, AYR, ASU, ASY, AWP, END, EUN, EUL, EWL, EWJ, EWG, EWF, EAH, DPU, EAJ, EHQ, FEW, CGL, CZR, GDS, CZP, AME, CGM, CDG, EDR, FEX, EAG, ERW, EWK, EWN
Category Reparaturanleitung

There are no reviews for this product at the moment.

Similar repair manuals

General body repairs

Examplepage for repair manual General body repairs

For Golf / Golf Variant / Vento (1992 - 1999)

15,60 € Details

Body self-diagnosis

Examplepage for repair manual Body self-diagnosis

For Golf / Golf Variant / Vento (1992 - 1999)

5,46 € Details

Digifant injection and ignition system (4-valve)

Examplepage for repair manual Digifant injection and ignition system (4-valve)

For Golf / Golf Variant / Vento (1992 - 1999)

8,41 € Details

Diesel Injection and Glow Plug System

Examplepage for repair manual Diesel Injection and Glow Plug System

For Golf / Golf Variant / Vento (1992 - 1999)

7,13 € Details

4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine)

Examplepage for repair manual 4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine)

For Golf / Golf Variant / Vento (1992 - 1999)

11,89 € Details

Ecomatic Self-diagnosis

Examplepage for repair manual Ecomatic Self-diagnosis

For Golf / Golf Variant / Vento (1992 - 1999)

6,40 € Details

Mono Motronic injection and ignition system

Examplepage for repair manual Mono Motronic injection and ignition system

For Golf / Golf Variant / Vento (1992 - 1999)

9,43 € Details

6-cyl. fuel injection engine Mechanics

Examplepage for repair manual 6-cyl. fuel injection engine Mechanics

For Golf / Golf Variant / Vento (1992 - 1999)

14,65 € Details

Motronic injection and ignition system

Examplepage for repair manual Motronic injection and ignition system

For Golf / Golf Variant / Vento (1992 - 1999)

7,95 € Details

1AV fuel injection and ignition system

Examplepage for repair manual 1AV fuel injection and ignition system

For Golf / Golf Variant / Vento (1992 - 1999)

8,22 € Details

Our Best Sellers

Did you know? We also offer original spare parts.

car part 80B265340S Schlauch

80B265340S

Schlauch

138,22 €

Details
car part 80A820035C Ventil

80A820035C

Ventil

158,75 €

Details
car part 06H103495AJ Abscheider

06H103495AJ

Abscheider

124,53 €

Details
car part 1K0971813B9B9 Abdeckung

1K0971813B9B9

Abdeckung

11,77 €

Details
car part ASE44726700000 Bloecke

ASE44726700000

Bloecke

460,47 €

Details

Heizung, Klimaanlage

Examplepage for repair manual Heizung, Klimaanlage

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

12,76 € Details

Standheizung, Zusatzheizung

Examplepage for repair manual Standheizung, Zusatzheizung

For Touareg (2011) / Touareg FL (2015 > )

6,64 € Details

4-Zyl. Einspritzmotor

Examplepage for repair manual 4-Zyl. Einspritzmotor

For New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)

21,00 € Details

image/svg+xml About Clonck

Original repair manuals und spare parts

Our repair manuals are original, come directly from Volkswagen and meet the highest quality standards.

In our original parts shop we sell high-quality original spare parts from car manufacturers. Use the search function to enter the desired part number (OE number) and order the required spare part quickly and easily.

Highest quality standards

At Clonck, we want to make car mechanics and car professionals happy. That's why you will only find professional and high-quality repair manuals at Clonck that will help you to repair your vehicle professionally.

Our partners

Autohaus Schmidt GmbH
Automag GmbH Filiale Laim
KFZ-VERLAG GmbH
Zimpel und Franke GmbH

Clonck: The car repair shop - also as app!

Clonck App Logo Play Store

Clonck: Fitting car parts for your car repair

4,5 90

With Clonck you can order the right original spare parts in no time.

  • Add your car model
  • Select assembly group
  • Enter vehicle identification number (VIN)
  • Access to over 5,000 original repair manuals
Start app now
Clonck App Preview Car Mobilephone Carparts