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  • Examplepage for repair manual 5-speed manual gearbox 02D four-wheel drive
  • Examplepage for repair manual 2 5-speed manual gearbox 02D four-wheel drive
  • Examplepage for repair manual 3 5-speed manual gearbox 02D four-wheel drive
  • Examplepage for repair manual 5-speed manual gearbox 02D four-wheel drive
  • Examplepage for repair manual 2 5-speed manual gearbox 02D four-wheel drive
  • Examplepage for repair manual 3 5-speed manual gearbox 02D four-wheel drive

5-speed manual gearbox 02D four-wheel drive

For Transporter Caravelle / Transporter Doppelkab / Transporter Kasten / Transporter Kombi/Cam / Transporter Pritsche

Original Volkswagen repair manual


33,33 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

9.176 KB

455 Sites

Detailed technical data

Immediately readable

This repair manual contains: Servicing clutch control, Removing and installing operating elements for differential lock and freewheel, Differential and freewheel pipes and hoses routing diagram, Checking oil in manual gearbox with bevel box, Adjusting input shaft and Renewing bevel box output flange seal. Show more
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Repair manual 5-speed manual gearbox 02D 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, gearbox allocation, ratios, capacities
    2
  • 2 Rear final drive identification
    7
  • 2.1 Rear final drive identification
    7
  • 2.2 Code letters, assembly allocation, ratios, capacities
    8
  • 3 Transmission layout
    12
  • 3.1 Transmission layout
    12
  • 4 Calculating overall ratio "i"
    14
  • 4.1 Calculating overall ratio "i"
    14
  • 5 Notes on performance test, brake test and towing
    14
  • 5.1 Notes on performance test, brake test and towing
    14
  • 6 General repair instructions
    14
  • 6.1 General repair instructions
    14
  • Clutch
    17
  • 1 Servicing clutch control
    17
  • 1.1 Servicing clutch control
    17
  • 1.2 Assembly overview - Pedal cluster - Hydraulic clutch control
    19
  • 1.3 Removing and installing clutch pedal - Hydraulic clutch control
    22
  • 1.4 Assembly overview - Hydraulic system
    23
  • 1.5 Removing and installing slave cylinder for vehicles with short front end
    26
  • 1.6 Removing and installing slave cylinder for vehicles with long front end
    30
  • 1.7 Bleeding clutch system
    33
  • 1.8 Assembly overview - Pedal cluster - Mechanical clutch control
    34
  • 1.9 Removing and installing over-centre spring
    37
  • 1.10 Removing and installing clutch pedal - Mechanical clutch control
    38
  • 1.11 Assembly overview - Mechanics
    39
  • 1.12 Removing and installing clutch cable
    43
  • 2 Servicing clutch release mechanism
    46
  • 2.1 Servicing clutch release mechanism
    46
  • 3 Servicing clutch
    49
  • 3.1 Servicing clutch
    49
  • Controls, Housing
    56
  • 1 Servicing gear selector mechanism
    56
  • 1.1 Servicing gear selector mechanism
    56
  • 1.2 Installation position of gear selector mechanism
    56
  • 1.3 Removing and installing gear stick housing
    58
  • 1.4 Removing and installing gear stick
    61
  • 1.5 Removing and installing selector and gate rods
    64
  • 1.6 Removing and installing selector mechanism
    73
  • 1.7 Adjusting gear selector mechanism
    76
  • 2 Removing and installing operating elements for differential lock and freewheel
    78
  • 2.1 Removing and installing operating elements for differential lock and freewheel
    78
  • 2.2 Removing and installing valve for operating differential lock and warning light
    78
  • 2.3 Removing and installing actuator for differential lock
    79
  • 2.4 Adjusting differential lock
    80
  • 2.5 Removing and installing actuator for freewheel lock
    80
  • 3 Differential and freewheel pipes and hoses routing diagram
    82
  • 3.1 Differential and freewheel pipes and hoses routing diagram
    82
  • 3.2 Routing diagram for vehicles with petrol engine
    83
  • 3.3 Routing diagram for vehicles with diesel engine
    95
  • 4 Removing and installing gearbox
    104
  • 4.1 Removing and installing gearbox
    104
  • 4.2 Differences between Transporter with long and short front end from 01.96
    105
  • 4.3 Removing and installing gearbox for vehicles with short front end
    106
  • 4.4 Removing and installing gearbox on vehicles with long front end
    129
  • 5 Removing and installing bevel box
    146
  • 5.1 Removing and installing bevel box
    146
  • 6 Checking oil in manual gearbox with bevel box
    153
  • 6.1 Checking oil in manual gearbox with bevel box
    153
  • 7 Dismantling and assembling gearbox
    155
  • 7.1 Dismantling and assembling gearbox
    155
  • 7.2 Assembly overview
    155
  • 7.3 Removing and installing cover for gearbox housing and 5th gear
    156
  • 7.4 Removing and installing gearbox housing and selector mechanism
    159
  • 7.5 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    161
  • 7.6 Assembly sequence
    164
  • 8 Servicing gearbox housing
    180
  • 8.1 Servicing gearbox housing
    180
  • 9 Servicing clutch housing
    184
  • 9.1 Servicing clutch housing
    184
  • 10 Dismantling and assembling gearbox selector mechanism
    192
  • 10.1 Dismantling and assembling gearbox selector mechanism
    192
  • 11 Dismantling and assembling selector forks
    197
  • 11.1 Dismantling and assembling selector forks
    197
  • Gears, Shafts
    204
  • 1 Dismantling and assembling input shaft
    204
  • 1.1 Dismantling and assembling input shaft
    204
  • 2 Adjusting input shaft
    216
  • 2.1 Adjusting input shaft
    216
  • 2.2 Table of adjustment shims
    218
  • 2.3 Performing measurement check
    220
  • 3 Dismantling and assembling output shaft (pinion shaft)
    221
  • 3.1 Dismantling and assembling output shaft (pinion shaft)
    221
  • 4 Adjusting output shaft
    250
  • 4.1 Adjusting output shaft
    250
  • 5 Dismantling and assembling reverse shaft
    253
  • 5.1 Dismantling and assembling reverse shaft
    253
  • Final drive, Differential rear
    259
  • 1 Removing and installing seal for drive flange or flange shaft
    259
  • 1.1 Removing and installing seal for drive flange or flange shaft
    259
  • 1.2 Removing and installing oil seal for left-hand flanged shaft
    259
  • 1.3 Removing and installing oil seal for right drive flange
    263
  • 2 Renewing bevel box output flange seal
    267
  • 2.1 Renewing bevel box output flange seal
    267
  • 3 Dismantling and assembling differential
    269
  • 3.1 Dismantling and assembling differential
    269
  • 4 Adjustment overview
    283
  • 4.1 Adjustment overview
    283
  • 5 Adjusting differential
    284
  • 5.1 Adjusting differential
    284
  • 6 Dismantling and assembling bevel box
    286
  • 6.1 Dismantling and assembling bevel box
    286
  • 6.2 Assembly overview
    287
  • 6.3 Dismantling and assembling sequence
    295
  • 7 Adjusting shaft bevel gear and bevel gear (gear set)
    309
  • 7.1 Adjusting shaft bevel gear and bevel gear (gear set)
    309
  • 7.2 General notes
    309
  • 7.3 Adjusting and marking of gear sets
    310
  • 7.4 Position of shims
    313
  • 7.5 Adjustment overview (bevel box)
    313
  • 7.6 Determining shaft bevel gear installation position (actual measurement)
    314
  • 7.7 Recommended sequence for adjusting gear set
    314
  • 7.8 Determining shim "S4" thickness when replacing output flange
    315
  • 7.9 Adjusting shaft bevel gear
    316
  • 7.10 Adjusting bevel gear
    321
  • 8 Removing and installing 2-section propshaft
    324
  • 8.1 Removing and installing 2-section propshaft
    324
  • 8.2 Removing and installing 2-part propshaft underfloor mountings
    327
  • 9 Removing and installing 3-section propshaft
    328
  • 9.1 Removing and installing 3-section propshaft
    328
  • 9.2 Removing and installing 3-section propshaft underfloor mounting
    331
  • 10 Servicing 2-section propshaft
    335
  • 10.1 Servicing 2-section propshaft
    335
  • 11 Servicing 3-section propshaft
    348
  • 11.1 Servicing 3-section propshaft
    348
  • 12 Checking function of viscous coupling
    362
  • 12.1 Checking function of viscous coupling
    362
  • 13 Removing and installing viscous coupling
    363
  • 13.1 Removing and installing viscous coupling
    363
  • 15 Removing and installing flange shaft or drive flange oil seal (final drive installed)
    366
  • 15.1 Removing and installing flange shaft or drive flange oil seal (final drive installed)
    366
  • 15.2 Renewing right-hand flange shaft oil seal
    366
  • 15.3 Renewing left drive flange seal
    369
  • 16 Functional check of freewheel
    373
  • 16.1 Functional check of freewheel
    373
  • 17 Functional check of freewheel lock
    373
  • 17.1 Functional check of freewheel lock
    373
  • 18 Removing and installing rear final drive
    374
  • 18.1 Removing and installing rear final drive
    374
  • 19 Checking rear final drive oil
    377
  • 19.1 Checking rear final drive oil
    377
  • 20 Dismantling and assembling rear final drive
    378
  • 20.1 Dismantling and assembling rear final drive
    378
  • 20.2 Removing and installing viscous coupling and pinion housing
    379
  • 20.3 Removing and installing differential lock and freewheel lock
    381
  • 20.4 Removing and installing input shaft bevel gear and differential lock control
    386
  • 20.5 Assembly sequence
    390
  • 21 Dismantling and assembling differential and freewheel (assembly overview)
    401
  • 21.1 Dismantling and assembling differential and freewheel (assembly overview)
    401
  • 22 Dismantling and assembling differential (assembly sequence)
    405
  • 22.1 Dismantling and assembling differential (assembly sequence)
    405
  • 23 Removing and installing freewheel (sequence)
    409
  • 23.1 Removing and installing freewheel (sequence)
    409
  • 24 Dismantling and assembling freewheel (sequence)
    410
  • 24.1 Dismantling and assembling freewheel (sequence)
    410
  • 25 Servicing shaft bevel gear bearings
    411
  • 25.1 Servicing shaft bevel gear bearings
    411
  • 25.2 Assembly overview
    411
  • 25.3 Assembly sequence
    413
  • 26 Servicing input shaft bevel gear bearings
    419
  • 26.1 Servicing input shaft bevel gear bearings
    419
  • 26.2 Assembly overview
    419
  • 26.3 Assembly sequence
    427
  • 27 Dismantling and assembling differential lock controls
    434
  • 27.1 Dismantling and assembling differential lock controls
    434
  • 28 Adjusting bevel gear and shaft bevel gear (gear set)
    436
  • 28.1 Adjusting bevel gear and shaft bevel gear (gear set)
    436
  • 28.2 General notes
    436
  • 28.3 Adjusting and marking of gear sets
    436
  • 28.4 Position of shims
    439
  • 28.5 Adjustment overview (rear final drive)
    439
  • 28.6 Determining shaft bevel gear installation position (actual measurement)
    440
  • 28.7 Recommended sequence for adjusting gear set
    440
  • 28.8 Adjusting shaft bevel gear
    441
  • 28.9 Adjusting bevel gear
    446
Manufacturer's designation 5-speed manual gearbox 02D four-wheel drive
Manufacturer Volkswagen
Suitable for Transporter Caravelle / Transporter Doppelkab / Transporter Kasten / Transporter Kombi/Cam / Transporter Pritsche (1991 - 1996)
Suitable car types 70
Transmission designations 02DB, 02DC, 02DE, 02DF
Transmission types ARF, CLY, ARL, CLZ, DQV, CLW, CLX, CRV, CRW, DCY, EWD, EWC, DQP, DQN, DCZ, CTV, DDA, DQQ, EWE
Category Reparaturanleitung

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