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

5-speed manual gearbox 02G, four-wheel drive

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

Original Volkswagen repair manual


22,95 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

7.213 KB

289 Sites

Detailed technical data

Immediately readable

This repair manual contains: Repairing clutch mechanism, Removing and installing gearbox and bevel box, Input shaft, Checking function of viscous coupling, Renewing viscous coupling seal in rear final drive (final drive installed), Adjustment overview and Differential. Show more
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Repair manual 5-speed manual gearbox 02G, four-wheel drive PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Identification of gearbox
    1
  • 1.1 Location on gearbox
    1
  • 1.2 Code letters, allocation, ratios, capacities
    1
  • 2 Identifying rear final drive
    3
  • 2.1 Location on final drive
    3
  • 2.2 Code letters, allocation, ratios, capacities
    3
  • 3 Overview - power transmission
    5
  • 4 Calculating overall gear ratio “i”
    7
  • 5 Notes on performance test
    8
  • 6 General repair instructions
    9
  • 6.1 Components
    9
  • Clutch
    11
  • 1 Repairing clutch mechanism
    11
  • 1.1 Assembly overview - pedal cluster
    12
  • 1.2 Removing and installing clutch pedal
    13
  • 1.3 Assembly overview - hydraulics and clutch release mechanism
    13
  • 1.4 Removing and installing over-centre spring
    15
  • 1.5 Bleeding clutch system
    16
  • 2 Repairing clutch
    18
  • Controls, housing
    21
  • 1 Repairing selector mechanism
    21
  • 1.1 Installation position of selector mechanism
    21
  • 1.2 Removing and installing selector housing
    23
  • 1.3 Removing and installing gear selector rod and gate selector rod
    24
  • 1.4 Removing and installing gear lever
    30
  • 1.5 Removing and installing cover for selector housing
    32
  • 1.6 Removing and installing selector mechanism
    33
  • 1.7 Adjusting selector mechanism
    35
  • 1.8 Installation position of selector mechanism
    37
  • 1.9 Removing and installing selector housing
    39
  • 1.10 Removing and installing gear selector rod and gate selector rod
    40
  • 1.11 Removing and installing gear lever
    42
  • 1.12 Removing and installing selector mechanism
    44
  • 1.13 Adjusting selector mechanism
    46
  • 2.2 Removing and installing control element for differential lock
    50
  • 2.3 Adjusting differential lock
    51
  • 2.4 Removing and installing control element for freewheel lock
    51
  • 3.1 Routing diagram for vehicles with diesel engine
    54
  • 4 Removing and installing gearbox and bevel box
    60
  • 4.1 Removing
    62
  • 4.2 Transporting gearbox
    67
  • 4.3 Installing
    68
  • 5 Removing and installing bevel box
    72
  • 5.1 Removing
    72
  • 5.2 Installing
    75
  • 6 Checking oil in manual gearbox with bevel box
    77
  • 7 Dismantling and assembling gearbox
    78
  • 7.1 Assembly overview
    78
  • 7.2 Dismantling and assembling gearbox housing and selector mechanism
    80
  • 7.4 Assembly procedure
    82
  • 8 Repairing gearbox housing
    88
  • 9 Repairing clutch housing
    93
  • 10 Dismantling and assembling selector mechanism in gearbox
    99
  • Gears, shafts
    102
  • 1 Input shaft
    102
  • 1.1 Dismantling and assembling input shaft
    102
  • 1.2 Adjusting input shaft
    109
  • 2 Output shaft
    114
  • 2.1 Dismantling and assembling output shaft
    114
  • 2.2 Adjusting output shaft
    128
  • 3 Removing and installing gear wheel for reverse gear
    133
  • Final drive - rear differential
    136
  • 1 Two-part propshaft
    136
  • 1.1 Removing and installing two-part propshaft
    136
  • 1.2 Removing and installing two-part propshaft support on underbody
    138
  • 1.3 Repairing two-part propshaft
    138
  • 2 Three-part propshaft
    146
  • 2.1 Removing and installing three-part propshaft
    146
  • 2.2 Removing and installing three-part propshaft supports on underbody
    148
  • 2.3 Repairing three-part propshaft
    150
  • 3 Checking function of viscous coupling
    159
  • 4 Removing and installing viscous coupling
    160
  • 4.1 Removing
    160
  • 4.2 Installing
    161
  • 5 Renewing viscous coupling seal in rear final drive (final drive installed)
    163
  • 6 Renewing flange shaft or drive flange oil seals (final drive installed)
    164
  • 6.1 Renewing seal for right flange shaft
    164
  • 6.2 Renewing left drive flange oil seal
    165
  • 7 Checking function of freewheel
    169
  • 8 Checking function of freewheel lock
    170
  • 9 Removing and installing rear final drive
    171
  • 9.1 Removing
    171
  • 9.2 Installing
    172
  • 10 Checking gear oil in rear final drive
    174
  • 11 Dismantling and assembling rear final drive
    175
  • 11.1 Removing and installing viscous coupling and pinion housing
    176
  • 11.2 Removing and installing differential and freewheel lock
    177
  • 11.4 Assembly procedure
    180
  • 12 Dismantling and assembling differential and freewheel
    189
  • 12.1 Assembly overview
    189
  • 12.2 Dismantling and assembling differential (procedure)
    191
  • 12.3 Removing and installing freewheel (procedure)
    194
  • 12.4 Dismantling and assembling freewheel (procedure)
    195
  • 13 Repairing shaft bevel gear bearing
    197
  • 13.1 Assembly overview
    197
  • 13.2 Assembly procedure
    198
  • 14 Repairing bearing for bevel gear with stub shaft
    203
  • 14.1 Assembly overview
    203
  • 14.2 Assembly procedure
    207
  • 15 Dismantling and assembling differential lock control
    214
  • 16.1 General information
    215
  • 16.2 Adjustment and marking of final drive gear sets
    215
  • 16.3 Position of shims
    216
  • 16.4 Adjustment overview - rear final drive
    216
  • 16.5 Determining fitting position of shaft bevel gear (actual values)
    217
  • 16.6 Recommended sequence for new adjustment of final drive gear set
    217
  • 16.7 Adjusting shaft bevel gear
    218
  • 16.8 Adjusting bevel gear (with stub shaft)
    221
  • Final drive - front differential
    227
  • 1 Removing and installing oil seal for drive flange or flange shaft
    227
  • 2 Renewing oil seal for drive flange and bevel box
    231
  • 3 Adjustment overview
    236
  • 4 Differential
    237
  • 4.1 Dismantling and assembling differential
    237
  • 4.2 Adjusting differential
    246
  • 5 Dismantling and assembling bevel box
    251
  • 5.1 Assembly overview
    251
  • 5.2 Assembly procedure
    254
  • 6.1 General information
    268
  • 6.2 Adjustment and marking of final drive gear sets
    268
  • 6.3 Position of shims
    269
  • 6.4 Adjustment overview - bevel box
    269
  • 6.5 Recommended sequence for new adjustment of final drive gear set
    270
  • 6.6 Adjusting shaft bevel gear
    270
  • 6.7 Adjusting bevel gear (with stub shaft)
    277
Manufacturer's designation 5-speed manual gearbox 02G, 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 02G
Transmission types CEV, CEU, DYA, EME, EMF, AFL, DQR, EEZ, FTV, AFK, DXZ, FJS
Category Reparaturanleitung

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