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  • Examplepage for repair manual 5-speed manual gearbox 02J
  • Examplepage for repair manual 2 5-speed manual gearbox 02J
  • Examplepage for repair manual 3 5-speed manual gearbox 02J

5-speed manual gearbox 02J

For Bora / Bora Variant / Golf / Golf Variant

Original Volkswagen repair manual


21,07 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

7.337 KB

262 Sites

Detailed technical data

Immediately readable

This repair manual contains: Servicing clutch control, Removing and installing gearbox and Adjusting input shaft. Show more
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Repair manual Bora / Bora Variant / Golf / Golf Variant 5-speed manual gearbox 02J 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 Transmission layout
    17
  • 2.1 Transmission layout
    17
  • 3 Calculating overall ratio "i"
    19
  • 3.1 Calculating overall ratio "i"
    19
  • 4 General repair instructions
    19
  • 4.1 General repair instructions
    19
  • Clutch
    22
  • 1 Servicing clutch control
    22
  • 1.1 Servicing clutch control
    22
  • 1.2 Assembly overview - Pedal cluster
    23
  • 1.3 Removing and installing over-centre spring
    26
  • 1.4 Removing and installing clutch pedal
    28
  • 1.5 Assembly overview - Hydraulic system
    30
  • 1.6 Removing and installing master cylinder
    33
  • 1.7 Bleeding clutch system
    37
  • 2 Servicing clutch release mechanism
    38
  • 2.1 Servicing clutch release mechanism
    38
  • 3 Servicing clutch
    43
  • 3.1 Servicing clutch
    43
  • Controls, Housing
    48
  • 1 Servicing gear selector mechanism up to 05.99
    48
  • 1.1 Servicing gear selector mechanism up to 05.99
    48
  • 1.2 Installation position of gear selector mechanism
    48
  • 1.3 Assembly overview - removing and installing selector cables
    50
  • 1.4 Removing and installing gear selector mechanism
    55
  • 1.5 Servicing gear stick housing
    59
  • 1.6 Servicing gear stick
    62
  • 1.7 Adjusting gear selector mechanism up to 05.99
    66
  • 2 Servicing gear selector mechanism from 05.99
    71
  • 2.1 Servicing gear selector mechanism from 05.99
    71
  • 2.2 Installation position of gear selector mechanism
    71
  • 2.3 Removing and installing selector lever knob and gaiter
    74
  • 2.4 Servicing gear stick and gear stick housing
    76
  • 2.5 Assembly overview - Removing and installing selector cables
    80
  • 2.6 Removing and installing selector mechanism
    84
  • 2.7 Adjusting gear selector mechanism from 05.99
    88
  • 3 Removing and installing gearbox
    93
  • 3.1 Removing and installing gearbox
    93
  • 4 Checking gear oil
    113
  • 4.1 Checking gear oil
    113
  • 5 Dismantling and assembling gearbox
    115
  • 5.1 Dismantling and assembling gearbox
    115
  • 5.2 Overview
    115
  • 5.3 Assembly overview
    117
  • 5.4 Removing and installing cover for gearbox housing and 5th gear
    118
  • 5.5 Removing and installing gearbox housing and selector mechanism
    121
  • 5.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    123
  • 5.7 Assembly sequence
    126
  • 6 Servicing gearbox housing and clutch housing
    144
  • 6.1 Servicing gearbox housing and clutch housing
    144
  • 7 Dismantling and assembling gearbox selector mechanism up to 05.99
    156
  • 7.1 Dismantling and assembling gearbox selector mechanism up to 05.99
    156
  • 8 Dismantling and assembling gearbox selector mechanism from 05.99
    161
  • 8.1 Dismantling and assembling gearbox selector mechanism from 05.99
    161
  • 9 Dismantling and assembling selector forks
    167
  • 9.1 Dismantling and assembling selector forks
    167
  • Gears, Shafts
    176
  • 1 Dismantling and assembling input shaft
    176
  • 1.1 Dismantling and assembling input shaft
    176
  • 1.2 From gearbox build date 05 11 1 circlips for 5th gear synchronisation have been modified
    189
  • 2 Adjusting input shaft
    191
  • 2.1 Adjusting input shaft
    191
  • 2.2 Table of adjustment shims
    193
  • 2.3 Performing measurement check
    195
  • 3 Dismantling and assembling output shaft
    196
  • 3.1 Dismantling and assembling output shaft
    196
  • 4 Adjusting output shaft
    226
  • 4.1 Adjusting output shaft
    226
  • 5 Dismantling and assembling reverse shaft
    229
  • 5.1 Dismantling and assembling reverse shaft
    229
  • Final drive, Differential rear
    234
  • 1 Renewing oil seals for flanged shafts with gearbox installed
    234
  • 1.1 Renewing oil seals for flanged shafts with gearbox installed
    234
  • 1.2 Renewing oil seal for left flanged shaft
    234
  • 1.3 Renew right flange shaft oil seal
    236
  • 2 Dismantling and assembling differential
    240
  • 2.1 Dismantling and assembling differential
    240
  • 3 Adjustment overview
    255
  • 3.1 Adjustment overview
    255
  • 4 Adjusting differential
    256
  • 4.1 Adjusting differential
    256
Manufacturer's designation 5-speed manual gearbox 02J
Manufacturer Volkswagen
Suitable for Bora / Bora Variant / Golf / Golf Variant (1998 - 2006)
Suitable car types 1J
Category Reparaturanleitung

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