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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 New Beetle Cabrio / New Beetle

Original Volkswagen repair manual


19,87 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

7.028 KB

245 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 New Beetle Cabrio / New Beetle 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 Identification code, assembly allocation, ratios, capacities
    2
  • 2 Transmission layout
    6
  • 2.1 Transmission layout
    6
  • 3 Calculating overall ratio "i"
    8
  • 3.1 Calculating overall ratio "i"
    8
  • 4 General repair instructions
    8
  • 4.1 General repair instructions
    8
  • Clutch
    11
  • 1 Servicing clutch control
    11
  • 1.1 Servicing clutch control
    11
  • 1.2 Assembly overview - Pedal cluster
    12
  • 1.3 Removing and installing over-centre spring
    15
  • 1.4 Removing and installing clutch pedal
    17
  • 1.5 Assembly overview - Hydraulic system
    19
  • 1.6 Removing and installing master cylinder
    22
  • 1.7 Bleeding clutch system
    27
  • 2 Servicing clutch release mechanism
    28
  • 2.1 Servicing clutch release mechanism
    28
  • 3 Repairing clutch
    30
  • 3.1 Repairing clutch
    30
  • Controls, Housing
    36
  • 1 Servicing selector mechanism up to 05.99
    36
  • 1.1 Servicing selector mechanism up to 05.99
    36
  • 1.2 Installation position of gear selector mechanism
    36
  • 1.3 Assembly overview - removing and installing selector cables
    38
  • 1.4 Removing and installing selector mechanism
    43
  • 1.5 Servicing gear stick housing
    46
  • 1.6 Servicing gear stick
    50
  • 1.7 Adjusting gear selector mechanism
    54
  • 2 Servicing selector mechanism as of 06.99
    59
  • 2.1 Servicing selector mechanism as of 06.99
    59
  • 2.2 Installation position of gear selector mechanism
    59
  • 2.3 Removing and installing gear stick knob and cover
    62
  • 2.4 Servicing gear stick and gear stick housing
    64
  • 2.5 Assembly overview - removing and installing selector cables
    68
  • 2.6 Removing and installing selector mechanism
    71
  • 2.7 Adjusting gear selector mechanism
    75
  • 3 Removing and installing gearbox
    78
  • 3.1 Removing and installing gearbox
    78
  • 3.2 Modifying support rails VW 457/1
    80
  • 3.3 Modifying guide 10-222 A/21 from support device 10-222 A
    80
  • 4 Checking gearbox oil
    97
  • 4.1 Checking gearbox oil
    97
  • 5 Dismantling and assembling gearbox
    99
  • 5.1 Dismantling and assembling gearbox
    99
  • 5.2 Overview
    99
  • 5.3 Assembly overview
    101
  • 5.4 Removing and installing cover for gearbox housing and 5th gear
    102
  • 5.5 Removing and installing gearbox housing and selector mechanism
    105
  • 5.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    107
  • 5.7 Assembly sequence
    110
  • 6 Repairing gearbox housing and clutch housing
    128
  • 6.1 Repairing gearbox housing and clutch housing
    128
  • 7 Dismantling and assembling selector mechanism on gearbox side, up to 05.99
    140
  • 7.1 Dismantling and assembling selector mechanism on gearbox side, up to 05.99
    140
  • 8 Dismantling and assembling selector mechanism on gearbox side from 06.99
    145
  • 8.1 Dismantling and assembling selector mechanism on gearbox side from 06.99
    145
  • 9 Dismantling and assembling selector forks
    151
  • 9.1 Dismantling and assembling selector forks
    151
  • Gears, Shafts
    160
  • 1 Dismantling and assembling input shaft
    160
  • 1.1 Dismantling and assembling input shaft
    160
  • 2 Adjusting input shaft
    174
  • 2.1 Adjusting input shaft
    174
  • 2.2 Table of adjustment shims
    176
  • 2.3 Carrying out check measurement
    178
  • 3 Dismantling and assembling output shaft
    179
  • 3.1 Dismantling and assembling output shaft
    179
  • 3.2 From gearbox manufacturing date 09.00: Revised 1st gear synchromesh
    205
  • 4 Adjusting output shaft
    209
  • 4.1 Adjusting output shaft
    209
  • 5 Dismantling and assembling reverse shaft
    211
  • 5.1 Dismantling and assembling reverse shaft
    211
  • Final drive, Differential
    216
  • 1 Renewing flanged shaft oil seals (gearbox installed)
    216
  • 1.1 Renewing flanged shaft oil seals (gearbox installed)
    216
  • 1.2 Renewing oil seal for left flanged shaft
    216
  • 1.3 Renewing oil seal for right flanged shaft
    218
  • 2 Dismantling and assembling differential
    223
  • 2.1 Dismantling and assembling differential
    223
  • 3 Adjustment overview
    238
  • 3.1 Adjustment overview
    238
  • 4 Adjusting differential
    239
  • 4.1 Adjusting differential
    239
Manufacturer's designation 5-speed manual gearbox 02J
Manufacturer Volkswagen
Suitable for New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)
Suitable car types 1Y, 9C
Category Reparaturanleitung

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