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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
  • 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 Caddy Kasten/Kombi / Polo Classic / Polo Variant

Original Volkswagen repair manual


18,58 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

6.100 KB

227 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 Caddy Kasten/Kombi / Polo Classic / Polo 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
    5
  • 2.1 Transmission layout
    5
  • 3 Calculating overall ratio "i"
    7
  • 3.1 Calculating overall ratio "i"
    7
  • 4 General repair instructions
    7
  • 4.1 General repair instructions
    7
  • Clutch
    10
  • 1 Servicing clutch control
    10
  • 1.1 Servicing clutch control
    10
  • 1.2 Assembly overview - Pedal cluster
    11
  • 1.3 Removing and installing over-centre spring
    14
  • 1.4 Removing and installing clutch pedal
    15
  • 1.5 Removing and installing mounting bracket
    17
  • 1.6 Assembly overview - Hydraulic system
    21
  • 1.7 Removing and installing master cylinder
    25
  • 1.8 Bleeding clutch system
    27
  • 2 Servicing clutch release mechanism
    28
  • 2.1 Servicing clutch release mechanism
    28
  • 3 Servicing clutch
    31
  • 3.1 Servicing clutch
    31
  • Controls, Housing
    36
  • 1 Servicing gear selector mechanism up to 09.99
    36
  • 1.1 Servicing gear selector mechanism up to 09.99
    36
  • 1.2 Installation position of gear selector mechanism
    36
  • 1.3 Removing and installing gear selector cables
    38
  • 1.4 Removing and installing gear stick housing
    44
  • 1.5 Installing gear stick gaiter to gear stick knob
    47
  • 1.6 Removing and installing gear stick
    48
  • 1.7 Adjusting gear selector mechanism up to 09.99
    52
  • 2 Servicing gear selector mechanism from 10.99
    56
  • 2.1 Servicing gear selector mechanism from 10.99
    56
  • 2.2 Installation position of gear selector mechanism
    56
  • 2.3 Removing and installing selector lever knob and gaiter
    59
  • 2.4 Servicing gear stick and gear stick housing
    61
  • 2.5 Assembly overview - Removing and installing selector cables
    65
  • 2.6 Removing and installing selector mechanism
    68
  • 2.7 Adjusting gear selector mechanism from 10.99
    70
  • 3 Removing and installing gearbox
    74
  • 3.1 Removing and installing gearbox
    74
  • 4 Checking gear oil
    88
  • 4.1 Checking gear oil
    88
  • 5 Dismantling and assembling gearbox
    89
  • 5.1 Dismantling and assembling gearbox
    89
  • 5.2 Overview
    89
  • 5.3 Assembly overview
    91
  • 5.4 Removing and installing cover for gearbox housing and 5th gear
    92
  • 5.5 Removing and installing gearbox housing and selector mechanism
    95
  • 5.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    97
  • 5.7 Assembly sequence
    100
  • 6 Servicing gearbox housing and clutch housing
    118
  • 6.1 Servicing gearbox housing and clutch housing
    118
  • 7 Dismantling and assembling gearbox selector mechanism up to 09.99
    128
  • 7.1 Dismantling and assembling gearbox selector mechanism up to 09.99
    128
  • 8 Dismantling and assembling gearbox selector mechanism from 10.99
    133
  • 8.1 Dismantling and assembling gearbox selector mechanism from 10.99
    133
  • 9 Dismantling and assembling selector forks
    139
  • 9.1 Dismantling and assembling selector forks
    139
  • Gears, Shafts
    146
  • 1 Dismantling and assembling input shaft
    146
  • 1.1 Dismantling and assembling input shaft
    146
  • 2 Adjusting input shaft
    160
  • 2.1 Adjusting input shaft
    160
  • 2.2 Table of adjustment shims
    162
  • 2.3 Performing measurement check
    164
  • 3 Dismantling and assembling output shaft
    165
  • 3.1 Dismantling and assembling output shaft
    165
  • 4 Adjusting output shaft
    195
  • 4.1 Adjusting output shaft
    195
  • 5 Dismantling and assembling reverse shaft
    198
  • 5.1 Dismantling and assembling reverse shaft
    198
  • Final drive, Differential rear
    203
  • 1 Renewing flanged shaft oil seals (gearbox installed)
    203
  • 1.1 Renewing flanged shaft oil seals (gearbox installed)
    203
  • 2 Dismantling and assembling differential
    206
  • 2.1 Dismantling and assembling differential
    206
  • 3 Adjustment overview
    220
  • 3.1 Adjustment overview
    220
  • 4 Adjusting differential
    221
  • 4.1 Adjusting differential
    221
Manufacturer's designation 5-speed manual gearbox 02J
Manufacturer Volkswagen
Suitable for Caddy Kasten/Kombi (1996 - 2003) / Polo Classic / Polo Variant (1996 - 2002)
Suitable car types 9K, 6V
Transmission designations 02J
Transmission types EWX, GRJ, EWW, CZL, DBZ, DQY, DSF, DSG, DTA, DUE, EGS, EGR, EGF, EGD, EGC, EGB, EFG, EEA, ECW, EMT, EMS, EMR, ELG, EKW, EKV, EKU, EKH, EKG, EBS, EBQ, EBP, EBN, EBM, EBJ, EBF, EBD, EBA, DZQ, DZL, DZK, DZF, DZC, DYP, DYN, EHA, EGZ, EGY, EGX, EGW, EGV, EGU, EGT, DTK, GPK, FQL, FDU, FDS, FCK, FCJ, FCH, FCF, FBY, FBX, FBW, FBV, FBL, FBK, EZK, EZH, EYD, EXE, EXD, EXB, EXA, EWZ, EWY, EWV, EWU, EWQ, EVS, EVR, EVQ, EUW, EUQ, EUH, ESV, ESP, ERS, ENJ, ENH, EHN, EHC, EHB, DCL, CZM, DEA, JDW, JDM, JEG, JDH, LCC, JDJ, JDR, JEJ, GBV, JDQ
Category Reparaturanleitung

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