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

5-speed manual gearbox 02R

For Polo / Polo A05

Original Volkswagen repair manual


17,21 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

10.301 KB

208 Sites

Detailed technical data

Immediately readable

This repair manual contains: Repairing clutch mechanism, Removing and installing gearbox, Polo 2002 ►, Checking gear oil, Input shaft, Adjustment overview and Differential. Show more
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Repair manual Polo / Polo A05 5-speed manual gearbox 02R PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Gearbox identification
    1
  • 1.1 Location on gearbox
    1
  • 1.2 Identification codes, assembly allocation, capacities, Polo 2002 ►
    1
  • 1.3 Identification codes, assembly allocation, capacities, Polo 2010 ►
    4
  • 2 Overview - power transmission
    7
  • 3 General repair notes
    9
  • 3.1 Gearbox
    9
  • 3.2 Seals and sealing rings
    9
  • 3.3 Sealant
    9
  • 3.4 Locking devices
    10
  • 3.5 Nuts and bolts
    10
  • 3.6 Bearings
    10
  • 3.7 Shims
    10
  • 3.8 Synchro-rings
    11
  • 3.9 Gear wheels
    11
  • 3.10 Synchromeshed gears
    11
  • 3.11 Clutch
    11
  • Clutch
    12
  • 1 Repairing clutch mechanism
    12
  • 1.1 Overview - clutch actuation
    12
  • 1.2 Assembly overview - pedal cluster, Polo 2002 ►
    13
  • 1.3 Assembly overview - pedal cluster, Polo 2010 ►
    14
  • 1.4 Distinguishing between clutch pedal switches F36
    16
  • 1.5 Removing and installing clutch pedal switch F36 with rectangular housing
    16
  • 1.6 Removing and installing clutch pedal switch F36 with round housing
    17
  • 1.7 Removing and installing over-centre spring, Polo 2002 ►
    18
  • 1.8 Removing and installing mounting bracket, Polo 2002 ►
    20
  • 1.9 Removing and installing mounting bracket with master cylinder, Polo 2010 ►
    22
  • 1.10 Removing and installing clutch pedal, Polo 2002 ►
    26
  • 1.11 Removing and installing clutch pedal with over-centre spring, Polo 2010 ► LHD
    28
  • 1.12 Removing and installing clutch pedal with extension spring, Polo 2010 ► LHD
    31
  • 1.13 Removing and installing clutch pedal, Polo 2010 ► RHD
    33
  • 1.14 Assembly overview - hydraulics (LHD)
    36
  • 1.15 Assembly overview - hydraulics (RHD)
    39
  • 1.16 Removing and installing master cylinder, Polo 2002 ►
    41
  • 1.17 Removing and installing master cylinder, Polo 2010 ►
    43
  • 1.18 Removing and installing slave cylinder
    44
  • 1.19 Bleeding clutch system
    45
  • 2 Repairing clutch release mechanism
    47
  • 3 Repairing clutch
    49
  • Controls, housing
    52
  • 1 Repairing selector mechanism
    52
  • 1.1 Installation position of selector mechanism
    52
  • 1.2 Overview of selector mechanism
    53
  • 1.3 Assembly overview - selector lever knob and cover, Polo 2002 ►
    54
  • 1.4 Removing and installing gear knob and cover, Polo 2002 ►
    54
  • 1.5 Assembly overview - selector lever knob and cover, Polo 2010 ►
    56
  • 1.6 Removing and installing gear knob and cover, Polo 2010 ►
    57
  • 1.7 Repairing gear lever and selector housing (through 05.06)
    58
  • 1.8 Repairing gear lever and selector housing (from 06.06)
    60
  • 1.9 Assembly overview - removing and installing selector cables
    62
  • 1.10 Removing and installing selector mechanism
    66
  • 1.11 Adjusting selector mechanism
    70
  • 2 Removing and installing gearbox, Polo 2002 ►
    74
  • 2.1 Removing gearbox
    75
  • 2.2 Installing gearbox
    81
  • 3 Removing and installing gearbox, Polo 2010 ►
    89
  • 3.1 Removing gearbox
    91
  • 3.2 Installing gearbox
    100
  • 4 Transporting gearbox
    109
  • 5 Checking gear oil
    110
  • 6 Dismantling and assembling gearbox
    111
  • 6.1 Overview - gearbox
    111
  • 6.2 Assembly overview
    112
  • 6.7 Assembly sequence - Dismantling and assembling gearbox completely
    121
  • 7 Repairing gearbox housing and clutch housing
    135
  • 10 Dismantling and assembling selector forks
    148
  • Gears, shafts
    153
  • 1 Input shaft
    153
  • 1.1 Dismantling and assembling input shaft
    153
  • 1.2 Adjusting input shaft
    160
  • 2 Output shaft
    165
  • 2.1 Dismantling and assembling output shaft
    165
  • 2.2 Adjusting output shaft
    177
  • 3 Reverse shaft
    181
  • 3.1 Dismantling and assembling reverse shaft
    181
  • Final drive - differential
    184
  • 1 Renewing flange shaft oil seals with gearbox installed
    184
  • 1.1 Renewing oil seal for left flange shaft
    184
  • 1.2 Distinguishing seals for right flange shaft
    186
  • 1.3 Renewing seal (two-part seal and sleeve for right flange shaft)
    186
  • 2 Adjustment overview
    192
  • 3 Differential
    193
  • 3.1 Dismantling and assembling differential
    193
  • 3.2 Adjusting differential
    201
Manufacturer's designation 5-speed manual gearbox 02R
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007) / Polo A05 (2010)
Suitable car types 9N1, 6R1
Transmission designations 02R
Transmission types GVZ, HVU, HWY, EWR, GGV, GGU, HGY, HGX, HGW, HET, EWT, EMD, HZP, JEP, EET, EWS, FNY, MDN, MZM, KFK, MAL, MAR, MAT, MNY, MUW, MUX, MZK, MZL, MZN, MZR, MZS, HZN, JCZ, JDA, JDB, JDC, JDD, JDE, JXY, JYF
Category Reparaturanleitung

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