5-speed manual gearbox 02R

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