5-speed manual gearbox 02R Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation and capacities
  1
• 2 Overview - power transmission
  3
• 3 Calculating overall gear ratio “i”
  5
• 4 General repair instructions
  6
• 4.1 Gearbox
  6
• 4.2 Gaskets and seals
  6
• 4.3 Sealant
  6
• 4.4 Locking devices
  7
• 4.5 Nuts and bolts
  7
• 4.6 Mountings
  7
• 4.7 Shims
  7
• 4.8 Synchro-rings
  8
• 4.9 Gear wheels
  8
• 4.10 Synchromeshed gears
  8
• 4.11 Clutch
  8
• Clutch
  9
• 1 Fault finding, power transmission
  9
• 2 Repairing clutch mechanism
  10
• 2.1 Overview - clutch actuation
  10
• 2.2 Assembly overview - pedal cluster
  11
• 2.3 Distinguishing between clutch pedal switches F36
  12
• 2.4 Removing and installing clutch pedal switch F36 with rectangular housing
  12
• 2.5 Removing and installing clutch pedal switch F36 with round housing
  13
• 2.6 Removing and installing over-centre spring
  13
• 2.7 Removing and installing mounting bracket for clutch pedal
  15
• 2.8 Removing and installing clutch pedal
  18
• 2.9 Assembly overview - hydraulics - LHD
  19
• 2.10 Assembly overview - hydraulics - RHD
  22
• 2.11 Removing and installing master cylinder
  24
• 2.12 Removing and installing slave cylinder
  26
• 2.13 Bleeding clutch mechanism
  28
• 3 Repairing clutch release mechanism
  30
• 4 Repairing clutch
  32
• Controls, housing
  35
• 1 Fault finding, power transmission
  35
• 2 Repairing selector mechanism
  36
• 2.1 Installation position of selector mechanism
  36
• 2.2 Overview of selector mechanism
  37
• 2.3 Assembly overview - gear knob and cover
  38
• 2.5 Repairing gear lever and selector housing (through 05. 06)
  40
• 2.6 Repairing gear lever and selector housing (from 06.06)
  42
• 2.7 Assembly overview - removing and installing selector cables
  44
• 2.8 Removing and installing selector mechanism
  48
• 2.9 Adjusting selector mechanism
  52
• 3 Removing and installing gearbox
  56
• 3.1 Removing gearbox
  57
• 3.2 Transporting gearbox
  62
• 3.3 Install gearbox
  62
• 4 Checking gear oil
  68
• 5 Dismantling and assembling gearbox
  69
• 5.1 Overview - gearbox
  69
• 5.2 Assembly overview
  69
• 5.7 Assembly sequence - Dismantling and assembling gearbox completely
  81
• 6 Repairing gearbox housing and clutch housing
  94
• 9 Dismantling and assembling selector forks
  106
• Gears, shafts
  111
• 1 Input shaft
  111
• 1.1 Dismantling and assembling input shaft
  111
• 1.2 Modification in springs for 5th gear synchronisation from gearbox date 05111
  118
• 1.3 Adjusting input shaft
  118
• 2 Output shaft
  123
• 2.1 Dismantling and assembling output shaft
  123
• 2.2 Adjusting output shaft
  136
• 3 Reverse shaft
  140
• 3.1 Dismantling and assembling reverse shaft
  140
• Final drive - differential
  144
• 1 Renewing flange shaft oil seals with gearbox installed
  144
• 1.1 Renewing oil seal for left flange shaft
  144
• 1.2 Distinguishing seals for right flange shaft
  146
• 1.3 Renewing seal (two-part seal and sleeve for right flange shaft)
  146
• 2 Adjustment overview
  153
• 3 Differential
  154
• 3.1 Dismantling and assembling differential
  154
• 3.2 Adjusting differential
  162