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

5-speed manual gearbox 02T

For Polo / Polo A05

Original Volkswagen repair manual


17,28 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

6.480 KB

209 Sites

Detailed technical data

Immediately readable

This repair manual contains: Repairing clutch mechanism, Removing and installing gearbox, Polo 2002 ► with petrol engine, Transporting gearbox, Dismantling and assembling input shaft and Differential. Show more
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Repair manual Polo / Polo A05 5-speed manual gearbox 02T 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 ►
    13
  • 2 Overview - power transmission
    15
  • 3 General repair notes
    17
  • 3.1 Contact corrosion!
    17
  • 3.2 Special tools
    17
  • 3.3 Gearbox
    17
  • 3.4 Seals and sealing rings
    17
  • 3.5 Sealant
    18
  • 3.6 Locking devices
    18
  • 3.7 Nuts and bolts
    18
  • 3.8 Bearings
    18
  • 3.9 Shims
    19
  • 3.10 Synchro-rings
    19
  • 3.11 Gear wheels
    19
  • 3.12 Synchromeshed gears
    19
  • 3.13 Clutch
    19
  • 4 Safety measures for vehicles with start/stop system
    20
  • Clutch
    21
  • 1 Repairing clutch mechanism
    21
  • 1.1 Overview - clutch actuation
    21
  • 1.2 Assembly overview - pedal cluster, Polo 2002 ►
    22
  • 1.3 Assembly overview - pedal cluster, Polo 2010 ►
    23
  • 1.4 Distinguishing between clutch pedal switches F36
    25
  • 1.5 Removing and installing, adjusting clutch pedal switch F36 with round housing
    25
  • 1.6 Removing and installing clutch pedal switch F36 with round housing
    26
  • 1.7 Removing and installing over-centre spring, Polo 2002 ►
    27
  • 1.8 Removing and installing mounting bracket, Polo 2002 ►
    29
  • 1.9 Removing and installing mounting bracket with master cylinder, Polo 2010 ►
    31
  • 1.10 Removing and installing clutch pedal, Polo 2002 ►
    35
  • 1.11 Removing and installing clutch pedal with over-centre spring, Polo 2010 ► LHD
    37
  • 1.12 Removing and installing clutch pedal with extension spring, Polo 2010 ► LHD
    40
  • 1.13 Removing and installing clutch pedal, Polo 2010 ► RHD
    42
  • 1.14 Assembly overview - hydraulics (LHD)
    45
  • 1.15 Assembly overview - hydraulics (RHD)
    48
  • 1.16 Removing and installing master cylinder, Polo 2002 ►
    50
  • 1.17 Removing and installing master cylinder, Polo 2010 ►
    52
  • 1.18 Removing and installing slave cylinder
    53
  • 1.19 Bleeding clutch system
    54
  • 2 Repairing clutch release mechanism
    56
  • 3 Repairing clutch
    58
  • Controls, housing
    61
  • 1 Repairing selector mechanism
    61
  • 1.1 Installation position of selector mechanism
    61
  • 1.2 Overview of selector mechanism
    62
  • 1.3 Assembly overview - selector lever knob and cover, Polo 2002 ►
    63
  • 1.4 Removing and installing gear knob and cover, Polo 2002 ►
    63
  • 1.5 Assembly overview - selector lever knob and cover, Polo 2010 ►
    65
  • 1.6 Removing and installing gear knob and cover, Polo 2010 ►
    66
  • 1.7 Repairing gear lever and selector housing (through 05.06)
    67
  • 1.8 Repairing gear lever and selector housing (from 06.06)
    69
  • 1.9 Assembly overview - removing and installing selector cables
    71
  • 1.10 Removing and installing selector mechanism
    75
  • 1.11 Adjusting selector mechanism
    79
  • 2 Removing and installing gearbox, Polo 2002 ► with petrol engine
    83
  • 2.1 Removing gearbox
    84
  • 2.2 Installing gearbox
    89
  • 3 Removing and installing gearbox, Polo 2002 ► with 4-cyl. diesel engine
    96
  • 3.1 Removing gearbox
    97
  • 3.2 Installing gearbox
    102
  • 4 Removing and installing gearbox, Polo 2002 ► with 3-cylinder TDI engine
    108
  • 4.1 Removing gearbox
    109
  • 4.2 Installing gearbox
    115
  • 5 Removing and installing gearbox, Polo 2010 ►
    122
  • 5.1 Removing gearbox
    123
  • 5.2 Installing gearbox
    129
  • 6 Transporting gearbox
    136
  • 7 Checking gear oil
    137
  • 8 Dismantling and assembling gearbox
    139
  • 8.1 Overview - gearbox
    139
  • 8.2 Assembly overview
    140
  • 8.4 Assembly overview - removing and installing clutch housing
    142
  • 8.6 Dismantling and assembling procedure
    144
  • 9 Repairing gearbox housing and clutch housing
    155
  • 10 Repairing selector unit
    160
  • 11 Dismantling and assembling selector forks
    163
  • Gears, shafts
    168
  • 1 Dismantling and assembling input shaft
    168
  • 2 Dismantling and assembling output shaft
    179
  • Final drive - differential
    186
  • 1 Renewing flange shaft oil seals with gearbox installed
    186
  • 1.1 Renewing oil seal for left flange shaft
    186
  • 1.2 Renewing seal for right flange shaft
    188
  • 2 Differential
    191
  • 2.1 Dismantling and assembling differential
    191
  • 2.2 Adjusting differential
    200
Manufacturer's designation 5-speed manual gearbox 02T
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007) / Polo A05 (2010)
Suitable car types 9N1, 6R1
Transmission designations 02T
Transmission types GEG, GKZ, GRT, GSK, FNT, FLU, GSE, GEQ, GRY, HCS, EYX, HDT, GSJ, GSH, GSF, GSD, GSB, GSA, GRZ, GRX, GRU, GRS, GRQ, GRP, GLW, GKW, GKV, GKU, GKT, GKS, GKR, GKP, GKN, GKL, GKJ, GEW, GEV, GEU, GET, GES, GER, GEP, GEM, GEL, GEJ, GEF, GDR, GDQ, FSP, FRA, FQE, FQD, FMX, FHE, FDV, FCT, GDP, GDN, GDM, GDL, GDJ, GDH, GDG, GCD, GBZ, FYK, FYH, FXP, FVU, FVT, FVS, FCV, FDM, FDN, FCU, GXS, HSG, FDL, HDK, JFY, JFZ, JGC, JGF, JGJ, JGQ, JGX, JHH, JHL, JHN, JHQ, JUS, EYW, EYY, EZJ, FCX, FNJ, FPU, FVV, GEY, GKX, GSC, HZK, JGN, JGP, JGR, JGS, JHM, JHS, JQM, HZL, JHP, JHG, EJY, FDX, FQT, GAR, GEH, GEK, GEN, GKK, GKM, GKQ, GNB, GRR, GRV, GRW, JGZ, JHJ, HGF, ELR, FXB, JHK, JJZ, KRJ, LGQ, JGU, LNJ, LNR, LUC, LUE, LUP, LUQ, LUS, LUX, LUY, LVA, LVC, LVE, LVG, MAB, MAH, MFX, MGZ, MKN, JGW, HXL, HZM, JFM, JGT, JJL, JFN
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