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

5-speed manual gearbox 02Z

For California / Multivan / Transporter / Transporter/Kombi LR

Original Volkswagen repair manual


16,19 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.672 KB

194 Sites

Detailed technical data

Immediately readable

This repair manual contains: Clutch operation, Selector mechanism, Removing and installing gearbox, Gear oil, Output shaft and Differential. Show more
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Repair manual 5-speed manual gearbox 02Z PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Identification
    1
  • 1.1 Gearbox identification
    1
  • 2 Technical data
    2
  • 2.1 Technical data, gearbox
    2
  • 2.2 Calculating overall gear ratio “i”
    8
  • 3 Overview - power transmission
    10
  • 3.1 Overview - power transmission
    10
  • 4 Repair notes
    12
  • 4.1 General repair instructions
    12
  • 5 Electrical components
    15
  • 5.1 Overview of fitting locations - electrical components, manual gearbox
    15
  • 5.2 Overview of fitting locations – electrical components, clutch mechanism
    15
  • Clutch
    16
  • 1 Clutch operation
    16
  • 1.1 Assembly overview - pedal cluster
    16
  • 1.2 Assembly overview - clutch hydraulics
    18
  • 1.3 Assembly overview - clutch release mechanism
    20
  • 1.4 Removing and installing clutch pedal switch F36
    22
  • 1.5 Removing and installing mounting bracket for clutch pedal
    22
  • 1.6 Removing and installing clutch pedal with mounting bracket removed
    24
  • 1.8 Removing and installing clutch master cylinder
    26
  • 1.9 Removing and installing clutch slave cylinder
    31
  • 1.10 Bleeding clutch mechanism
    34
  • 2 Clutch
    35
  • 2.1 Assembly overview - clutch
    35
  • 2.2 Removing and installing clutch
    37
  • Controls, housing
    40
  • 1 Selector mechanism
    40
  • 1.1 Installation position - selector mechanism
    40
  • 1.2 Assembly overview - gear knob and cover
    42
  • 1.3 Assembly overview - Gear lever and selector housing
    43
  • 1.5 Assembly overview - selector cables
    47
  • 1.6 Removing and installing selector mechanism
    49
  • 1.7 Distinguishing between selector mechanisms
    51
  • 1.8 Adjusting selector mechanism in neutral, selector gate for 1st and 2nd gears
    52
  • 1.9 Adjusting selector mechanism with 2nd gear engaged
    55
  • 1.10 Renewing selector shaft seal
    59
  • 1.11 Removing and installing relay lever
    60
  • 2 Removing and installing gearbox
    63
  • 2.1 Specified torques for gearbox
    63
  • 2.2 Removing gearbox
    63
  • 2.3 Removing gearbox, 2010►
    69
  • 2.4 Installing gearbox
    76
  • 2.5 Installing gearbox, 2010►
    80
  • 3 Transporting gearbox
    86
  • 3.1 Transporting gearbox
    86
  • 4 Gear oil
    87
  • 4.1 Checking gear oil level
    87
  • 5 Dismantling and assembling gearbox
    88
  • 5.1 Schematic overview - gearbox
    88
  • 5.2 Assembly overview - cover for gearbox housing and 5th gear
    90
  • 5.3 Assembly overview - gearbox housing and selector mechanism
    91
  • 5.4 Assembly overview - selector unit
    92
  • 5.5 Assembly overview - input shaft, output shaft, differential and selector forks
    93
  • 5.6 Assembly overview - selector forks
    94
  • 5.7 Dismantling and assembling gearbox
    95
  • 5.8 Dismantling and assembling selector unit
    108
  • 5.9 Dismantling and assembling selector forks
    109
  • 5.10 Removing cover for gearbox housing and 5th gear
    113
  • 5.11 Installing cover for gearbox housing and 5th gear
    120
  • 6 Gearbox housing, clutch housing
    124
  • 6.1 Assembly overview - gearbox housing
    124
  • 6.2 Assembly overview - clutch housing
    125
  • 6.3 Repairing gearbox housing
    127
  • 6.4 Repairing clutch housing
    134
  • Gears, shafts
    141
  • 1 Input shaft
    141
  • 1.1 Assembly overview - input shaft
    141
  • 1.2 Dismantling and assembling input shaft
    142
  • 2 Output shaft
    149
  • 2.1 Assembly overview - output shaft
    149
  • 2.2 Dismantling and assembling output shaft
    151
  • 2.3 Adjusting output shaft
    163
  • 3 Reverse shaft
    168
  • 3.1 Assembly overview - reverse shaft
    168
  • 3.2 Dismantling and assembling reverse shaft
    169
  • Final drive - differential
    171
  • 1 Oil seals
    171
  • 1.1 Overview of fitting locations - seals
    171
  • 1.2 Renewing left seal
    172
  • 1.3 Renewing right oil seal
    173
  • 1.4 Renewing input shaft seal
    177
  • 2 Differential
    180
  • 2.1 Assembly overview - differential
    180
  • 2.2 Dismantling and assembling differential
    182
  • 2.3 Adjusting differential
    185
  • 3 Adjustment overview
    190
Manufacturer's designation 5-speed manual gearbox 02Z
Manufacturer Volkswagen
Suitable for California / Multivan / Transporter / Transporter/Kombi LR (2003 - 2007) / Transporter (2003 - 2007) / Transporter (2010)
Suitable car types 7H, 7F, 7E
Transmission designations 02Z
Transmission types FJH, FJK, FJJ, GUB, GUA, GTZ, GTY, GTX, GTW, GTV, GRC, GRB, GRA, GQZ, GQY, GQX, GQW, GMS, FJL, FJN, FJM, HCW, HDC, LRS, MAG, MQR, MQS, MQT, GTF, HCX, HCY, HCZ, JCC, JCD, JCE, JCF, JCG, JCH, JCJ, JQQ, JQR, JQS, JQT, JQU, JQV, JQW
Category Reparaturanleitung

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