5-speed manual gearboxes 02T and 0DF

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  4
• 3.1 Allocation gearbox - engine
  4
• 3.2 Capacities
  5
• 3.3 Calculation of gear ratios
  5
• 4 Overview - power transmission
  6
• 5 Electrical components
  8
• 5.1 Overview of fitting locations - electrical components
  8
• 6 Repair instructions
  11
• 6.1 General repair instructions
  11
• Clutch
  15
• 1 Clutch mechanism
  15
• 1.1 Overview of fitting locations – clutch mechanism
  15
• 1.2 Assembly overview - pedal cluster
  17
• 1.3 Assembly overview - clutch hydraulics
  21
• 1.4 Assembly overview - clutch release mechanism
  27
• 1.5 Removing and installing bearing bush
  28
• 1.6 Removing and installing clutch pedal
  30
• 1.7 Removing and installing over-centre spring
  33
• 1.8 Removing and installing extension spring
  35
• 1.9 Removing and installing mounting bracket
  36
• 1.10 Removing and installing clutch master cylinder
  48
• 1.11 Removing and installing clutch slave cylinder
  50
• 1.12 Removing and installing lines for clutch mechanism
  56
• 1.13 Bleeding clutch mechanism
  60
• 1.14 Removing and installing clutch pedal switch F36
  61
• 1.15 Checking clutch master cylinder and clutch slave cylinder
  62
• 1.16 Removing and installing clutch position sender G476
  63
• 1.17 Repairing clutch release mechanism
  66
• 2 Clutch
  69
• 2.1 Assembly overview - clutch
  69
• 2.2 Removing and installing clutch
  69
• Controls, housing
  75
• 1 Selector mechanism
  75
• 1.1 Installation position - selector mechanism
  75
• 1.2 Assembly overview – gear knob and cover
  76
• 1.3 Assembly overview - selector mechanism
  77
• 1.4 Removing and installing gear knob
  81
• 1.5 Removing and installing selector mechanism
  84
• 1.6 Repairing selector mechanism
  87
• 1.7 Adjusting selector mechanism
  92
• 1.8 Checking selector mechanism
  98
• 2 Removing and installing gearbox
  99
• 2.1 Differentiating between gearboxes, Polo
  99
• 2.2 Removing gearbox
  99
• 2.3 Installing gearbox
  126
• 2.4 Specified torques for gearbox
  140
• 3 Assembly mountings
  142
• 3.1 Assembly overview - assembly mountings, up!
  142
• 3.2 Assembly overview - assembly mountings, Polo
  143
• 4 Transporting gearbox
  146
• 5 Gear oil
  147
• 5.1 Checking gear oil level
  147
• 5.2 Draining and filling gear oil
  148
• 6 Securing to engine and gearbox support
  150
• 6.1 Securing to engine and gearbox support, gearboxes for up!
  150
• 6.2 Securing to engine and gearbox support, gearboxes for Polo
  151
• 7 Dismantling and assembling gearbox
  153
• 7.1 Schematic overview - gearbox
  153
• 7.2 Assembly overview - gearbox
  155
• 7.3 Assembly overview - cover for gearbox housing and 5th gear
  156
• 7.4 Assembly overview - clutch housing
  158
• 7.5 Assembly overview - shafts, differential, selector mechanism
  159
• 7.6 Assembly overview - selector unit
  161
• 7.7 Assembly overview - selector forks
  164
• 7.8 Removing and installing selector unit with gearbox installed
  165
• 7.9 Repairing selector forks
  174
• 7.10 Repairing selector unit
  179
• 7.11 Renewing selector shaft seal
  181
• 7.12 Dismantling and assembling gearbox
  183
• 8 Gearbox housing, clutch housing
  196
• 8.1 Assembly overview - gearbox housing and clutch housing
  196
• 8.2 Repairing clutch housing
  200
• Gears, shafts
  203
• 1 Input shaft
  203
• 1.1 Assembly overview - input shaft
  203
• 1.2 Dismantling and assembling input shaft
  205
• 1.3 Renewing input shaft seal
  218
• 2 Output shaft
  221
• 2.1 Assembly overview - output shaft
  221
• 2.2 Dismantling and assembling output shaft
  223
• Final drive - differential
  232
• 1 Oil seals
  232
• 1.1 Overview of fitting locations - seals
  232
• 1.2 Renewing left seal
  232
• 1.3 Renewing right seal
  238
• 2 Differential
  244
• 2.1 Assembly overview - differential
  244
• 2.2 Dismantling and assembling differential
  247
• 2.3 Adjusting differential
  257