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  • Examplepage for repair manual 5 Speed Manual Gearbox 02C four wheel drive
  • Examplepage for repair manual 2 5 Speed Manual Gearbox 02C four wheel drive
  • Examplepage for repair manual 3 5 Speed Manual Gearbox 02C four wheel drive

5 Speed Manual Gearbox 02C four wheel drive

For Passat / Passat Variant

Original Volkswagen repair manual


23,22 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

7.271 KB

293 Sites

Detailed technical data

Immediately readable

This repair manual contains: Servicing clutch control, Removing and installing gearbox, Adjusting input shaft, Renewing bevel box output flange oil seal (bevel box removed), Functional check of free-wheel, Checking rear final drive oil and Dismantling and assembling differential and freewheel (assembly overview). Show more
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Repair manual Passat / Passat Variant 5 Speed Manual Gearbox 02C four wheel drive PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Gearbox identification
    1
  • 1.1 Gearbox identification
    1
  • 1.2 Code letters, gearbox allocation, ratios, capacities
    2
  • 2 Rear final drive identification
    3
  • 2.1 Rear final drive identification
    3
  • 2.2 Code letters, assembly allocation, ratios, capacities
    3
  • 3 Transmission layout
    4
  • 3.1 Transmission layout
    4
  • 4 Calculating overall ratio (i)
    6
  • 4.1 Calculating overall ratio (i)
    6
  • 4.2 Notes on brake and performance tests and towing
    6
  • 5 General repair instructions
    6
  • 5.1 General repair instructions
    6
  • Clutch
    9
  • 1 Servicing clutch control
    9
  • 1.1 Servicing clutch control
    9
  • 1.2 Assembly overview - Pedal cluster
    10
  • 1.3 Removing and installing over-centre spring
    13
  • 1.4 Removing and installing clutch pedal
    14
  • 1.5 Assembly overview - Hydraulic system
    14
  • 1.6 Removing and installing master cylinder
    17
  • 1.7 Bleeding clutch system
    18
  • 2 Servicing clutch release mechanism
    19
  • 2.1 Servicing clutch release mechanism
    19
  • 3 Servicing clutch
    22
  • 3.1 Servicing clutch
    22
  • Controls, Housing
    26
  • 1 Servicing gear selector mechanism
    26
  • 1.1 Servicing gear selector mechanism
    26
  • 1.2 Installation position of gear selector mechanism
    26
  • 1.3 Removing and installing gear selector cables
    29
  • 1.4 Removing and installing gear stick housing
    35
  • 1.5 Removing and installing gear stick
    39
  • 1.6 Adjusting gear selector mechanism
    43
  • 2 Removing and installing gearbox
    46
  • 2.1 Removing and installing gearbox
    46
  • 2.2 Removing and installing gearbox and bevel box (Vehicles with 4 cylinder engine)
    46
  • 2.3 Removing and installing gearbox and bevel box (Vehicles with 6 cylinder fuel injection engine)
    57
  • 3 Removing and installing bevel box
    69
  • 3.1 Removing and installing bevel box
    69
  • 4 Checking oil in manual gearbox with bevel box
    80
  • 4.1 Checking oil in manual gearbox with bevel box
    80
  • 5 Dismantling and assembling gearbox
    81
  • 5.1 Dismantling and assembling gearbox
    81
  • 5.2 Removing and installing cover for gearbox housing and 5th gear
    82
  • 5.3 Removing and installing gearbox housing and selector mechanism
    85
  • 5.4 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
    87
  • 5.5 Dismantling and assembling sequence
    89
  • 6 Servicing gearbox housing and clutch housing
    106
  • 6.1 Servicing gearbox housing and clutch housing
    106
  • 7 Dismantling and assembling gearbox selector mechanism
    114
  • 7.1 Dismantling and assembling gearbox selector mechanism
    114
  • 8 Dismantling and assembling selector forks
    119
  • 8.1 Dismantling and assembling selector forks
    119
  • Gears, Shafts
    125
  • 1 Dismantling and assembling input shaft
    125
  • 1.1 Dismantling and assembling input shaft
    125
  • 2 Adjusting input shaft
    136
  • 2.1 Adjusting input shaft
    136
  • 2.2 Table of adjustment shims
    137
  • 2.3 Carrying out check measurement
    139
  • 3 Dismantling and assembling output shaft (pinion shaft)
    140
  • 3.1 Dismantling and assembling output shaft (pinion shaft)
    140
  • 4 Adjusting output shaft
    164
  • 4.1 Adjusting output shaft
    164
  • 5 Dismantling and assembling reverse shaft
    167
  • 5.1 Dismantling and assembling reverse shaft
    167
  • Final drive, Differential rear
    171
  • 1.2 Renewing left-hand flange shaft oil seal
    171
  • 1.3 Renewing right-hand drive flange oil seal
    172
  • 2 Renewing bevel box output flange oil seal (bevel box removed)
    173
  • 2.1 Renewing bevel box output flange oil seal (bevel box removed)
    173
  • 3 Dismantling and assembling differential
    175
  • 3.1 Dismantling and assembling differential
    175
  • 4 Adjustment overview
    187
  • 4.1 Adjustment overview
    187
  • 5 Adjusting differential
    187
  • 5.1 Adjusting differential
    187
  • 6 Dismantling and assembling bevel box
    190
  • 6.1 Dismantling and assembling bevel box
    190
  • 6.2 Assembly overview
    190
  • 6.3 Dismantling and assembling sequence
    200
  • 7 Adjusting shaft bevel gear and bevel gear (gear set)
    210
  • 7.1 Adjusting shaft bevel gear and bevel gear (gear set)
    210
  • 7.2 General notes
    210
  • 7.3 Adjusting and marking of gear sets
    210
  • 7.4 Position of shims
    211
  • 7.5 Adjustment overview (bevel box)
    211
  • 7.6 Recommended sequence for adjusting gear set
    212
  • 7.7 Determining shim "S4" thickness when replacing output flange
    212
  • 7.8 Adjusting shaft bevel gear
    213
  • 7.9 Adjusting bevel gear
    218
  • 8 Removing and installing propshaft
    221
  • 8.1 Removing and installing propshaft
    221
  • 9 Servicing propshaft
    225
  • 9.1 Servicing propshaft
    225
  • 10 Checking function of viscous coupling
    233
  • 10.1 Checking function of viscous coupling
    233
  • 11 Removing and installing viscous coupling
    233
  • 11.1 Removing and installing viscous coupling
    233
  • 13 Removing and installing drive flange oil seal (rear final drive installed)
    235
  • 13.1 Removing and installing drive flange oil seal (rear final drive installed)
    235
  • 14 Functional check of free-wheel
    237
  • 14.1 Functional check of free-wheel
    237
  • 15 Functional check of free-wheel lock
    237
  • 15.1 Functional check of free-wheel lock
    237
  • 16 Removing and installing rear final drive
    238
  • 16.1 Removing and installing rear final drive
    238
  • 17 Checking rear final drive oil
    241
  • 17.1 Checking rear final drive oil
    241
  • 18 Dismantling and assembling rear final drive
    242
  • 18.1 Dismantling and assembling rear final drive
    242
  • 18.2 Removing viscous coupling and rear axle housing from bevel gear housing
    254
  • 18.3 Servicing shaft bevel gear bearings
    256
  • 18.4 Pressing bevel gear off and on input shaft
    260
  • 18.5 Servicing bevel gear/input shaft bearings
    261
  • 18.6 Servicing differential bearings
    264
  • 18.7 Installing rear axle housing on bevel gear housing and building on viscous coupling
    266
  • 19 Dismantling and assembling differential and freewheel (assembly overview)
    270
  • 19.1 Dismantling and assembling differential and freewheel (assembly overview)
    270
  • 20 Dismantling and assembling differential (sequence)
    274
  • 20.1 Dismantling and assembling differential (sequence)
    274
  • 21 Removing and installing freewheel (sequence)
    275
  • 21.1 Removing and installing freewheel (sequence)
    275
  • 22 Dismantling and assembling freewheel (sequence)
    276
  • 22.1 Dismantling and assembling freewheel (sequence)
    276
  • 23 Adjusting bevel gear and shaft bevel gear (gear set)
    277
  • 23.1 Adjusting bevel gear and shaft bevel gear (gear set)
    277
  • 23.2 General notes
    277
  • 23.3 Adjusting and marking of gear sets
    278
  • 23.4 Position of shims
    279
  • 23.5 Adjustment overview (rear final drive)
    279
  • 23.6 Recommended sequence for adjusting gear set
    280
  • 23.7 Adjusting shaft bevel gear
    280
  • 23.8 Adjusting bevel gear
    284
Manufacturer's designation 5 Speed Manual Gearbox 02C four wheel drive
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1994 - 1997)
Suitable car types 3A
Transmission designations 02C, 02CA
Transmission types AMF, AWR, DDP, CTT, CSR, CDH, CBC, CBB, AYR, ASU, ASY, AWP, END, EUN, EUL, EWL, EWJ, EWG, EWF, EAH, DPU, EAJ, EHQ, FEW, CGL, CZR, GDS, CZP, AME, CGM, CDG, EDR, FEX, EAG, ERW, EWK, EWN
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