6-speed direct shift gearbox 02E

Chapter overview

• Technical data
  1
• 1 Summary of important information - general repair notes
  1
• 1.1 Information on the direct shift gearbox DSG
  1
• 1.2 Tools
  2
• 1.3 Gearbox
  3
• 1.4 Overview
  3
• 1.5 Seals and sealing rings
  4
• 1.6 Checking oil and oil level
  4
• 1.7 Nuts and bolts
  5
• 1.8 Electrical components
  5
• 1.9 Guided fault finding, vehicle self-diagnosis and testing
  5
• 2 Gearbox identification
  6
• 2.1 Reading gearbox code letters
  7
• 3 Code letters, engine allocation
  10
• 4 Capacities
  11
• 4.1 Direct shift gearbox
  11
• Clutch
  12
• 1 Notes on clutch*
  12
• 2 Removing and installing clutch
  13
• 2.1 Removing clutch cover (end cover)
  13
• 2.2 Installing clutch cover (end cover)
  14
• 2.3 Removing clutch
  16
• 2.4 Preparing installation of multi-clutch
  17
• 2.5 Installing and adjusting clutch
  19
• Controls, housing
  26
• 1 Electrical and electronic components and their locations DSG
  26
• 2 Removing and installing oil cooler
  43
• 2.1 Removing
  43
• 2.2 Installing
  44
• 3 Removing and installing oil pump
  46
• 3.1 Removing oil pump
  46
• 3.2 Installing oil pump
  47
• 3.3 Renew seal on selector shaft lever
  48
• 4 Selector mechanism
  51
• 4.1 Overview - selector mechanism
  51
• 4.2 Removing and installing selector lever cable
  52
• 4.3 Checking selector lever cable
  53
• 4.4 Adjust selector lever cable
  54
• 4.5 Emergency release of selector lever
  55
• 4.6 Checking selector mechanism
  56
• 5 Removing and installing gearbox
  58
• 5.1 Removing gearbox - vehicles with 77 kW -1.9 l TDI diesel engine
  58
• 5.2 Transporting gearbox
  62
• 5.3 Installing gearbox - vehicles with 77 kW -1.9 l TDI diesel engine
  63
• 5.4 Torque settings
  63
• 6 Changing oil and filter of direct shift gearbox and adjusting oil level
  64
• 6.1 Changing oil and filter
  64
• Gears, shafts
  68
• 1 Repairing gears and shafts
  68
• Final drive - differential
  69
• 1 Repairing front final drive and differential
  69