6-speed dual clutch gearbox 02E, Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 General repair instructions
  1
• 1.1 Tools
  2
• 1.2 Gearbox
  2
• 1.3 Overview - dual clutch gearbox
  2
• 1.4 Seals
  3
• 1.5 Dual clutch gearbox oil
  3
• 1.6 Nuts and bolts
  5
• 1.7 Electrical components
  6
• 2 Fault finding
  7
• 2.1 General notes on fault finding
  7
• 2.2 Useful information about the “behaviour of the control unit in the event of a gearbox fault”
  8
• 2.3 Special notes on fault finding
  9
• 3 Identification of gearbox
  11
• 3.1 Reading gearbox code letters
  11
• 4 Code - engine allocation
  14
• 4.1 Golf “GTI Edition 30” and “Golf GTI Pirelli”
  14
• 4.2 Golf “R”
  14
• 4.3 Golf “R32” NAR
  15
• 4.4 Passat “R36” and Passat estate “R36”
  15
• 4.5 Scirocco “R”
  15
• 5 Capacity
  17
• Clutch
  18
• 1 Notes on clutch
  18
• 2 Removing and installing clutch
  19
• 2.1 Removing clutch cover (end cover)
  19
• 2.2 Installing clutch cover (end cover)
  20
• 2.3 Remove clutch
  22
• 2.4 Preparing installation of multi-clutch
  23
• 2.5 Installing and adjusting clutch
  25
• Controls, housing
  30
• 1.1 Electrical and electronic components and their locations
  30
• 1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
  31
• 1.3 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
  38
• 2 Removing and installing gear oil cooler
  47
• 2.1 Removing
  47
• 2.2 Installing
  48
• 3 Removing and installing oil pump
  50
• 3.1 Removing oil pump
  50
• 3.2 Installing oil pump
  52
• 4 Renewing seal on gearbox selector lever
  53
• 5 Emergency release of selector lever
  55
• 6 Removing and installing knob
  56
• 7 Selector mechanism up to 02.2009
  58
• 7.1 Overview of selector mechanism up to 02.2009
  58
• 7.2 Removing and installing gear selector cable
  59
• 7.3 Checking selector lever cable
  66
• 7.4 Adjusting selector lever cable
  66
• 7.5 Checking selector mechanism
  67
• 8 Selector mechanism from 03.2009 onwards
  69
• 8.1 Overview of selector mechanism in vehicles from 03.2009 onwards
  69
• 8.2 Removing and installing selector lever and selector mechanism with selector lever cable
  70
• 9 Removing and installing gearbox
  72
• 9.1 General notes on removing and installing gearbox
  72
• 9.2 Removing gearbox, Golf 2004 ►, with 2.0 l engine (front-wheel drive)
  74
• 9.3 Removing gearbox, Golf 2009 ►, with 2.0 l engine (four-wheel drive)
  77
• 9.4 Removing gearbox, Golf 2004 ►, with 3.2 l V6 engine (four-wheel drive)
  85
• 9.5 Removing gearbox, Passat 2006 ►, with 3.6 l V6 engine (four-wheel drive)
  97
• 9.6 Removing gearbox, Passat 2011 ► with 3.6 l V6 engine (four-wheel drive)
  106
• 9.7 Removing gearbox, Scirocco 2009 ►, with 2.0 l engine (front-wheel drive)
  113
• 9.8 Transporting gearbox and securing to assembly stand
  119
• 9.9 Installing gearbox
  121
• 10 Torque settings and note on engine mountings
  124
• 10.1 Torque settings, assembly mountings and gearbox to engine (2.0 l engine)
  124
• 12 Removing and installing gearbox, Golf 2009 ► with 2.0 l engine
  133
• 13 Removing and installing bevel box , Passat 2011 ► with 3.6 l V6 engine
  136
• 14 Oil and oil filter
  140
• 14.1 Oil filter: renewing
  140
• 14.2 Checking oil level and topping up
  141
• 14.3 Draining and filling oil
  144
• Gears, shafts
  148
• 1 Currently, no repairs can be made to gears and shafts
  148
• Final drive - differential
  149
• 1 Overview - seals
  149
• 2 Renewing seals for flange shaft or stub shaft
  150
• 2.1 Renewing oil seal for left flange shaft - front and all-wheel drive
  150
• 2.2 Renewing seals for right flange shaft or stub shaft - front-wheel drive
  152
• 2.3 Renewing oil seal for right flange shaft - all-wheel drive
  154
• 2.4 Dismantling and assembling flange shaft
  156
• 2.5 Checking and topping up gear oil in bevel box
  158
• 2.6 Checking oil level in front bevel box - all-wheel drive
  161
• 3 Renewing oil seal for propshaft drive flange at bevel box
  162
• 4 Assembly overview - Flange shafts and seals on bevel box
  168
• 4.1 Renewing seal on gearbox between bevel box and gearbox
  169
• 4.2 Removing and installing right flange shaft
  170
• 4.3 Renewing seal for right flange shaft on outside of bevel box
  172
• 4.4 Renewing needle bearing (polygon bearing) for right flange shaft
  173
• 4.5 Renewing seal on bevel box between gearbox and bevel box
  175
• 5 Checking function of Haldex coupling
  177
• 6 Propshaft and rear final drive
  178