6-speed dual clutch gearbox 02E

Chapter overview

• Technical data
  1
• 1 General repair notes
  1
• 1.1 Tools
  2
• 1.2 Gearbox
  2
• 1.3 Overview
  2
• 1.4 O-rings, seals and gaskets
  3
• 1.5 Dual clutch gearbox oil
  4
• 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”
  7
• 2.3 Special notes on fault finding
  8
• 3 Gearbox identification
  10
• 3.1 Reading gearbox code letters
  10
• 4 Code - engine allocation
  13
• 4.1 Identification code
  13
• 5 Capacity
  14
• Clutch
  15
• 1 Assembly overview - dual clutch
  15
• 2 Removing and installing dual clutch
  18
• 2.1 Removing clutch end cover
  18
• 2.2 Installing clutch end cover
  20
• 2.3 Removing dual clutch
  24
• 2.4 Installing and adjusting the dual clutch
  26
• Controls, housing
  33
• 1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
  33
• 1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
  46
• 2 Removing and installing gear oil cooler
  57
• 2.1 Removing gear oil cooler
  57
• 2.2 Installing gear oil cooler
  59
• 3 Removing and installing oil pump
  60
• 3.1 Removing oil pump
  60
• 3.2 Installing oil pump
  62
• 4 Renew seal on selector shaft lever
  64
• 5 Selector mechanism
  66
• 5.1 Overview - selector mechanism in vehicles up to 02.2009
  66
• 5.2 Removing and installing selector lever cable - vehicles up to 02.2009
  67
• 5.3 Overview of selector mechanism - vehicles from 03.2009 onwards
  75
• 5.4 Removing and installing selector mechanism - vehicles as of 03.2009
  76
• 5.5 Checking selector lever cable
  82
• 5.6 Adjusting selector lever cable
  82
• 5.7 Emergency release of selector lever
  84
• 5.8 Removing and installing selector lever knob
  84
• 5.9 Moving button to installation position in knob
  87
• 5.10 Checking selector mechanism
  88
• 2010 ►
  90
• 6.1 Removing gearbox
  90
• 6.2 Installing gearbox
  101
• 6.3 Specified torques
  104
• 7 Removing and installing gearbox, Jetta 2011 ►
  107
• 7.1 Removing gearbox, Jetta 2011 with 2.0 l - 103 kW diesel engine
  107
• 7.2 Installing gearbox, Jetta 2011 with 2.0 l - 103 kW diesel engine
  119
• 7.3 Removing gearbox, Jetta 2011 with 2.0 l - 147 kW petrol engine
  121
• 7.4 Installing gearbox, Jetta 2011 with 2.0 l - 147 kW petrol engine
  134
• 7.5 Specified torques
  136
• 8 Transporting gearbox and securing to assembly stand
  138
• 9 Oil and oil filter
  139
• 9.1 Renewing oil filter
  139
• 9.2 Checking oil level and topping up
  140
• 9.3 Draining and filling oil
  143
• Gears, shafts
  147
• 1 Currently, no repairs can be made to gears and shafts
  147
• Final drive - differential
  148
• 1 Renewing seals for flange shaft or stub shaft
  148
• 1.1 Overview of fitting locations- seals
  148
• 1.2 Renewing oil seal for left flange shaft
  149
• 1.3 Renewing seals for right flange shaft or stub shaft
  151