6-speed dual clutch gearbox 02E Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 Safety instructions
  1
• 1.1 General safety regulations
  1
• 1.2 Safety precautions when working on vehicles with a start/stop system
  2
• 1.3 Safety measures when tow-starting and towing
  2
• 2 Identification
  4
• 2.1 Gearbox identification
  4
• 3 Repair instructions
  7
• 3.1 General repair notes
  7
• 3.2 Seals and sealing rings
  8
• 3.3 Nuts and bolts
  8
• 4 Technical data
  9
• 4.1 Allocation gearbox - engine
  9
• 4.2 Capacities
  9
• 5 Electrical components
  10
• 5.1 Fitting location overview - electrical components
  10
• Clutch
  11
• 1 Clutch
  11
• 1.1 Assembly overview - dual clutch
  11
• 1.2 Removing and installing clutch end cover
  13
• 1.3 Removing dual clutch
  17
• 1.4 Installing dual clutch
  18
• Controls, housing
  24
• 1 Mechatronic unit
  24
• 1.1 Assembly overview - mechatronic unit
  24
• 1.2 Removing and installing sump
  26
• 1.3 Removing and installing mechatronic unit
  29
• 2 Selector mechanism
  49
• 2.1 Assembly overview - selector mechanism
  49
• 2.2 Emergency release from position P
  52
• 2.3 Removing and installing selector lever handle
  53
• 2.4 Moving push button to installation position in the handle
  55
• 2.5 Removing and installing selector mechanism
  57
• 2.6 Removing and installing selector lever cable
  64
• 2.7 Checking selector mechanism
  67
• 2.8 Checking and adjusting selector lever cable
  68
• 2.9 Renewing oil seal for selector shaft
  70
• 3 Removing and installing gearbox
  73
• 3.1 Removing gearbox
  73
• 3.2 Installing gearbox
  78
• 3.3 Specified torques for gearbox
  81
• 4 Assembly mountings
  82
• 4.1 Assembly overview - assembly mountings
  82
• 5 Transporting gearbox
  84
• 6 Dismantling and assembling gearbox
  85
• 6.1 Assembly overview - gearbox
  85
• 7 Attachment to engine and gearbox support
  88
• 8 Gearbox oil circuit
  89
• 8.1 Removing and installing gearbox oil cooler
  89
• 8.2 Removing and installing cover for gear oil pump
  91
• 8.3 Removing and installing gearbox oil pump
  93
• 8.4 Removing and installing gearbox oil filter
  94
• 9 Gear oil
  96
• 9.1 Checking gear oil level
  96
• 9.2 Draining and filling gearbox oil
  99
• Gears, shafts
  103
• 1 Currently, no repairs can be made to gears and shafts
  103
• Final drive - differential
  104
• 1 Oil seals
  104
• 1.1 Fitting location overview - seals
  104
• 1.2 Renewing left oil seal
  104
• 1.3 Renewing right oil seal
  107
• 1.4 Dismantling and assembling flange shaft
  112