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  • Examplepage for repair manual 6-speed manual gearbox 02N four-wheel drive
  • Examplepage for repair manual 2 6-speed manual gearbox 02N four-wheel drive
  • Examplepage for repair manual 3 6-speed manual gearbox 02N four-wheel drive

6-speed manual gearbox 02N four-wheel drive

For Sharan

Original Volkswagen repair manual


33,11 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

11.065 KB

451 Sites

Detailed technical data

Immediately readable

This repair manual contains: Servicing clutch control, Connecting VAS 5051 and selecting functions, Locations of electrical/electronic components, Checking oil in manual gearbox with bevel box, Adjusting input shaft, Dismantling and assembling output shaft for 5th, 6th and reverse gear, Replacing bevel box output flange oil seal (bevel box removed) and Renewing O-rings for rear axle housing cover (final drive installed). Show more
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Repair manual Sharan 6-speed manual gearbox 02N 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, assembly 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
    4
  • 3 Transmission layout
    5
  • 3.1 Transmission layout
    5
  • 4 Calculating overall ratio "i"
    7
  • 4.1 Calculating overall ratio "i"
    7
  • 4.2 Notes on brake and performance tests and towing
    7
  • 5 General repair instructions
    7
  • 5.1 General repair instructions
    7
  • Clutch
    10
  • 1 Servicing clutch control
    10
  • 1.1 Servicing clutch control
    10
  • 1.2 Assembly overview - Pedal cluster
    11
  • 1.3 Removing and installing mounting bracket
    16
  • 1.4 Removing and installing clutch pedal
    21
  • 1.5 Adjusting clutch pedal travel
    26
  • 1.6 Removing and installing over-centre spring
    27
  • 1.7 Assembly overview - Hydraulic system (left-hand drive)
    31
  • 1.8 Assembly overview - Hydraulic system (right-hand drive)
    36
  • 1.9 Removing and installing master cylinder
    41
  • 1.10 Removing and installing pipe/hose assembly
    46
  • 1.11 Bleeding clutch system
    51
  • 2 Servicing clutch release mechanism
    52
  • 2.1 Servicing clutch release mechanism
    52
  • 3 Servicing clutch
    54
  • 3.1 Servicing clutch
    54
  • 3.2 Adjusting ring of self-adjusting pressure plate on vehicles with 6-cylinder engines
    59
  • Controls, Housing
    62
  • 1 Connecting VAS 5051 and selecting functions
    62
  • 1.1 Connecting VAS 5051 and selecting functions
    62
  • 2 Locations of electrical/electronic components
    64
  • 2.1 Locations of electrical/electronic components
    64
  • 2.2 Removing and installing four-wheel drive control unit -J492
    70
  • 2.3 Removing and installing Haldex coupling pump -V181-
    71
  • 3 Servicing gear selector mechanism
    74
  • 3.1 Servicing gear selector mechanism
    74
  • 3.2 Installation position of gear selector mechanism
    74
  • 3.3 Removing and installing selector lever knob and gaiter
    77
  • 3.4 Servicing gear stick and gear stick housing
    79
  • 3.5 Assembly overview - removing and installing selector cables
    83
  • 3.6 Removing and installing gear stick and gear stick housing
    88
  • 3.7 Removing and installing operating cables
    90
  • 3.8 Adjusting gear selector mechanism
    98
  • 4 Removing and installing gearbox
    101
  • 4.1 Removing and installing gearbox
    101
  • 4.2 Removing and installing gearbox (vehicles with 4 cylinder engine)
    101
  • 4.3 Removing and installing gearbox (vehicles with 6-cylinder engine)
    125
  • 5 Removing and installing bevel box
    147
  • 5.1 Removing and installing bevel box
    147
  • 6 Checking oil in manual gearbox with bevel box
    153
  • 6.1 Checking oil in manual gearbox with bevel box
    153
  • 7 Dismantling and assembling gearbox
    155
  • 7.1 Dismantling and assembling gearbox
    155
  • 7.2 Overview
    155
  • 7.3 Assembly overview
    157
  • 7.4 Removing and installing gearbox housing and selector mechanism
    158
  • 7.6 Assembly sequence
    167
  • 8 Servicing gearbox housing
    175
  • 8.1 Servicing gearbox housing
    175
  • 9 Servicing clutch housing
    184
  • 9.1 Servicing clutch housing
    184
  • 10 Dismantling and assembling gearbox selector mechanism
    191
  • 10.1 Dismantling and assembling gearbox selector mechanism
    191
  • 11 Dismantling and assembling selector forks
    195
  • 11.1 Dismantling and assembling selector forks
    195
  • Gears, Shafts
    198
  • 1 Dismantling and assembling input shaft
    198
  • 1.1 Dismantling and assembling input shaft
    198
  • 2 Adjusting input shaft
    208
  • 2.1 Adjusting input shaft
    208
  • 3 Dismantling and assembling output shaft, 1st-4th gear
    212
  • 3.1 Dismantling and assembling output shaft, 1st-4th gear
    212
  • 4 Adjusting output shaft for 1st-4th gears
    233
  • 4.1 Adjusting output shaft for 1st-4th gears
    233
  • 5 Dismantling and assembling output shaft for 5th, 6th and reverse gear
    238
  • 5.1 Dismantling and assembling output shaft for 5th, 6th and reverse gear
    238
  • 6 Adjusting output shaft for 5th, 6th and reverse gear
    254
  • 6.1 Adjusting output shaft for 5th, 6th and reverse gear
    254
  • Final drive, Differential
    259
  • 1 Renewing oil seals for flanged shafts
    259
  • 1.1 Renewing oil seals for flanged shafts
    259
  • 1.2 Renewing oil seal for left flanged shaft
    259
  • 1.3 Renewing oil seal for right flanged shaft
    263
  • 2 Replacing bevel box output flange oil seal (bevel box removed)
    265
  • 2.1 Replacing bevel box output flange oil seal (bevel box removed)
    265
  • 3 Dismantling and assembling differential
    268
  • 3.1 Dismantling and assembling differential
    268
  • 4 Adjustment overview
    282
  • 4.1 Adjustment overview
    282
  • 5 Adjusting differential
    283
  • 5.1 Adjusting differential
    283
  • 6 Dismantling and assembling bevel box
    288
  • 6.1 Dismantling and assembling bevel box
    288
  • 7 Adjusting shaft bevel gear and bevel gear (gear set)
    312
  • 7.1 Adjusting shaft bevel gear and bevel gear (gear set)
    312
  • 7.2 General notes
    312
  • 7.3 Adjusting and marking of gear sets
    313
  • 7.4 Position of shims
    315
  • 7.5 Adjustment overview (bevel box)
    315
  • 7.6 Recommended sequence for adjusting gear set
    316
  • 7.7 Determining shim "S4" thickness when replacing output flange
    316
  • 7.8 Adjusting shaft bevel gear
    317
  • 7.9 Adjusting bevel gear
    325
  • 8 Removing and installing propshaft
    329
  • 8.1 Removing and installing propshaft
    329
  • 8.2 Removing and installing rear flexible coupling
    334
  • 9 Servicing propshaft
    337
  • 9.1 Servicing propshaft
    337
  • 10 Checking function of Haldex coupling
    348
  • 10.1 Checking function of Haldex coupling
    348
  • 11 Renewing propshaft flange oil seal on rear final drive (final drive removed)
    349
  • 11.1 Renewing propshaft flange oil seal on rear final drive (final drive removed)
    349
  • 12 Renewing flange shaft oil seal (final drive installed)
    353
  • 12.1 Renewing flange shaft oil seal (final drive installed)
    353
  • 14 Renewing O-rings for rear axle housing cover (final drive installed)
    359
  • 14.1 Renewing O-rings for rear axle housing cover (final drive installed)
    359
  • 15 Removing and installing rear final drive
    361
  • 15.1 Removing and installing rear final drive
    361
  • 16 Checking rear final drive oil
    365
  • 16.1 Checking rear final drive oil
    365
  • 17 Checking oil level in Haldex coupling or changing oil
    366
  • 17.1 Checking oil level in Haldex coupling or changing oil
    366
  • 17.2 Checking Haldex coupling oil level
    366
  • 17.3 Changing oil in Haldex coupling
    368
  • 17.4 Changing Haldex coupling oil filter
    369
  • 18 Dismantling and assembling rear final drive
    371
  • 18.1 Dismantling and assembling rear final drive
    371
  • 18.2 Removing and installing Haldex coupling cover and plates
    372
  • 18.3 Removing and installing pinion housing
    376
  • 18.4 Removing and installing differential and input shaft bevel gear
    380
  • 18.5 Removing and installing Haldex coupling plate housing cover
    384
  • 18.6 Assembly sequence
    389
  • 19 Dismantling and assembling differential
    402
  • 19.1 Dismantling and assembling differential
    402
  • 20 Servicing shaft bevel gear bearings
    408
  • 20.1 Servicing shaft bevel gear bearings
    408
  • 21 Servicing input shaft bevel gear bearings
    421
  • 21.1 Servicing input shaft bevel gear bearings
    421
  • 22 Adjusting bevel gear and shaft bevel gear (gear set)
    431
  • 22.1 Adjusting bevel gear and shaft bevel gear (gear set)
    431
  • 22.2 General notes
    431
  • 22.3 Adjusting and marking of gear sets
    432
  • 22.4 Position of shims
    434
  • 22.5 Adjustment overview (rear final drive)
    434
  • 22.6 Recommended sequence for adjusting gear set
    435
  • 22.7 Adjusting shaft bevel gear
    436
  • 22.8 Adjusting bevel gear
    441
Manufacturer's designation 6-speed manual gearbox 02N four-wheel drive
Manufacturer Volkswagen
Suitable for Sharan (1995 - 2010)
Suitable car types 7M
Category Reparaturanleitung

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