6-speed manual gearbox 02Q, 0BB

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Repair instructions
  5
• 3.1 General repair instructions
  5
• 4 Technical data
  8
• 4.1 Capacities
  8
• 4.2 Allocation gearbox - engine
  8
• 4.3 Calculation of gear ratios
  9
• 5 Overview - power transmission
  10
• 5.1 Overview - power transmission - front-wheel drive
  10
• 5.2 Overview - power transmission - all-wheel drive
  12
• 6 Electrical components
  14
• 6.1 Overview of fitting locations - electrical components
  14
• Clutch
  16
• 1 Clutch operation
  16
• 1.1 Assembly overview - pedal cluster
  16
• 1.2 Assembly overview - clutch hydraulics
  19
• 1.3 Assembly overview - clutch release mechanism
  22
• 1.4 Removing and installing clutch pedal
  23
• 1.5 Removing and installing over-centre spring
  24
• 1.6 Removing and installing return spring
  27
• 1.7 Removing and installing mounting bracket
  30
• 1.8 Removing and installing bearing bush
  35
• 1.9 Removing and installing clutch master cylinder
  35
• 1.10 Removing and installing clutch slave cylinder together with release bearing
  36
• 1.11 Removing and installing lines for clutch mechanism
  37
• 1.12 Removing and installing bleeder
  39
• 1.13 Bleeding clutch mechanism
  41
• 1.14 Checking clutch master cylinder and clutch slave cylinder
  42
• 1.15 Removing and installing clutch position sender G476
  42
• 1.16 Repairing clutch release mechanism
  43
• 2 Clutch
  45
• 2.1 Determining make of clutch
  45
• 2.2 Assembly overview - clutch
  46
• 2.3 Removing and installing clutch
  50
• Controls, housing
  63
• 1 Bevel box
  63
• 1.1 Assembly overview - bevel box
  63
• 1.2 Bevel box differences, Golf and Golf estate
  64
• 1.3 Removing bevel box
  65
• 1.4 Installing bevel box
  71
• 2 Selector mechanism
  75
• 2.1 Installation position - selector mechanism
  75
• 2.2 Assembly overview - gear knob and cover
  76
• 2.3 Assembly overview - selector mechanism
  77
• 2.4 Removing and installing gear knob
  78
• 2.5 Removing and installing selector mechanism
  80
• 2.6 Adjusting selector mechanism
  87
• 2.7 Checking selector mechanism
  90
• 2.8 Renewing selector shaft seal
  90
• 3 Removing and installing gearbox
  92
• 3.1 Specified torques for gearbox
  92
• 3.2 Removing gearbox
  92
• 3.3 Installing gearbox
  127
• 4 Assembly mountings
  144
• 4.1 Assembly overview - assembly mountings
  144
• 5 Front differential lock
  147
• 5.1 Assembly overview - front differential lock
  147
• 5.2 Allocation of front differential lock
  147
• 5.3 Removing front differential lock
  147
• 5.4 Installing front differential lock
  150
• 6 Transporting gearbox
  153
• 6.1 Transporting gearbox
  153
• 6.2 Transporting front differential lock
  154
• 7 Dismantling and assembling gearbox
  155
• 7.1 Schematic overview - gearbox
  155
• 7.2 Assembly overview - gearbox
  159
• 7.3 Assembly overview - gearbox housing and selector mechanism
  161
• 7.4 Assembly overview - selector unit
  163
• 7.5 Assembly overview - input shaft, output shafts, differential, selector rods
  164
• 7.6 Assembly overview - selector forks
  168
• 7.7 Renewing selector shaft seal
  168
• 7.8 Dismantling and assembling gearbox
  170
• 8 Gearbox housing, clutch housing
  185
• 8.1 Assembly overview - gearbox housing
  185
• 8.2 Assembly overview - clutch housing
  187
• 8.3 Repairing gearbox housing
  188
• 8.4 Repairing clutch housing
  195
• 9 Securing to engine and gearbox support
  198
• 9.1 Installing manual gearbox to engine and gearbox support
  198
• 9.2 Installing bevel box or front differential lock to engine and gearbox support
  199
• 10 Gear oil
  201
• 10.1 Distinguishing between different manual gearbox types when filling oil
  201
• 10.2 Checking gear oil level
  201
• Gears, shafts
  206
• 1 Input shaft
  206
• 1.1 Assembly overview - input shaft
  206
• 1.2 Dismantling and assembling input shaft
  207
• 1.3 Renewing input shaft seal
  211
• 2 Output shaft
  213
• 2.1 Assembly overview - output shaft
  213
• 2.2 Dismantling and assembling output shaft
  220
• 2.3 Adjusting output shaft
  242
• Final drive - differential
  253
• 1 Gear oil
  253
• 1.1 Checking gear oil level
  253
• 2 Oil seals
  258
• 2.1 Overview of fitting locations - seals
  258
• 2.2 Renewing left seal
  259
• 2.3 Renewing right oil seal
  261
• 3 Differential
  274
• 3.1 Assembly overview - differential
  274
• 3.2 Dismantling and assembling differential
  279
• 3.3 Adjusting differential
  290
• 4 Adjustment overview
  295
• 5 Components of bevel box
  296
• 5.1 Assembly overview - components of bevel box
  296
• 5.2 Renewing output flange and redetermining thickness of shim
  297
• 5.3 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft
  298
• 5.4 Renewing bevel box seals
  301
• 6 Components of front differential lock
  312
• 6.1 Assembly overview - components of front differential lock
  312
• 6.2 Checking function
  313
• 6.3 Removing and installing pump V181
  313
• 6.4 Removing and installing coupling for front differential lock
  315
• 6.5 Removing and installing differential lock control unit J647
  315
• 6.6 Renewing seals for front differential lock
  316
• 6.7 Renewing ball bearing for flange shaft
  319
• 7 Oil for front differential lock
  322
• 7.1 Checking oil level for front differential lock
  322
• 7.2 Draining and filling oil for front differential lock
  323