6-speed manual gearbox 02Q, four-wheel drive

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification codes, assembly allocation, Golf
  2
• 1.3 Identification codes, assembly allocation, Passat
  6
• 2 Capacities
  8
• 2.1 Capacity, manual gearbox
  8
• 2.2 Capacity, bevel box
  8
• 3 Overview - power transmission
  9
• 4 Calculating overall gear ratio “i”
  11
• 4.1 Notes on performance test
  11
• 5 General repair instructions
  12
• 5.1 Contact corrosion
  12
• 5.2 Repair instructions
  12
• Clutch
  15
• 1 Repairing clutch mechanism, Golf
  15
• 1.1 Overview - clutch actuation
  15
• 1.2 Assembly overview - pedal cluster
  16
• 1.3 Removing and installing over-centre spring
  17
• 1.4 Removing and installing clutch pedal
  21
• 1.5 Removing and installing mounting bracket, Golf
  26
• 1.6 Removing and installing master cylinder
  32
• 1.7 Removing and installing clutch position sender G476
  33
• 1.8 Assembly overview - hydraulics (LHD vehicles)
  35
• 1.9 Assembly overview - hydraulics (RHD vehicles)
  38
• 1.10 Bleeding clutch system
  39
• 2 Repairing clutch mechanism, Passat
  41
• 2.1 Overview - clutch actuation
  41
• 2.2 Assembly overview - pedal cluster
  42
• 2.3 Removing and installing mounting bracket, Passat
  43
• 2.4 Removing and installing over-centre spring
  46
• 2.5 Removing and installing clutch pedal
  48
• 2.6 Removing and installing master cylinder
  50
• 2.7 Removing and installing clutch position sender G476
  52
• 2.8 Assembly overview - hydraulics (LHD vehicles)
  54
• 2.9 Assembly overview - hydraulics (RHD vehicles)
  57
• 2.10 Bleeding clutch system
  58
• 3 Repairing clutch release mechanism
  60
• 3.1 Assembly overview
  60
• 3.2 Removing pipe/hose line or plastic line and bleeder from and installing on slave cylinder
  61
• 3.3 Removing and installing slave cylinder with release bearing
  62
• 3.4 Removing and installing pipe/hose line or plastic line
  63
• 3.5 Renewing input shaft seal
  65
• 4 Clutch - vehicles with turbo diesel engine
  67
• 2.0 l - 103 kW turbo diesel engine
  67
• 4.2 Removing and installing “Sachs” clutch
  68
• 4.3 Repairing “Sachs” clutch
  70
• 4.4 Removing and installing “LuK” clutch
  71
• 4.5 Repairing “LuK” clutch
  73
• 5 Clutch - vehicles with petrol engine
  75
• 5.1 Removing and installing clutch
  75
• 5.2 Repairing clutch
  77
• Controls, housing
  79
• 1 Fault finding, power transmission
  79
• 2 Repairing selector mechanism
  80
• 2.1 Installation position of selector mechanism
  80
• 2.2 Removing and installing gear knob and cover
  82
• 2.3 Removing and installing gaiter with gear knob and noise insulation, Golf
  82
• 2.4 Removing and installing gaiter with gear knob and noise insulation, Passat
  84
• 2.5 Repairing gear lever and selector housing (through 10.06)
  85
• 2.6 Repairing gear lever and selector housing (from 11.06)
  88
• 2.7 Assembly overview - removing and installing selector cables
  92
• 2.8 Removing and installing selector mechanism
  96
• 2.9 Adjusting selector mechanism
  100
• 2.10 Checking selector mechanism
  102
• 4 Removing and installing gearbox, Golf
  107
• 4.1 Removing and installing gearbox, vehicles with turbo diesel engine
  107
• 4.2 Removing and installing gearbox, vehicles with 6-cylinder petrol engines
  127
• 4.3 Transporting gearbox
  146
• 5 Removing and installing gearbox, Passat
  148
• 5.1 Removing and installing gearbox
  148
• 5.2 Transporting gearbox
  167
• 6 Gear oil
  169
• 6.1 Distinguishing between different manual gearbox types when filling oil
  169
• 6.2 Checking oil level in gearbox
  169
• 7.1 Removing bevel box
  174
• 7.2 Installing bevel box
  179
• 8 Removing and installing bevel box, vehicles with turbo diesel engine and particulate filter
  183
• 8.1 Removing bevel box
  183
• 8.2 Installing bevel box
  188
• 9 Checking or topping up gear oil in bevel box
  192
• 9.1 Checking gear oil in bevel box
  192
• 9.2 Topping up gear oil in bevel box
  193
• 10 Dismantling and assembling gearbox
  196
• 10.1 Overview - gearbox
  196
• 10.2 Assembly overview
  197
• 10.3 Removing and installing gearbox housing and selector mechanism
  198
• 10.4 Removing and installing input shaft, output shafts, differential, bevel box and selector rods
  200
• 10.5 Assembly order, gearbox »without« retaining ring A for input shaft sealing cover
  201
• 10.6 Assembly order, gearbox »with« retaining ring A for input shaft sealing cover
  214
• 11 Repairing gearbox housing
  226
• 12 Repairing clutch housing
  236
• 13 Repairing selector mechanism, gearbox side
  240
• 13.1 Renewing selector shaft seal
  241
• 14 Repairing selector forks
  243
• Gears, shafts
  246
• 1 Input shaft
  246
• 1.1 Dismantling and assembling input shaft
  246
• 2 Output shaft for 1st to 4th gears
  253
• 2.1 Dismantling and assembling output shaft for 1st to 4th gears
  253
• 2.2 Adjusting output shaft for 1st to 4th gears
  266
• 3 Output shaft for 5th and 6th gears and reverse gear
  272
• 3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears
  272
• 3.2 Adjusting output shaft for 5th, 6th and reverse gears
  282
• Final drive - front differential
  288
• 1 Renewing flange shaft oil seals with gearbox and bevel box installed
  288
• 1.1 Renewing oil seal for left flange shaft
  288
• 1.2 Renewing seal for right flange shaft
  289
• 2 Renewing seal between gearbox and bevel box, in gearbox
  293
• 3 Renewing seal between gearbox and bevel box with bevel box removed
  295
• 4 Renewing bevel box output flange oil seal (bevel box removed)
  297
• 5 Renewing polygon needle bearing and seal on right flange shaft
  302
• 5.1 Removing
  303
• 5.2 Installing
  305
• 6 Adjustment overview
  306
• 7 Differential
  307
• 7.1 Dismantling and assembling differential
  307
• 7.2 Adjusting differential
  313