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

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

For Golf / Passat / Passat Variant

Original Volkswagen repair manual


25,24 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.169 KB

323 Sites

Detailed technical data

Immediately readable

This repair manual contains: Repairing clutch mechanism, Golf, Clutch - vehicles with turbo diesel engine, Fault finding, power transmission, Removing and installing gearbox, Passat, Gear oil, Input shaft, Output shaft for 5th and 6th gears and reverse gear, Renewing bevel box output flange oil seal (bevel box removed), Adjustment overview and Differential. Show more
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Repair manual Golf / Passat / Passat Variant 6-speed manual gearbox 02Q, four-wheel drive PDF download has the following content:

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
Manufacturer's designation 6-speed manual gearbox 02Q, four-wheel drive
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Passat / Passat Variant (2005 - 2008)
Suitable car types 1K1, 3C
Transmission designations 02QA
Transmission types FUQ, FUS, GUM, GVU, HCR, HJR, HJS, HJT, HJW, HJX, JET, KDT, JYS, JYT, JYV, KDL, KDP, KDX, KNP, KNQ, KNT, KDY, KDZ, KNV, KNW, KNZ, GQU, HJY, HVT, 02Q, KZN, KZV, KXU, KXV, KRN, KSC, KXY, KZT, LHC, LNM, LPR, LPT, LWP, MKH, MPG, MRW, NFR, NFV, JLV, JLX, JLY, JRA, JRB, JRE, JLR, FUP, FWZ, JLS
Category Reparaturanleitung

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