Name: 6-speed manual gearbox 02Q
Brand: Volkswagen
SKU: CDGc89cf556ce1d
Price: 46.43 EUR
Availability: InStock

Content
Details
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Repair manual 6-speed manual gearbox 02Q PDF download has the following content:

Chapter overview

Technical data
1
1 Front-wheel drive - gearbox identification
1
1.1 Location on gearbox
1
1.2 Front-wheel drive - identification codes, assembly allocation, Golf 2004 ►
2
1.3 Front-wheel drive - identification codes, assembly allocation, Golf 2009 ►
4
1.4 Identification codes, assembly allocation, Golf Plus 2005 ►
6
1.5 Identification codes, assembly allocation, Golf Plus 2009 ►
7
1.6 Front-wheel drive - identification codes, assembly allocation, Passat 2006 ►
8
1.7 Identification codes, engine allocation, Passat CC 2009 ►
11
1.8 Front-wheel drive, identification codes, assembly allocation, CC 2010 ►
12
1.9 Identification codes, assembly allocation, Eos 2006 ►
14
1.10 Identification codes, engine allocation, Touran 2003 ►
16
2 All-wheel drive - gearbox identification
19
2.1 Location on gearbox
19
2.2 All-wheel drive - identification codes, assembly allocation, Golf 2004 ►
20
2.3 All-wheel drive - identification codes, assembly allocation, Golf 2009 ►
23
2.4 All-wheel drive - identification codes, assembly allocation, Passat 2006 ►
24
2.5 All-wheel drive, identification codes, assembly allocation, CC 2010 ►
25
3 Capacities
26
3.1 Capacity, manual gearbox
26
3.2 Capacity, bevel box
26
4 Front-wheel drive - Overview power transmission
27
5 Overview - all-wheel drive power train
29
6 Calculating overall gear ratio “i”
31
7 All-wheel drive - notes on performance test
32
8 General repair instructions
33
8.1 Special tool
33
8.2 Gearbox
33
8.3 Gaskets and seals
33
8.4 Sealant
33
8.5 Locking devices
34
8.6 Nuts and bolts
34
8.7 Bearings
34
8.8 Shims
34
8.9 Synchro-rings
35
8.10 Gear wheels
35
8.11 Synchromeshed gears
35
8.12 Clutch
35
9 Safety precautions for vehicles with a start-stop system
36
Clutch
37
1 Repairing clutch mechanism
37
1.1 Overview
37
1.4 Removing and installing over-centre spring
41
1.6 Removing and installing clutch pedal
63
1.7 Removing and installing mounting bracket, Golf 2004 ►
66
1.8 Removing and installing mounting bracket, Golf 2009 ► LHD
72
1.9 Removing and installing mounting bracket, Golf Plus left-hand drive
77
1.11 Removing and installing master cylinder
89
1.12 Assembly overview - hydraulics (LHD)
91
1.13 Assembly overview - hydraulics (RHD)
93
1.14 Touran: Removing and installing clutch pedal switch F36
95
1.15 Removing and installing mounting bracket (all Tourans)
96
1.16 Touran: removing and installing master cylinder with mounting bracket removed (to 05.03)
104
1.17 Removing and installing mounting bracket, Passat, Passat CC and CC
106
1.18 Removing and installing mounting bracket, Eos
110
2 Removing and installing clutch position sender G476
115
2.1 Removing
115
2.2 Installing
117
3 Bleeding clutch system
119
4 Repairing clutch release mechanism
121
4.1 Assembly overview
121
4.2 Removing line and bleeder from and installing on slave cylinder
122
4.3 Removing and installing slave cylinder with release bearing
123
4.4 Removing and installing line for clutch mechanism
124
5 Repairing clutch, in conjunction with dual-mass flywheel
127
2.0 l - 103 kW turbo diesel engine)
128
5.2 Removing and installing “Sachs” clutch
129
5.3 Repairing “Sachs” clutch
131
5.4 Removing and installing “LuK” clutch
132
5.5 Repairing LuK clutch
135
6 Repairing clutch, in conjunction with one-piece flywheel
137
Controls, housing
140
1 Repairing selector mechanism
140
1.1 Installation position of selector mechanism
140
1.2 Overview of selector mechanism
141
1.3 Assembly overview - gear knob and cover
141
1.5 Removing and installing gaiter with gear knob and noise insulation, Golf Plus
144
1.6 Removing and installing gaiter with gear knob, Touran
146
1.8 Repairing gear lever and selector housing (to 10.06)
149
1.9 Repairing gear lever and selector housing (from 11.06)
151
1.10 Assembly overview - removing and installing selector cables
156
1.11 Removing and installing selector mechanism
161
1.12 Adjusting selector mechanism
167
1.13 Checking selector mechanism
169
3 Touran, identifying gearbox for removal and installation
174
4.1 Removing gearbox
177
4.2 Installing gearbox
183
6.1 Removing gearbox
194
6.2 Installing gearbox
204
7.1 Removing gearbox
215
7.2 Installing gearbox
223
8 Removing and installing gearbox, Golf 2004 ► front-wheel drive
233
8.1 Removing gearbox
235
8.2 Installing gearbox
243
9 Removing and installing gearbox, Golf 2009 ► front-wheel drive with turbo diesel engine
252
9.1 Removing gearbox
255
9.2 Installing gearbox
263
10 Removing and installing gearbox, Golf 2009 ► front-wheel drive with petrol engine
272
10.1 Removing gearbox
275
10.2 Installing gearbox
283
11 Removing and installing gearbox, Golf 2004 ► all-wheel drive
292
11.1 Removing and installing gearbox in vehicles with turbo diesel engine
292
11.2 Removing and installing gearbox, vehicles with 6-cylinder petrol engine
311
12 Removing and installing gearbox, Golf 2009 ► all-wheel drive
331
12.1 Removing gearbox
334
12.2 Installing gearbox
344
13 Removing and installing gearbox, Golf Plus 2005 ►
355
13.1 Removing gearbox
357
13.2 Installing gearbox
366
14 Removing and installing gearbox, Golf Plus 2009 ►
375
14.1 Removing gearbox
378
14.2 Installing gearbox
388
15 Removing and installing gearbox, Passat 2006 ► front-wheel drive
397
15.1 Removing gearbox
398
15.2 Installing gearbox
407
16 Removing and installing gearbox, Passat 2006 ► all-wheel drive
416
16.1 Removing gearbox
417
16.2 Installing gearbox
426
17.1 Removing gearbox
439
17.2 Installing gearbox
448
18.1 Removing gearbox
458
18.2 Installing gearbox
467
19 Removing and installing gearbox, CC all-wheel drive
476
19.1 Removing gearbox
479
19.2 Installing gearbox
488
20 Removing and installing gearbox, Eos
500
20.1 Removing gearbox
502
20.2 Installing gearbox
510
21 Transporting gearbox
518
21.1 Front-wheel drive - transporting gearbox
518
21.2 All-wheel drive - transporting gearbox
518
22 Securing to engine and gearbox support
520
23 Gear oil
522
23.1 Distinguishing between different manual gearbox types when filling oil
522
23.2 Checking gear oil level
522
24.1 Removing bevel box
527
24.2 Installing bevel box
532
25.1 Removing bevel box
538
25.2 Installing bevel box
543
26.1 Removing bevel box
546
26.2 Installing bevel box
550
27 Checking or topping up gear oil in bevel box
553
27.1 Checking gear oil in bevel box
554
27.2 Topping up gear oil in bevel box
554
28 Dismantling and assembling gearbox
558
28.1 Overview - gearbox, front-wheel drive, Golf 2004 ► and Touran
558
28.3 Overview - gearbox, all-wheel drive
560
28.4 Assembly overview - front-wheel drive
561
28.5 Assembly overview - all-wheel drive
562
28.6 Assembly overview - removing and installing gearbox housing and selector unit
563
28.10 Installation position of shafts and selector rods in gearbox
570
28.11 Assembly order, gearbox »without« circlip A for input shaft cover made from sheet metal
570
29 Repairing gearbox housing
602
30 Front-wheel drive - repairing clutch housing
613
31 four-wheel drive - repairing clutch housing
617
32 Repairing selector unit
621
32.1 Renewing selector shaft seal
622
33 Repairing selector forks
624
Gears, shafts
627
1 Input shaft
627
1.1 Assembly overview - input shaft
627
1.2 Dismantling and assembling input shaft
629
1.3 Renewing input shaft seal
634
2 Output shaft for 1st to 4th gears
636
2.1 Assembly overview - output shaft for 1st to 4th gears
636
2.2 Dismantling and assembling output shaft for 1st to 4th gears
638
2.3 Adjusting output shaft for 1st to 4th gears
660
3 Output shaft for 5th and 6th gears and reverse gear
665
3.1 Assembly overview - output shaft for 5th, 6th and reverse gears
665
3.2 Dismantling and assembling output shaft for 5th, 6th and reverse gears
667
3.3 Adjusting output shaft for 5th, 6th and reverse gears
676
Final drive - differential
682
1.1 Renewing oil seal for left flange shaft
682
1.2 Identifying gearbox to renew right oil seal, Golf and Touran
684
1.3 Renewing stub shaft seal - Golf and Touran to gearbox manufacture date 31 10 4
685
01 11 4, Golf Plus, Passat, Passat CC, Eos
686
2.1 Renewing oil seal for left flange shaft
689
2.2 Renewing seal for right flange shaft
689
3 Renewing seal between gearbox and bevel box, in gearbox
692
5 Renewing seal between gearbox and bevel box with bevel box removed
696
6 Renewing bevel box output flange oil seal (bevel box removed)
698
7 Renewing output flange and redetermining thickness of shim (bevel box removed)
708
8 Renewing polygon needle bearing and seal on right flange shaft
709
8.1 Removing
710
8.2 Installing
711
9 Adjustment overview - manual gearbox
713
10 Differential
714
10.1 Front-wheel drive - dismantling and assembling differential
714
10.2 All-wheel drive - dismantling and assembling differential
721
10.3 Adjusting differential
728

Manufacturer's designation	6-speed manual gearbox 02Q
Manufacturer	Volkswagen
Suitable for	Golf (2004 - 2007) / Touran (2003 - 2011) / Passat / Passat Variant (2005 - 2008) / Golf Plus (2005 - 2007) / EOS (2006) / Passat CC (2009) / Golf (2009) / Golf Plus (2009)
Suitable car types	1K1, 3C, 5M, 1F, 357, 5K1, 521
Transmission designations	02Q, 02QA
Transmission types	HVS, GVT, HDU, HDV, GXC, GRF, GNE, KDM, KDN, KDQ, KDS, KDU, KNR, KNS, KNU, KNY, KPA, KNX, KDR, KXW, KXX, KXZ, KZS, KZW, LHD, FUR, JLU, JMA, KRM, KXD, LNP, LNZ, LPA, KZU, LWN, MHA, NEH, LMN, MAX, MAY, MDL, NFL, NFN, NFP, NFU, NGB, NGC, NGD, HJH, JLW, JLZ, JLT, JQN, JRC, JRD, JRF, JRK, 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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