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  • Examplepage for repair manual 6-speed manual gearbox 02Q
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6-speed manual gearbox 02Q

For Golf / Touran / Passat / Passat Variant / Golf Plus / EOS / Passat CC

Original Volkswagen repair manual


46,43 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

12.249 KB

740 Sites

Detailed technical data

Immediately readable

This repair manual contains: Repairing clutch mechanism, Touran, identifying gearbox for removal and installation, Removing and installing gearbox, Golf 2004 ► front-wheel drive, Gear oil, Input shaft, Output shaft for 5th and 6th gears and reverse gear, 11 4, Golf Plus, Passat, Passat CC, Eos, Renewing bevel box output flange oil seal (bevel box removed), Adjustment overview - manual gearbox and Differential. Show more
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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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