6-speed manual gearbox 02Q Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 Safety instructions
  1
• 1.1 Safety precautions when working on vehicles with a Start/Stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Repair instructions
  3
• 3.1 General repair notes
  3
• 4 Technical data
  6
• 4.1 Allocation of gearbox to motor
  6
• 4.2 Capacities
  6
• 4.3 Calculation of gear ratios
  6
• 5 Overview - power transmission
  7
• 5.1 Overview - power transmission
  7
• Clutch
  9
• 1 Clutch operation
  9
• 1.1 Overview of fitting locations - clutch mechanism
  9
• 1.2 Assembly overview - pedal cluster
  11
• 1.3 Assembly overview - clutch hydraulics
  13
• 1.4 Assembly overview - clutch release mechanism
  15
• 1.5 Removing and installing clutch position sender G476
  16
• 1.6 Removing and installing over-centre spring
  18
• 1.7 Removing and installing clutch pedal
  23
• 1.8 Removing and installing mounting bracket
  28
• 1.9 Removing and installing master cylinder
  33
• 1.10 Removing and installing bleeder
  35
• 1.11 Removing and installing lines for clutch mechanism
  36
• 1.12 Removing and installing clutch slave cylinder together with release bearing
  39
• 1.13 Bleeding clutch mechanism
  40
• 1.14 Repairing clutch release mechanism
  41
• 2 Clutch
  43
• 2.1 Assembly overview - clutch
  43
• 2.2 Removing and installing clutch
  46
• 2.3 Removing line and bleeder from and installing on slave cylinder
  58
• Controls, housing
  59
• 1 Selector mechanism
  59
• 1.1 Installation position - selector mechanism
  59
• 1.2 Assembly overview - gear lever knob and cover
  60
• 1.3 Assembly overview - selector mechanism
  61
• 1.4 Removing and installing gear knob
  64
• 1.5 Removing and installing selector mechanism
  66
• 1.6 Repairing selector mechanism
  73
• 1.7 Adjusting selector mechanism
  75
• 1.8 Checking selector mechanism
  77
• 1.9 Plastic relay lever
  78
• 2 Removing and installing gearbox
  81
• 2.1 Removing gearbox
  81
• 2.2 Installing gearbox
  91
• 2.3 Specified torques for gearbox
  99
• 3 Transporting gearbox
  100
• 3.1 Transporting gearbox
  100
• 4 Gear oil
  101
• 4.1 Checking gear oil level
  101
• 5 Dismantling and assembling gearbox
  103
• 5.1 Schematic overview - gearbox
  103
• 5.2 Assembly overview - gearbox
  104
• 5.3 Assembly overview - gearbox housing and selector mechanism
  105
• 5.4 Assembly overview - selector unit
  107
• 5.5 Assembly overview - shafts, differential, selector mechanism
  108
• 5.6 Assembly overview - selector forks
  110
• 5.7 Renewing oil seal for selector shaft
  110
• 5.8 Dismantling and assembling gearbox
  112
• 6 Gearbox housing, clutch housing
  137
• 6.1 Assembly overview - gearbox housing
  137
• 6.2 Assembly overview - clutch housing
  139
• 6.3 Repairing gearbox housing
  141
• 6.4 Repairing clutch housing
  149
• Gears, shafts
  152
• 1 Input shaft
  152
• 1.1 Assembly overview - input shaft
  152
• 1.2 Dismantling and assembling input shaft
  154
• 1.3 Renewing input shaft seal
  159
• 2 Output shaft
  161
• 2.1 Assembly overview - output shaft
  161
• 2.2 Dismantling and assembling output shaft
  166
• 2.3 Adjusting output shaft
  189
• Final drive - differential
  210
• 1 Oil seals
  210
• 1.1 Overview of fitting locations - seals
  210
• 1.2 Renewing left oil seal
  211
• 1.3 Renewing right oil seal
  213
• 2 Differential
  216
• 2.1 Assembly overview - differential
  216
• 2.2 Dismantling and assembling differential
  218
• 2.3 Adjusting differential
  223
• 3 Adjustment overview
  228