6-speed manual gearbox 02Q Volkswagen R GmbH

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety precautions when working on vehicles with a start/stop system
  2
• 2 Identification
  3
• 2.1 Gearbox identification
  3
• 3 Technical data
  4
• 3.1 Allocation gearbox - engine
  4
• 3.2 Capacities
  4
• 3.3 Calculation of gear ratios
  4
• 4 Overview - power transmission
  6
• 4.1 Overview - power transmission - front-wheel drive
  6
• 5 Electrical components
  8
• 5.1 Overview of fitting locations - electrical components
  8
• 6 Repair notes
  10
• 6.1 General repair instructions
  10
• Clutch
  13
• 1 Clutch operation
  13
• 1.1 Overview of fitting locations – clutch mechanism
  13
• 1.2 Assembly overview - pedal cluster
  15
• 1.3 Assembly overview - clutch hydraulics
  17
• 1.4 Assembly overview - clutch release mechanism
  20
• 1.5 Removing and installing bearing bush
  21
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  22
• 1.7 Removing and installing clutch position sender G476
  22
• 1.8 Removing and installing return spring
  23
• 1.9 Removing and installing over-centre spring
  25
• 1.10 Removing and installing clutch pedal
  28
• 1.11 Removing and installing mounting bracket
  29
• 1.12 Removing and installing clutch master cylinder
  33
• 1.13 Removing and installing bleeder
  34
• 1.14 Removing and installing lines for clutch mechanism
  36
• 1.15 Removing and installing clutch slave cylinder together with release bearing
  38
• 1.16 Bleeding clutch mechanism
  40
• 1.17 Repairing clutch release mechanism
  41
• 2 Clutch
  43
• 2.1 Assembly overview - clutch
  43
• 2.2 Removing and installing clutch
  44
• Controls, housing
  48
• 1 Selector mechanism
  48
• 1.1 Installation position - selector mechanism
  48
• 1.2 Assembly overview - gear knob and cover
  50
• 1.3 Assembly overview - selector mechanism
  51
• 1.4 Removing and installing gear knob
  52
• 1.5 Dismantling and assembling selector mechanism
  54
• 1.6 Removing and installing selector mechanism
  58
• 1.7 Removing and installing gear selector cable and gate selector cable
  65
• 1.8 Adjusting selector mechanism
  67
• 1.9 Checking selector mechanism
  70
• 2 Removing and installing gearbox
  71
• 2.1 Removing gearbox
  71
• 2.2 Installing gearbox
  82
• 2.3 Specified torques for gearbox
  89
• 3 Assembly mountings
  90
• 3.1 Assembly overview - assembly mountings
  90
• 4 Front differential lock
  93
• 4.1 Assembly overview - front differential lock
  93
• 4.2 Allocation of front differential lock
  93
• 4.3 Removing front differential lock
  93
• 4.4 Installing front differential lock
  96
• 5 Transporting gearbox
  99
• 5.1 Transporting gearbox
  99
• 5.2 Transporting front differential lock
  100
• 6 Gear oil
  101
• 6.1 Checking gear oil level
  101
• 7 Installing to engine and gearbox support
  103
• 7.1 Installing manual gearbox to engine and gearbox support
  103
• 7.2 Securing front differential lock to engine and gearbox support
  104
• 8 Dismantling and assembling gearbox
  106
• 8.1 Schematic overview - gearbox
  106
• 8.2 Assembly overview - gearbox
  108
• 8.3 Assembly overview - gearbox housing and selector mechanism
  109
• 8.4 Assembly overview - selector unit
  111
• 8.5 Assembly overview - shafts, differential, selector mechanism
  112
• 8.6 Assembly overview - selector forks
  114
• 8.7 Renewing oil seal for selector shaft
  114
• 8.8 Dismantling and assembling gearbox
  116
• 9 Gearbox housing, clutch housing
  132
• 9.1 Assembly overview - gearbox housing
  132
• 9.2 Assembly overview - clutch housing
  134
• 9.3 Repairing gearbox housing
  135
• 9.4 Repairing clutch housing
  143
• Gears, shafts
  145
• 1 Input shaft
  145
• 1.1 Assembly overview - input shaft
  145
• 1.2 Dismantling and assembling input shaft
  146
• 1.3 Renewing input shaft seal
  150
• 2 Output shaft
  152
• 2.1 Assembly overview - output shaft
  152
• 2.2 Dismantling and assembling output shaft
  159
• 2.3 Adjusting output shaft
  195
• Final drive - differential
  206
• 1 Oil seals
  206
• 1.1 Overview of fitting locations - seals
  206
• 1.2 Renewing left oil seal
  207
• 1.3 Renewing right oil seal
  209
• 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
• 4 Components of front differential lock
  229
• 4.1 Assembly overview - components of front differential lock
  229
• 4.2 Checking function
  230
• 4.3 Removing and installing pump V181
  230
• 4.4 Removing and installing coupling for front differential lock
  232
• 4.5 Removing and installing differential lock control unit J647
  232
• 4.6 Renewing seals for front differential lock
  233
• 4.7 Renewing ball bearing for flange shaft
  236
• 5 Oil for front differential lock
  239
• 5.1 Checking oil level for front differential lock
  239
• 5.2 Draining and filling oil for front differential lock
  240