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

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification codes, assembly allocation, capacities, Golf 4 MOTION 2005 ▸
  1
• 1.3 Identification codes, assembly allocation, capacities, Passat 4 MOTION 2006 ▸
  3
• 2 Overview - power transmission
  5
• 3 Calculating overall gear ratio “i”
  7
• 3.1 Notes on performance test
  7
• 4 General repair notes
  8
• 4.1 Components
  8
• Clutch
  11
• 1 Repairing clutch mechanism, Golf
  11
• 1.1 Overview
  11
• 1.2 Assembly overview - pedal cluster
  12
• 1.3 Removing and installing over-centre spring, Golf
  13
• 1.4 Removing and installing clutch pedal, Golf
  17
• 1.5 Removing and installing mounting bracket, Golf
  22
• 1.6 Removing and installing master cylinder
  27
• 1.7 Removing and installing clutch position sender G476
  29
• 1.8 Assembly overview - hydraulics (LHD)
  31
• 1.9 Assembly overview - hydraulics (RHD)
  34
• 1.10 Removing and installing slave cylinder
  35
• 1.11 Bleeding clutch system
  37
• 2 Repairing clutch mechanism, Passat
  39
• 2.1 Overview
  39
• 2.2 Assembly overview - pedal cluster
  40
• 2.3 Removing and installing mounting bracket
  41
• 2.4 Removing and installing over-centre spring
  45
• 2.5 Removing and installing clutch pedal
  46
• 2.6 Removing and installing master cylinder
  48
• 2.7 Removing and installing clutch position sender G476
  50
• 2.8 Assembly overview - hydraulics (LHD)
  52
• 2.9 Assembly overview - hydraulics (RHD)
  55
• 2.10 Removing and installing slave cylinder
  56
• 2.11 Bleeding clutch system
  58
• 3 Repairing clutch release mechanism
  60
• 4 Repairing clutch
  62
• 4.1 Removing and installing Sachs clutch
  62
• 4.2 Repairing Sachs clutch
  64
• 4.3 Removing and installing LuK clutch
  65
• 4.4 Repairing LuK clutch
  67
• Controls, housing
  69
• 1 Repairing selector mechanism
  69
• 1.1 Installation position of selector mechanism
  69
• 1.2 Removing and installing gear knob and cover
  71
• 1.3 Removing and installing gaiter with gear knob and noise insulation, Golf
  71
• 1.5 Repairing gear lever and selector housing (through 10.06)
  74
• 1.6 Repairing gear lever and selector housing (from 11.06)
  77
• 1.7 Assembly overview - removing and installing selector cables
  81
• 1.8 Plastic relay lever
  86
• 1.9 Removing and installing selector mechanism
  87
• 1.10 Adjusting selector mechanism
  90
• 2 Removing and installing gearbox, Golf
  94
• 2.1 Removing gearbox
  95
• 2.2 Installing gearbox
  102
• 3 Removing and installing gearbox, Passat
  111
• 3.1 Removing gearbox
  112
• 3.2 Installing gearbox
  120
• 4 Checking and topping up gear oil
  129
• 4.1 Preparation
  129
• 4.2 Draining gear oil
  130
• 4.3 Fill with gear oil
  131
• 5 Removing and installing bevel box
  132
• 5.1 Removing bevel box
  132
• 5.2 Installing bevel box
  136
• 6 Checking or topping up gear oil in bevel box
  140
• 6.1 Checking gear oil in bevel box
  140
• 6.2 Topping up gear oil in bevel box
  141
• 7 Dismantling and assembling gearbox
  144
• 7.1 Overview - gearbox
  144
• 7.2 Assembly overview
  145
• 7.3 Removing and installing cover for gearbox housing and 5th and 6th gears
  146
• 7.4 Removing and installing gearbox housing and shift mechanism
  149
• 7.5 Removing and installing input shaft, output shaft, differential, selector forks and bevel box
  150
• 7.7 Assembly sequence - Dismantling and assembling gearbox completely
  157
• 8 Repairing gearbox housing and clutch housing
  175
• 9 Repairing gearbox housing cover
  180
• 10 Repairing selector unit
  184
• 11 Dismantling and assembling selector forks
  187
• Gears, shafts
  192
• 1 Input shaft
  192
• 1.1 Dismantling and assembling input shaft
  192
• 1.2 Adjusting input shaft
  200
• 2 Output shaft
  205
• 2.1 Dismantling and assembling output shaft
  205
• 2.2 Adjusting output shaft
  218
• 3 Reverse shaft
  223
• 3.1 Dismantling and assembling reverse shaft
  223
• Final drive - front differential
  226
• 1 Renewing flange shaft oil seals with gearbox and bevel box installed
  226
• 1.1 Renewing oil seal for left flange shaft
  226
• 1.2 Renewing seal for right flange shaft
  227
• 2 Renewing seal between gearbox and bevel box with gearbox installed
  231
• 3 Renewing seal between gearbox and bevel box with gearbox removed
  233
• 4 Renewing bevel box output flange oil seal (bevel box removed)
  235
• 5 Renewing polygon needle bearing and seal on right flange shaft
  240
• 5.1 Removing
  241
• 5.2 Installing
  243
• 6 Adjustment overview
  245
• 7 Differential
  246
• 7.1 Dismantling and assembling differential
  246
• 7.2 Adjusting differential
  254