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  • Examplepage for repair manual 6-speed manual gearbox 02S, four-wheel drive
  • Examplepage for repair manual 2 6-speed manual gearbox 02S, four-wheel drive
  • Examplepage for repair manual 3 6-speed manual gearbox 02S, four-wheel drive
  • Examplepage for repair manual 6-speed manual gearbox 02S, four-wheel drive
  • Examplepage for repair manual 2 6-speed manual gearbox 02S, four-wheel drive
  • Examplepage for repair manual 3 6-speed manual gearbox 02S, four-wheel drive

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

For Golf / Passat / Passat Variant

Original Volkswagen repair manual


21,14 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

10.586 KB

263 Sites

Detailed technical data

Immediately readable

This repair manual contains: Repairing clutch mechanism, Golf, Removing and installing gearbox, Passat, Input shaft, Renewing bevel box output flange oil seal (bevel box removed), Adjustment overview and Differential. Show more
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Repair manual Golf / Passat / Passat Variant 6-speed manual gearbox 02S, four-wheel drive PDF download has the following content:

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
Manufacturer's designation 6-speed manual gearbox 02S, four-wheel drive
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Passat / Passat Variant (2005 - 2008)
Suitable car types 1K1, 3C
Transmission designations 02SA
Transmission types FNB, FQF, GSU, HJN, FNC, HJM, JDX, JXQ, JYQ
Category Reparaturanleitung

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