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  • Examplepage for repair manual 6-speed manual gearbox 02S
  • Examplepage for repair manual 2 6-speed manual gearbox 02S
  • Examplepage for repair manual 3 6-speed manual gearbox 02S

6-speed manual gearbox 02S

For Jetta 4-türig Ll

Original Volkswagen repair manual


19,23 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

10.979 KB

236 Sites

Detailed technical data

Immediately readable

This repair manual contains: Clutch operation, Selector mechanism, Removing and installing gearbox, Assembly mounting, Gear oil, Output shaft and Differential. Show more
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Repair manual Jetta 4-türig Ll 6-speed manual gearbox 02S PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety measures when working on vehicles with a start/stop system
    1
  • 2 Identification
    3
  • 2.1 Gearbox identification
    3
  • 3 Repair notes
    4
  • 3.1 General repair instructions
    4
  • 4 Technical data
    8
  • 4.1 Capacities
    8
  • 4.2 Allocation gearbox - engine
    8
  • 4.3 Calculation of gear ratios
    8
  • 5 Overview - power transmission
    10
  • 5.1 Overview - power transmission - front-wheel drive
    10
  • 6 Electrical components
    12
  • 6.1 Overview of fitting locations - electrical components
    12
  • Clutch
    14
  • 1 Clutch operation
    14
  • 1.1 Assembly overview - pedal cluster
    14
  • 1.2 Assembly overview - clutch hydraulics
    17
  • 1.3 Assembly overview - clutch release mechanism
    21
  • 1.4 Removing and installing over-centre spring
    22
  • 1.5 Removing and installing clutch pedal
    26
  • 1.6 Removing and installing mounting bracket
    32
  • 1.7 Removing and installing clutch master cylinder
    38
  • 1.8 Removing and installing clutch slave cylinder
    40
  • 1.9 Checking clutch master cylinder and clutch slave cylinder
    42
  • 1.10 Removing and installing clutch position sender G476
    42
  • 1.11 Bleeding clutch mechanism
    45
  • 1.12 Repairing clutch release mechanism
    46
  • 2 Clutch
    48
  • 2.1 Determining make of clutch
    48
  • 2.2 Assembly overview - clutch
    49
  • 2.3 Removing and installing clutch
    53
  • Controls, housing
    63
  • 1 Selector mechanism
    63
  • 1.1 Installation position - selector mechanism
    63
  • 1.2 Assembly overview - gear knob and cover
    65
  • 1.3 Assembly overview - Gear lever and selector housing
    66
  • 1.4 Assembly overview - Selector cables
    68
  • 1.5 Removing and installing gear knob
    70
  • 1.6 Dismantling and assembling selector mechanism
    72
  • 1.7 Removing and installing selector mechanism
    78
  • 1.8 Removing and installing gear selector cable and gate selector cable
    83
  • 1.9 Adjusting selector mechanism
    85
  • 1.10 Checking selector mechanism
    87
  • 1.11 Renewing oil seal for selector shaft
    88
  • 2 Removing and installing gearbox
    90
  • 2.1 Specified torques for gearbox
    90
  • 2.2 Removing gearbox
    90
  • 2.3 Installing gearbox
    101
  • 3 Assembly mounting
    109
  • 3.1 Assembly overview - assembly mountings
    109
  • 4 Transporting gearbox
    111
  • 5 Dismantling and assembling gearbox
    112
  • 5.1 Schematic overview - gearbox
    112
  • 5.2 Assembly overview - cover for gearbox housing and 5th/6th gear
    114
  • 5.3 Assembly overview - gearbox housing and selector mechanism
    116
  • 5.4 Assembly overview - selector unit
    118
  • 5.5 Assembly overview - input shaft, output shafts, differential, selector rods
    119
  • 5.6 Assembly overview - selector forks
    120
  • 5.7 Repairing selector unit
    123
  • 5.8 Repairing selector forks
    124
  • 5.9 Removing cover for gearbox housing and 5th and 6th gears
    127
  • 5.10 Dismantling and assembling gearbox
    133
  • 5.11 Installing cover for gearbox housing and 5th and 6th gears
    147
  • 6 Gearbox housing, clutch housing
    152
  • 6.1 Assembly overview - gearbox housing
    152
  • 6.2 Assembly overview - clutch housing
    154
  • 6.3 Assembly overview - gearbox housing cover
    155
  • 6.4 Repairing gearbox housing
    156
  • 6.5 Repairing clutch housing
    163
  • 6.6 Repairing gearbox housing cover
    168
  • 7 Installing to engine and gearbox support
    170
  • 8 Gear oil
    171
  • 8.1 Checking gear oil level
    171
  • 8.2 Draining and filling gear oil
    171
  • Gears, shafts
    174
  • 1 Input shaft
    174
  • 1.1 Assembly overview - input shaft
    174
  • 1.2 Dismantling and assembling input shaft
    176
  • 1.3 Adjusting input shaft
    180
  • 2 Output shaft
    186
  • 2.1 Assembly overview - output shaft
    186
  • 2.2 Dismantling and assembling output shaft
    189
  • 2.3 Adjusting output shaft
    199
  • 3 Reverse shaft
    206
  • 3.1 Assembly overview - reverse shaft
    206
  • 3.2 Dismantling and assembling reverse shaft
    209
  • Final drive - differential
    212
  • 1 Oil seals
    212
  • 1.1 Overview of fitting locations - seals
    212
  • 1.2 Renewing left oil seal
    213
  • 1.3 Renewing right oil seal
    215
  • 1.4 Renewing input shaft seal
    219
  • 2 Differential
    221
  • 2.1 Assembly overview - differential
    221
  • 2.2 Dismantling and assembling differential
    223
  • 2.3 Adjusting differential
    228
  • 3 Adjustment overview
    232
Manufacturer's designation 6-speed manual gearbox 02S
Manufacturer Volkswagen
Suitable for Jetta 4-türig Ll (1980 - 1984)
Suitable car types 163
Transmission designations 02S
Transmission types JAU, FND, GPS, GQM, GQP, HGG, GXV, GQN, GQL, GLB, FYG, FNG, JXR, JYG, JYJ, JYL, KKP, KVY, KRX, HHS, HXP, HYG, JCK, JCQ, KRZ, KVT, KVV, KVW, KVX, KVZ, KWA, KWB, KWC, KWD, LKA, MDP, MUE, MUF, MAW, MCB, MFR, MJJ, MUJ, MYP, JCN, JWX, JCL, JCM, JCP, JWN, JWP, JXP, JYH, JYK
Category Reparaturanleitung

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