Name: 6-speed manual gearbox 02S
Brand: Volkswagen
SKU: CDG3b39dbd89042
Price: 32.65 EUR
Availability: InStock

Content
Details
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Repair manual 6-speed manual gearbox 02S PDF download has the following content:

Chapter overview

Technical data
1
1 Identification
1
1.1 Gearbox identification
1
2 Identification codes, assembly allocation, ratios and capacities
2
2.1 Identification codes, assembly allocation, ratios and capacities, Golf 2004 ►
2
2.2 Identification codes, assembly allocation, ratios and capacities, Golf 2009 ►
5
2.5 Identification codes, assembly allocation and capacities, Passat 2006 ►
9
2.6 Identification code, assembly allocation, transmission ratios and capacities, Passat 2011 ►
10
2.7 Identification codes, assembly allocation, gear ratios and capacities, Passat CC 2009 ►
11
2.8 Identification codes, assembly allocation, gear ratios and capacities, CC 2010 ►
12
2.9 Identification codes, assembly allocation and capacities, Eos 2006 ►
13
2.11 Calculating overall gear ratio “i”
14
3 Overview - power transmission
15
4 General repair instructions
17
5 Safety precautions
20
5.1 Safety precautions for vehicles with a start-stop system
20
Clutch
21
1 Clutch operation
21
1.1 Overview - clutch actuation
21
1.2 Assembly overview - pedal cluster
23
1.3 Removing and installing over-centre spring
25
1.4 Removing and installing clutch pedal
45
1.5 Removing and installing mounting bracket
48
1.6 Removing and installing master cylinder
77
1.7 Removing and installing clutch position sender G476
79
1.8 Assembly overview - hydraulics (LHD)
82
1.9 Assembly overview - hydraulics (RHD)
84
1.10 Removing and installing slave cylinder
85
1.11 Bleeding clutch system
87
2 Clutch release mechanism
89
2.1 Assembly overview - clutch release mechanism
89
2.2 Repairing clutch release mechanism
90
3 Clutch
91
3.1 Clutch in connection with dual mass flywheel
91
3.2 Clutch in connection with simple flywheel
99
Controls, housing
103
1 Selector mechanism
103
1.1 Installation position of selector mechanism
103
1.2 Overview - selector mechanism
104
1.3 Assembly overview - gear knob and cover
104
1.4 Removing and installing gear knob with gaiter and noise insulation
106
1.5 Assembly overview - Gear lever and selector housing
111
1.6 Dismantling and assembling selector mechanism (from 11.06)
114
1.7 Assembly overview - Selector cables
119
1.8 Removing and installing selector mechanism
127
1.9 Adjusting selector mechanism
131
2 Removing and installing gearbox
135
2.1 Removing and installing gearbox, Golf 2004 ►
135
2.2 Removing and installing gearbox, Golf 2009 ► with 1.4 l engine
149
2.3 Removing and installing gearbox, Golf 2009 ► with 1.8 l engine
166
2.4 Removing and installing gearbox, Golf Plus 2005 ►
184
2.5 Removing and installing gearbox, Golf Plus 2009 ►
199
2.6 Removing and installing gearbox, Passat 2006 ►
216
2.7 Removing and installing gearbox, Passat 2011 ► with turbo diesel engine
231
2.10 Removing and installing gearbox, Eos
280
2.11 Removing and installing gearbox - Scirocco
294
3 Transporting gearbox
312
4 Assembly overview - assembly mountings
313
5 Gear oil
315
5.1 Checking and topping up gear oil
315
6 Dismantling and assembling gearbox
318
6.1 Overview - gearbox
318
6.2 Overview - dismantling and assembling gearbox
319
6.7 Assembly sequence - Dismantling and assembling gearbox completely
331
7 Gearbox housing and clutch housing
352
7.1 Assembly overview - gearbox housing and clutch housing
352
7.2 Repairing gearbox housing and clutch housing
354
8 Gearbox housing cover
363
8.1 Assembly overview - gearbox housing cover
363
8.2 Repairing gearbox housing cover
364
9 Selector unit
367
9.1 Assembly overview - selector unit
367
9.2 Repairing selector unit
369
10 Selector forks
371
10.1 Assembly overview - selector forks in connection with reverse synchromeshed gear arrow
371
10.2 Assembly overview - selector forks in connection with reverse gear locking collar arrow
372
10.3 Repairing selector forks
374
Gears, shafts
378
1 Input shaft
378
1.1 Assembly overview - input shaft
378
1.2 Dismantling and assembling input shaft
380
1.3 Adjusting input shaft
386
1.4 Renewing input shaft seal
391
2 Output shaft
393
2.1 Assembly overview - output shaft
393
2.2 Dismantling and assembling output shaft
396
2.3 Adjusting output shaft
406
3 Reverse shaft
411
3.1 Assembly overview - reverse shaft with reverse synchromeshed gear arrow
411
3.2 Assembly overview - reverse shaft with reverse gear locking collar arrow
412
3.3 Dismantling and assembling reverse shaft
414
Final drive - differential
417
1 Oil seals
417
1.1 Renewing left flange shaft oil seal with gearbox installed
417
1.2 Distinguishing seals for right flange shaft
419
2 Adjustment overview
426
3 Differential
427
3.1 Assembly overview - differential
427
3.2 Dismantling and assembling differential
429
3.3 Adjusting differential
434

Manufacturer's designation	6-speed manual gearbox 02S
Manufacturer	Volkswagen
Suitable for	Golf (2004 - 2007) / Passat / Passat Variant (2005 - 2008) / Golf Plus (2005 - 2007) / EOS (2006) / Passat CC (2009) / Scirocco (2008) / Golf (2009) / Golf Plus (2009) / Passat/Passat Variant (2011 >)
Suitable car types	1K1, 5M, 1F, 357, 137, 5K1, 521, 362, 365
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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