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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 Golf / Passat / Passat Variant / Golf Plus / EOS / Passat CC / Scirocco / Passat/Passat Variant

Original Volkswagen repair manual


32,65 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

10.245 KB

443 Sites

Detailed technical data

Immediately readable

This repair manual contains: Clutch operation, Selector mechanism, Removing and installing gearbox, Assembly overview - assembly mountings, Gear oil, Output shaft and Differential. Show more
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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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