6-speed manual gearbox 02S

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation and capacities
  1
• 2 Overview - power transmission
  4
• 3 Calculating overall gear ratio “i”
  6
• 4 General repair notes
  7
• 4.1 Components
  7
• Clutch
  11
• 1 Fault finding, power transmission
  11
• 2 Repairing clutch mechanism
  12
• 2.1 Overview
  12
• 2.2 Assembly overview - pedal cluster
  13
• 2.3 Removing and installing over-centre spring
  14
• 2.4 Removing and installing clutch pedal
  19
• 2.5 Removing and installing mounting bracket
  25
• 2.6 Removing and installing clutch master cylinder
  31
• 2.7 Removing and installing clutch position sender G476
  33
• 2.8 Assembly overview - hydraulics (LHD)
  36
• 2.9 Assembly overview - hydraulics (RHD)
  39
• 2.10 Removing and installing clutch slave cylinder
  40
• 2.11 Bleeding clutch mechanism
  43
• 3 Repairing clutch release mechanism
  45
• 4 Repairing clutch, in conjunction with dual-mass flywheel
  47
• 4.1 Determining clutch manufacturer
  47
• 4.2 Removing and installing “Sachs” clutch
  49
• 4.3 Repairing “Sachs” clutch
  50
• 4.4 Removing and installing “LuK” clutch
  51
• 4.5 Repairing “LuK” clutch
  53
• 5 Repairing clutch, in conjunction with one-piece flywheel
  55
• Controls, housing
  58
• 1 Repairing selector mechanism
  58
• 1.1 Installation position of selector mechanism
  58
• 1.2 Overview of selector mechanism
  59
• 1.3 Assembly overview - gear lever knob and cover
  60
• 1.4 Removing and installing gaiter with gear knob and noise insulation
  61
• 1.5 Assembly overview - selector lever and selector housing (up to 10.06)
  62
• 1.6 Assembly overview - selector lever and selector housing (from 11.06)
  65
• 1.9 Removing and installing selector mechanism
  80
• 1.10 Removing and installing gear selector cable and gate selector cable
  84
• 1.11 Adjusting selector mechanism
  86
• 2 Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ►, Golf Variant 2010 ►
  90
• 2.1 Removing gearbox
  90
• 2.2 Installing gearbox
  97
• 3 Removing and installing gearbox, Jetta 2011 ►
  105
• 3.1 Removing gearbox
  105
• 3.2 Installing gearbox
  116
• 4 Transporting gearbox
  125
• 5 Checking and topping up gear oil
  126
• 5.1 Preparation
  126
• 5.2 Draining gear oil
  127
• 5.3 Filling with gear oil
  128
• 6 Dismantling and assembling gearbox
  129
• 6.1 Overview - gearbox
  129
• 6.2 Assembly overview - dismantling and assembling gearbox
  130
• 6.7 Assembly sequence - Dismantling and assembling gearbox completely
  142
• 7 Repairing gearbox housing and clutch housing
  163
• 8 Repairing gearbox housing cover
  170
• 9 Repairing selector unit
  174
• 10 Selector forks
  177
• 10.1 Assembly overview - selector forks in connection with reverse synchromeshed gear arrow
  177
• 10.2 Assembly overview - selector forks in connection with reverse gear locking collar arrow
  179
• 10.3 Repairing selector forks
  180
• Gears, shafts
  184
• 1 Input shaft
  184
• 1.1 Dismantling and assembling input shaft
  184
• 1.2 Adjusting input shaft
  193
• 2 Output shaft
  198
• 2.1 Dismantling and assembling output shaft
  198
• 2.2 Adjusting output shaft
  211
• 3 Reverse shaft
  216
• 3.1 Assembly overview - reverse shaft with reverse synchromeshed gear arrow
  216
• 3.2 Assembly overview - reverse shaft with reverse gear locking collar arrow
  217
• 3.3 Dismantling and assembling reverse shaft
  219
• Final drive - differential
  222
• 1 Renewing flange shaft oil seals with gearbox installed
  222
• 1.1 Renewing oil seal for left flange shaft with gearbox installed
  222
• 1.2 Distinguishing seals for right flange shaft
  224
• 2 Adjustment overview
  230
• 3 Differential
  231
• 3.1 Dismantling and assembling differential
  231
• 3.2 Adjusting differential
  239