6-speed manual gearbox 02S

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Location on gearbox
  1
• 1.2 Identification code, assembly allocation, capacities
  1
• 2 Overview - power transmission
  6
• 2.1 Designation:
  6
• 2.2 Ratio
  7
• 3 Calculating overall gear ratio “i”
  8
• 4 General repair instructions
  9
• 4.1 Gearbox
  9
• 4.2 Gaskets and seals
  9
• 4.3 Locking devices
  9
• 4.4 Nuts and bolts
  9
• 4.5 Mountings
  10
• 4.6 Shims
  10
• 4.7 Synchro-rings
  10
• 4.8 Gear wheels
  10
• 4.9 Synchromeshed gears
  11
• 4.10 Clutch
  11
• Clutch
  12
• 1 Repairing clutch mechanism
  12
• 1.1 Overview
  12
• 1.2 Assembly overview - pedal cluster with clutch pedal switch F36 to 05.03
  13
• 1.3 Removing and installing clutch pedal switch F36
  14
• 1.4 Removing and installing mounting bracket (all Tourans)
  15
• 1.7 Assembly overview - pedal cluster with clutch pedal sender G476 from 06.03
  26
• 1.8 Removing and installing over-centre spring with mounting bracket installed
  28
• 1.9 Removing and installing clutch pedal with mounting bracket installed
  30
• 1.11 Removing and installing clutch position sender G476 (from 06. 03)
  35
• 1.12 Assembly overview - hydraulics (LHD)
  37
• 1.13 Assembly overview - hydraulics (RHD)
  40
• 1.14 Removing and installing slave cylinder
  41
• 1.15 Bleeding clutch system
  44
• 2 Repairing clutch release mechanism
  46
• 3 Repairing clutch, in conjunction with dual-mass flywheel
  48
• 1.9 l - 77 kW turbo diesel engine
  48
• 3.2 Removing and installing Sachs clutch
  50
• 3.3 Repairing Sachs clutch
  52
• 3.4 Removing and installing LuK clutch
  53
• 3.5 Repairing LuK clutch
  55
• 4 Repairing clutch, in conjunction with one-piece flywheel
  57
• Controls, housing
  60
• 1 Repairing selector mechanism
  60
• 1.1 Installation position of selector mechanism
  60
• 1.2 Removing and installing gear knob and cover
  62
• 1.3 Removing and installing gaiter with gear knob
  62
• 1.4 Repairing gear lever and selector housing (to 10.06)
  64
• 1.5 Repairing gear lever and selector housing (from 11.06)
  66
• 1.6 Assembly overview - removing and installing selector cables
  71
• 1.7 Plastic relay lever
  76
• 1.8 Removing and installing selector mechanism
  78
• 1.9 Adjusting selector mechanism
  81
• 2 Removing and installing gearbox (except vehicles with 1.4 l engine)
  85
• 2.1 Removing gearbox
  87
• 2.2 Install gearbox
  96
• 3 Removing and installing gearbox (vehicles with 1.4 l engine only)
  104
• 3.1 Removing gearbox
  106
• 3.2 Install gearbox
  113
• 4 Transporting gearbox
  120
• 5 Checking and topping up gear oil
  121
• 5.1 Preparing
  121
• 5.2 Drain gear oil
  122
• 5.3 Fill with gear oil
  123
• 6 Dismantling and assembling gearbox
  124
• 6.1 Overview - gearbox
  124
• 6.2 Assembly overview
  125
• 6.3 Removing and installing cover for gearbox housing and 5th and 6th gears
  125
• 6.4 Removing and installing gearbox housing and shift mechanism
  128
• 6.5 Removing and installing input shaft, output shaft, differential and selector forks
  130
• 6.7 Assembly sequence - Dismantling and assembling gearbox completely
  138
• 7 Repairing gearbox housing and clutch housing
  158
• 8 Repairing gearbox housing cover
  165
• 9 Repairing selector unit
  169
• 10 Dismantling and assembling selector forks
  172
• Gears, shafts
  178
• 1 Input shaft
  178
• 1.1 Dismantling and assembling input shaft
  178
• 1.2 Adjusting input shaft
  186
• 2 Output shaft
  191
• 2.1 Dismantling and assembling output shaft
  191
• 2.2 Adjusting output shaft
  203
• 3 Dismantling and assembling reverse shaft
  208
• 3.1 Dismantling and assembling reverse shaft with synchromeshed gear for reverse gear arrow
  208
• Final drive - differential
  212
• 1 Renewing flange shaft oil seals with gearbox installed
  212
• 1.1 Renewing oil seal for left flange shaft
  212
• 1.2 Distinguishing seals for right flange shaft
  214
• 1.3 Renewing seal (two-part seal and sleeve for right flange shaft)
  214
• 2 Adjustment overview
  221
• 3 Differential
  222
• 3.1 Dismantling and assembling differential
  222
• 3.2 Adjusting differential
  229