6-speed manual gearbox 02S

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
  2
• 2.1 Gearbox identification
  2
• 3 Technical data
  3
• 3.1 Allocation gearbox - engine
  3
• 3.2 Capacities
  6
• 3.3 Calculation of gear ratios
  6
• 4 Overview - power transmission
  7
• 5 Electrical components
  9
• 5.1 Overview of fitting locations - electrical components
  9
• 6 Repair instructions
  11
• 6.1 General repair instructions
  11
• Clutch
  14
• 1 Clutch operation
  14
• 1.1 Overview of fitting locations – clutch mechanism
  14
• 1.2 Assembly overview - pedal cluster
  16
• 1.3 Assembly overview - clutch hydraulics
  20
• 1.4 Assembly overview - clutch release mechanism
  26
• 1.5 Removing and installing bearing bush
  27
• 1.6 Checking clutch master cylinder and clutch slave cylinder
  28
• 1.7 Removing and installing clutch position sender G476
  28
• 1.8 Removing and installing return spring
  31
• 1.9 Removing and installing over-centre spring
  33
• 1.10 Removing and installing clutch pedal
  46
• 1.11 Removing and installing mounting bracket
  51
• 1.12 Removing and installing clutch master cylinder
  70
• 1.13 Removing and installing clutch slave cylinder
  73
• 1.14 Removing and installing lines for clutch mechanism
  78
• 1.15 Bleeding clutch mechanism
  80
• 1.16 Repairing clutch release mechanism
  82
• 2 Clutch
  84
• 2.1 Assembly overview - clutch
  84
• 2.2 Removing and installing clutch
  87
• Controls, housing
  99
• 1 Selector mechanism
  99
• 1.1 Installation position - selector mechanism
  99
• 1.2 Overview - selector mechanism
  101
• 1.3 Assembly overview - gear knob and cover
  102
• 1.4 Assembly overview - Gear lever and selector housing
  104
• 1.5 Assembly overview - Selector cables
  106
• 1.6 Assembly overview - selector mechanism
  108
• 1.7 Removing and installing gear knob
  109
• 1.8 Dismantling and assembling selector mechanism
  115
• 1.9 Removing and installing selector mechanism
  119
• 1.10 Removing and installing gear selector cable and gate selector cable
  124
• 1.11 Repairing selector mechanism
  127
• 1.12 Adjusting selector mechanism
  129
• 1.13 Checking selector mechanism
  133
• 2 Removing and installing gearbox
  134
• 2.1 Distinguishing between different types of 1.4 l petrol engine, Golf Cabriolet, CC
  134
• 2.2 Removing gearbox
  135
• 2.3 Install gearbox
  205
• 2.4 Specified torques for gearbox
  246
• 3 Assembly mountings
  249
• 3.1 Assembly overview - assembly mountings
  249
• 4 Transporting gearbox
  251
• 5 Gear oil
  252
• 5.1 Checking gear oil level
  252
• 5.2 Draining and filling gear oil
  252
• 6 Installing to engine and gearbox support
  255
• 7 Dismantling and assembling gearbox
  256
• 7.1 Schematic overview - gearbox
  256
• 7.2 Assembly overview - gearbox
  258
• 7.3 Assembly overview - cover for gearbox housing and 5th/6th gear
  259
• 7.4 Assembly overview - gearbox housing and selector mechanism
  261
• 7.5 Assembly overview - selector unit
  263
• 7.6 Assembly overview - shafts, differential, selector mechanism
  264
• 7.7 Assembly overview - selector forks
  265
• 7.8 Repairing selector unit
  268
• 7.9 Renewing oil seal for selector shaft
  269
• 7.10 Repairing selector forks
  270
• 7.11 Removing cover for gearbox housing and 5th and 6th gears
  274
• 7.12 Dismantling and assembling gearbox
  281
• 7.13 Installing cover for gearbox housing and 5th and 6th gears
  294
• 8 Gearbox housing, clutch housing
  299
• 8.1 Assembly overview - gearbox housing and clutch housing
  299
• 8.2 Assembly overview - gearbox housing cover
  301
• 8.3 Repairing gearbox housing
  302
• 8.4 Repairing clutch housing
  307
• 8.5 Repairing gearbox housing cover
  308
• Gears, shafts
  312
• 1 Input shaft
  312
• 1.1 Assembly overview - input shaft
  312
• 1.2 Dismantling and assembling input shaft
  314
• 1.3 Adjusting input shaft
  319
• 1.4 Renewing input shaft seal
  324
• 2 Output shaft
  326
• 2.1 Assembly overview - output shaft
  326
• 2.2 Dismantling and assembling output shaft
  329
• 2.3 Adjusting output shaft
  339
• 3 Reverse shaft
  345
• 3.1 Assembly overview - reverse shaft
  345
• 3.2 Dismantling and assembling reverse shaft
  348
• Final drive - differential
  351
• 1 Oil seals
  351
• 1.1 Overview of fitting locations - seals
  351
• 1.2 Renewing left oil seal
  352
• 1.3 Renewing right oil seal
  354
• 2 Differential
  358
• 2.1 Assembly overview - differential
  358
• 2.2 Dismantling and assembling differential
  359
• 2.3 Adjusting differential
  365
• 3 Adjustment overview
  369