Name: 6-speed manual gearbox O2U
Brand: Volkswagen
SKU: CDGc9232da08464
Price: 13.34 EUR
Availability: InStock

Content
Details
Reviews

Repair manual Polo A05 6-speed manual gearbox O2U PDF download has the following content:

Chapter overview

Technical data
1
1 Safety instructions
1
1.1 Safety precautions 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
3
3.3 Calculation of gear ratios
3
4 Overview - power transmission
4
5 Electrical components
6
5.1 Overview of fitting locations – electrical components
6
6 Repair instructions
7
6.1 General repair notes
7
Clutch
10
1 Clutch operation
10
1.1 Overview of fitting locations – clutch mechanism
10
1.2 Assembly overview - pedal cluster
12
1.3 Assembly overview - clutch hydraulics
14
1.4 Assembly overview - clutch release mechanism
17
1.5 Removing and installing bearing bush
18
1.6 Checking clutch master cylinder and clutch slave cylinder
18
1.7 Removing and installing clutch position sender G476
18
1.8 Removing and installing over-centre spring
20
1.9 Removing and installing extension spring
22
1.10 Removing and installing clutch pedal
22
1.11 Removing and installing mounting bracket
24
1.12 Removing and installing clutch master cylinder
27
1.13 Removing and installing clutch slave cylinder
28
1.14 Removing and installing lines for clutch mechanism
29
1.15 Bleeding clutch mechanism
32
1.16 Repairing clutch release mechanism
34
2 Clutch
36
2.1 Assembly overview - clutch
36
2.2 Removing and installing clutch
37
Controls, housing
41
1 Selector mechanism
41
1.1 Installation position - selector mechanism
41
1.2 Assembly overview - gear knob and cover
43
1.3 Assembly overview - selector mechanism
44
1.4 Removing and installing gear knob
45
1.5 Removing and installing selector mechanism
47
1.6 Repairing selector mechanism
50
1.7 Adjusting selector mechanism
53
1.8 Checking selector mechanism
55
2 Removing and installing gearbox
56
2.1 Removing gearbox
56
2.2 Installing gearbox
64
2.3 Specified torques for gearbox
69
3 Assembly mountings
70
3.1 Assembly overview - assembly mountings
70
4 Transporting gearbox
72
5 Gear oil
73
5.1 Checking gear oil level
73
6 Installing to engine and gearbox support
75
7 Dismantling and assembling gearbox
77
7.1 Schematic overview - gearbox
77
7.2 Assembly overview - gearbox
78
7.3 Assembly overview - cover for gearbox housing and 5th/6th gear
79
7.4 Assembly overview - clutch housing
80
7.5 Assembly overview - shafts, differential, selector mechanism
81
7.6 Assembly overview - selector unit
82
7.7 Assembly overview - selector forks
84
7.8 Repairing selector forks
85
7.9 Repairing selector unit
88
7.10 Renewing oil seal for selector shaft
91
7.11 Dismantling and assembling gearbox
91
8 Gearbox housing, clutch housing
106
8.1 Assembly overview - gearbox housing and clutch housing
106
8.2 Assembly overview - gearbox housing cover
108
8.3 Repairing gearbox housing cover
109
8.4 Repairing clutch housing
110
Gears, shafts
113
1 Input shaft
113
1.1 Assembly overview - input shaft
113
1.2 Dismantling and assembling input shaft
116
1.3 Renewing input shaft seal
124
2 Output shaft
126
2.1 Assembly overview - output shaft
126
2.2 Dismantling and assembling output shaft
128
Final drive - differential
134
1 Oil seals
134
1.1 Overview of fitting locations - seals
134
1.2 Renewing left oil seal
135
1.3 Renewing right oil seal
137
2 Differential
140
2.1 Assembly overview - differential
140
2.2 Dismantling and assembling differential
141
2.3 Adjusting differential
147

Manufacturer's designation	6-speed manual gearbox O2U
Manufacturer	Volkswagen
Suitable for	Polo A05 (2010)
Suitable car types	6R
Transmission designations	02U
Transmission types	FSS, HBK, GPF, FUT, GVX, GSN, GEZ, LMD, NBV, MFV, MTH, NBU
Category	Reparaturanleitung

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