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  • Examplepage for repair manual 6-speed manual gearbox O2U
  • Examplepage for repair manual 2 6-speed manual gearbox O2U
  • Examplepage for repair manual 3 6-speed manual gearbox O2U

6-speed manual gearbox O2U

For Polo A05

Original Volkswagen repair manual


13,34 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

8.009 KB

155 Sites

Detailed technical data

Immediately readable

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