Volkswagen 6-speed Dual Clutch Gearbox 02E Workshop Manual (Edition 07.2010 MEX5R006620)
The 6-speed manual gearbox 09G is installed in the: Golf Variant 2007-, Golf Variant 2010-, Jetta 2005-, Jetta 2011-
Repair Group
CONTENTS
- Technical data
- General repair notes
- Tools
- Gearbox
- Overview
- O-rings, seals and gaskets
- Dual clutch gearbox oil
- Nuts and bolts
- Electrical components
- Fault finding
- General notes on fault finding
- Useful information about the „behaviour of the control unit in the event of a gearbox fault“
- Special notes on fault finding
- Gearbox identification
- Reading gearbox code letters
- Code – engine allocation
- Identification code
- Capacity
- Clutch
- Notes on clutch
- Removing and installing clutch
- Removing clutch cover (end cover)
- Installing clutch cover (end cover)
- Removing clutch
- Preparing installation of multi-clutch
- Installing and adjusting clutch
- Controls, housing
- Electrical and electronic components for the dual clutch gearbox and their locations
- Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
- Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
- Removing and installing gearbox input speed sender G182 and oil temperature sender in multi-plate clutch G509
- Removing and installing gearbox oil cooler
- Removing gearbox oil cooler
- Installing gearbox oil cooler
- Removing and installing oil pump
- Removing oil pump
- Installing oil pump
- Renew seal on selector shaft lever
- Selector mechanism
- Overview – selector mechanism in vehicles up to 02.2009
- Removing and installing selector lever cable – vehicles up to 02.2009
- Overview of selector mechanism – vehicles from 03.2009 onwards
- Removing and installing selector mechanism with selector lever and selector lever cable – vehicles from 03.2009 onwards
- Checking selector lever cable
- Adjusting selector lever cable
- Emergency release of selector lever
- Removing and installing selector lever knob
- Checking selector mechanism
- Removing and installing gearbox
- Removing gearbox
- Installing gearbox
- Torque settings
- Transporting gearbox and securing to assembly stand
- Changing oil and filter and adjusting oil level
- Changing oil and filter
- Gears, shafts
- Currently, no repairs can be made to gears and shafts
- Final drive – differential
- Renewing seals for flange shaft or stub shaft
- Renewing oil seal for left flange shaft
- Renewing seals for right flange shaft or stub shaft
Language: English
Format: PDF
Pages: 105