Volkswagen 6-speed Dual Clutch Gearbox 02E Workshop Manual

The 6-speed manual gearbox 09G is installed in the Golf Variant 2007-, Golf Variant 2010- -,  Jetta 2005-, Jetta 2011-. Edition 07.2010 (MEX5R006620)

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

Edition: 07.2010 (MEX5R006620)
Language: English
Format: PDF
Pages: 104

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