Volkswagen 6-speed Manual Gearbox 02Q Workshop Manual (Edition 06.2010 MEX5R006920)

Volkswagen 6-speed Manual Gearbox 02Q Workshop Manual (Edition 06.2010 MEX5R006920) PDF free online. The 6-speed manual gearbox 02Q is installed in the: Jetta 2005-, Golf Variant 2007-, Golf Variant 2010-, Jetta 2011-

in conjunction with a 4-cylinder engine.

Repair Group

CONTENTS

  • Technical data
    • Gearbox identification
    • Location on gearbox
    • Identification code, assembly allocation and capacities
    • Overview – power transmission
    • Calculating overall gear ratio „i“
    • General repair notes
    • Contact corrosion!
    • Special tools
    • Components
  • Clutch
    • Fault finding, power transmission
    • Repairing clutch mechanism
    • Overview
    • Assembly overview – pedal cluster
    • Removing and installing over-centre spring
    • Removing and installing clutch pedal
    • Removing and installing mounting bracket
    • Removing and installing master cylinder
    • Removing and installing clutch position sender G476
    • Assembly overview – hydraulics (LHD)
    • Assembly overview – hydraulics (RHD)
    • Bleeding clutch system
    • Repairing clutch release mechanism
    • Removing pipe/hose line and bleeder from and installing on slave cylinder
    • Removing and installing slave cylinder with release bearing
    • Removing and installing pipe/hose line or plastic line
    • Renewing input shaft seal
    • Repairing clutch – vehicles with turbo diesel engine
    • Determining clutch manufacturer
    • Removing and installing „Sachs“ clutch
    • Repairing „Sachs“ clutch
    • Removing and installing „LuK“ clutch
    • Repairing „LuK“ clutch
    • Repairing clutch – vehicles with petrol engine
    • Repairing clutch
    • Removing and installing clutch
  • Controls, housing
    • Repairing selector mechanism
    • Installation position of selector mechanism
    • Overview of selector mechanism
    • Removing and installing gear knob and frame
    • Removing and installing gaiter with gear knob and noise insulation
    • Repairing gear lever and selector housing (through 10.06)
    • Repairing gear lever and selector housing (from 11.06)
    • Assembly overview – removing and installing selector cables
    • Plastic relay lever
    • Removing and installing selector mechanism
    • Removing and installing gear selector cable and gate selector cable
    • Adjusting selector mechanism
    • Removing and installing gearbox in vehicles with turbo diesel engine
    • Removing gearbox
    • Transporting gearbox
    • Installing gearbox
    • Specified torques
    • Removing and installing gearbox, vehicles with petrol engine
    • Removing gearbox
    • Transporting gearbox
    • Installing gearbox
    • Specified torques
    • Checking gearbox oil
    • Dismantling and assembling gearbox
    • Overview – rear final drive
    • Assembly overview
    • Removing and installing gearbox housing and selector mechanism
    • Removing and installing input shaft, output shafts, differential and selector rods
    • Assembly order, gearbox »without« retaining ring A for input shaft sealing cover
    • Assembly order, gearbox »with« retaining ring A for input shaft sealing cover
    • Repairing gearbox housing
    • Repairing clutch housing
    • Repairing selector unit
    • Renewing oil seal for selector shaft
    • Repairing selector forks
  • Gears, shafts
    • Input shaft
    • Dismantling and assembling input shaft
    • Output shaft for 1st through 4th gears
    • Assembly overview – output shaft for 1st through 4th gears
    • Dismantling and assembling output shaft for 1st through 4th gears
    • Adjusting output shaft for 1st through 4th gears
    • Output shaft for 5th, 6th and reverse gears
    • Dismantling and assembling output shaft for 5th, 6th and reverse gears
    • Adjusting output shaft for 5th, 6th and reverse gears
  • Final drive – differential
    • Renewing flange shaft oil seals with gearbox installed
    • Renewing oil seal for left flange shaft
    • Renewing seal for right flange shaft
    • Adjustment overview
    • Differential
    • Dismantling and assembling differential
    • Adjusting differential

Language: English
Format: PDF
Pages: 246

Volkswagen 6-speed Manual Gearbox 02Q Workshop Manual (Edition 06.2010 MEX5R006920) PDF free online

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