Volkswagen 6-Speed Manual Gearbox 02S Workshop Manual (Edition 07.2009 – MEX5R007520)

Volkswagen 6-Speed Manual Gearbox 02S Workshop Manual (Edition 07.2009 – MEX5R007520) PDF free online

The 6-speed manual gearbox 02S is installed in the:

  • Jetta 2005-
  • Golf Variant 2007-
  • Golf Variant 2010-

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
    • 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 vehicles)
    • Assembly overview – hydraulics (RHD vehicles)
    • Removing and installing slave cylinder
    • Bleeding clutch system
    • Repairing clutch release mechanism
    • Repairing clutch, in conjunction with dual-mass flywheel
    • Determining clutch manufacturer
    • Removing and installing Sachs clutch
    • Repairing Sachs clutch
    • Removing and installing LuK clutch
    • Repairing LuK clutch
    • Repairing clutch, in conjunction with one-piece flywheel
  • Controls, housing
    • Fault finding, power transmission
    • 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
    • Removing gearbox
    • Installing gearbox
    • Checking and topping up gear oil
    • Preparation
    • Draining gear oil
    • Filling with gear oil
    • Dismantling and assembling gearbox
    • Overview – gearbox
    • Assembly overview
    • Removing and installing cover for gearbox housing and 5th and 6th gear
    • Removing and installing gearbox housing and shift mechanism
    • Removing and installing input shaft, output shaft, differential and selector forks
    • Assembly sequence – Removing and installing cover for gearbox housing and 5th and 6th gear
    • Assembly sequence – Dismantling and assembling gearbox completely
    • Repairing gearbox housing and clutch housing
    • Repairing gearbox housing cover
    • Repairing selector unit
    • Dismantling and assembling selector forks
  • Gears, shafts
    • Input shaft
    • Dismantling and assembling input shaft
    • Adjusting input shaft
    • Output shaft
    • Dismantling and assembling output shaft
    • Adjusting output shaft
    • Reverse shaft
    • Dismantling and assembling reverse shaft
  • Final drive – differential
    • Renewing flange shaft oil seals with gearbox installed
    • Renewing oil seal for left flange shaft
    • Distinguishing seals for right flange shaft
    • Renewing seal (two-part seal and sleeve for right flange shaft)
    • Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft)
    • Adjustment overview
    • Differential
    • Dismantling and assembling differential
    • Adjusting differential

Language: English
Format: PDF
Pages: 206

Volkswagen 6-Speed Manual Gearbox 02S Workshop Manual (Edition 07.2009 – MEX5R007520) PDF free online

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