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