Volkswagen 6 Speed Manual Gearbox 02s Workshop Manual

Volkswagen 6 Speed Manual Gearbox 02s Workshop Manual
Full download: http://manualplace.com/download/volkswagen-6-speed-manual-gearbox-02s-workshop-manual/
Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
6-speed manual gearbox 02S
Edition 07.2009
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Service Department. Technical Information

This is the cut pages sample. Download all 206 page(s) at: ManualPlace.com
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R007520

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . n.A.G.. .V.ol.ks.w.a.g.en. A. G. . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation and capacities wage . . . . . . . . . . . . . d.o.es. n. . . . . . . . . . . . 1
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2 Overview - power transmission . . . . . . . r.is.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . 5
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3 Calculating overall gear ratio “i” . . . s.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . 7
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4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
spec
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
rrectne
2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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2.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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2.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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2.8 Assembly overview - hydraulics (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2.9 Assembly overview - hydraulics (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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2.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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2.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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3 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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4 Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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4.1 Determining clutch manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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4.2 Removing and installing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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4.3 Repairing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
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4.4 Removing and installing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.5 Repairing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Repairing clutch, in conjunction with one-piece flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 54
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 61
2.5 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.7 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 70
2.8 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 78
2.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Contents i
4.2 Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.3 Filling with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.3 Removing and installing cover for gearbox housing and 5th and 6th gear . . . . . . . . . . . . 104
5.4 Removing and installing gearbox housing and shift mechanism . . . . . . . . . . . . . . . . . . . . 107
5.5 Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . . 108
5.6 Assembly sequence - Removing and installing cover for gearbox housing and 5th and 6th
gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 115
6 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.2 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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1.3 Renewing seal (two-part ris seal and sleeve for right flange shaft) tee.o. . . . . . . . . . . . . . . . . . . . . 186
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1.4 Renewing seal sands a sleeve together (one-piece seal and sleeve foracright flange shaft) . . . . 189
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2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

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3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

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3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

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ii Contents
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1 Gearbox identification a ra
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Code letters and date of manufacture -arrow 1- Manual gearbox
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Manual gearbox 02S -arrow 2-

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Identification code and date of gearbox manufacture

Example: FNG 12 11 3
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Identification Day Month Year (2003)
code of manufacture
Additional data provide information about the production facility.
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The gearbox code also appears on the vehicle identification

plates.
1.2 Identification code, assembly allocation and capacities

Manual gearbox 6-speed 02S
Identification code FNG HYG GQM
Manufactured from 05.05 05.06 05.05
to 05.05 09.06
Allocation Model Jetta 2005 ▸ Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸
1. Gearbox identification 1

Identification code FNG HYG GQM
Engine 1.9 l - 74 kW 1.4 l - 103 kW 1.9 l - 74 kW
turbo diesel turbo diesel
1.9 l - 77 kW 1.9 l - 77 kW
turbo diesel turbo diesel
Ratio Final drive 62 : 17 = 3.647 61 : 18 = 3.389 61 : 18 = 3.389
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Drive shaft flange ∅ 100 mm 100 mm 107 mm

Identification code JYL JCL JCN
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2 Rep. Gr.00 - Technical data


Identification code JYL JCL JCN
⇒ page 99 (gearbox partially dis‐
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09.06 to 09.06
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Identification code JXP JXR KWB
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Ratio Final drive 62 : 17 = 3,647
Z1 : Z2
Capacity of manual gearbox (gear‐ 2.1 l
Capacity of manual gearbox 1.9 l
mantled)
Drive shaft flange ∅ 100 mm
1. Gearbox identification 3

Identification code JXP JXR KWB
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2 Overview - power transmission

Designation
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2 - Clutch
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Ratio
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2. Overview - power transmission 5

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
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3 Calculating overall gear ratio “i” tho
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Example: ss c
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6th gear Final drive
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Drive gear ZG1 = 45 ZA1 = 18
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Driven gear ZG2 = 34 ZA2 = 60
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i = Z2 : Z1 1)
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iG = Gear ratio = ZG2: ZG1= 34 : 45 = 0.756
iA = Final drive ratio = ZA2 : ZA1 = 60 : 18 = 3.389
rrectness of i
itotal = Overall ratio = iG x iA = 0.756 x 3.389 = 2.562
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1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
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3. Calculating overall gear ratio “i” 7

4 General repair notes

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of instructions generally applicable to the various repair
procedures - which were previously repeated a number of times
at various places in the workshop manual are summarised under
the topic “components” ⇒ page 8 . They apply to this workshop
manual.
4.1 Components n AG. Volkswagen AG

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4.1.1 ss
auGearbox ra
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♦ When installing the manual gearbox, ensure that the dowel
pt
an
d
sleeves between the engine and gearbox are correctly seated.

itte
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♦ When installing mounting brackets or waxed components,
ility
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clean the contact surfaces. Contact surfaces must be free of
wit
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wax and grease.
h re
ole,
spec
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue “ETKA” . t to the co

♦ Capacity ⇒ page 1 .
rrectne
♦ If the gearbox is repaired, fill with gear oil.

Capacity, gearbox completely Gearbox capacity, gearbox
ss
dismantled partially dismantled

o
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⇒ page 99
inform
mer
2.1 l 1.9 l
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n
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4.1.2 O-rings, seals, gaskets and sealants

i
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♦ Thoroughly clean housing joint surfaces before applying seal‐

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ant .
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♦ Apply sealant -AMV 188 200 03- uniformly but not too thick. t. Cop py
rig
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♦ Always renew O-rings, seals and gaskets. yri
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♦ After removing gaskets and seals, always inspect contact sur‐
agen
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face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing radial shaft seals, lightly oil outer diameter
and half-fill space between sealing lips -arrow- with sealing
grease -G 052 128 A1- .
♦ The open side of the oil seal faces the side with fluid filling.
♦ Press in new oil seals so that sealing lip does not contact the
shaft in the same place as the old seal (make use of insertion
depth tolerances).
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
♦ After renewing seals and gaskets, check oil level in gearbox
and replenish if necessary ⇒ page 99 .

4.1.3 Locking devices

♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slit -A- should be in
line with the line of force -arrow-.
4.1.4 Nuts and bolts

♦ Loosen nuts or bolts in the order opposite to the tightening
sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened diagonally in stages if no tightening
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au ra
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♦ Torque settings are specified for unoiled bolts and nuts.
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♦ Always renew self-locking bolts and nuts.
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ility
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♦ Threads of bolts secured with locking fluid must be cleaned

wit
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with a wire brush. Then insert bolts with locking fluid -

h re
hole
AMV 185 101 A1- . spec

es, in part or in w
♦ Clean threaded holes in which self-locking bolts or bolts with

t to the co
locking fluid have been inserted, e.g. with a thread chaser.

Otherwise there is a danger that the bolts may shear when
removed again.
rrectness of i
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4.1.5 Bearing
♦ Install needle bearings with lettered side (thicker metal) to‐
nf
ercia
wards fitting tool.

rm
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atio
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♦ Lubricate all gearbox bearings with gear oil before installing.

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♦ Tapered roller bearings fitted to one shaft must be renewed as

te
sd
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a set. Use same make of bearings.

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♦ Heat inner races to about 100° C with the inductive heater -

f
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t.
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VAS 6414- before installing.
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♦ Do not interchange outer or inner races of bearings of the rig ht
py by
same size. The bearings are matched in pairs.
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4. General repair notes 9

4.1.6 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
4.1.7 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for “scoring” and “signs of abnormal wear”.
♦ Check cone of synchromeshed gear for “scoring” and “signs
of abnormal wear”.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
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4.1.8 Gears, synchro-hubs, inner races for Vo gu
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synchromeshed gears aut
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♦ Heat inner races for synchromeshed gear to about 100° C with
ce
le
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the inductive heater -VAS 6414- before installing.

an
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♦ Heat synchro-hub with inductive heater -VAS 6414- to approx.

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100 °C before installing. Press in to stop when installing so

ot
there is no axial clearance.

wit
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♦ Heat gears with inductive heater -VAS 6414- to approx. 100 °

spec
C before installing. Press in to stop when installing so there is

es, in part or in w
no axial clearance.
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♦ Observe installation position.

rrectness of i
4.1.9 Synchromeshed gears

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♦ After assembly, check synchromeshed gears for slight play, or

for freedom of movement.
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4.1.10 Clutch
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♦ When removing gearbox, remove slave cylinder without dis‐

n in
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connecting pipes.
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♦ If the clutch slave cylinder is removed with the hydraulic line

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attached, do not depress clutch pedal. Otherwise the piston

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will be pressed out of the slave cylinder. Cop
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Rep. Gr.00 - Technical data
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.
AG. Volkswagen AG d
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4. General repair notes 11

30 – Clutch
1 Fault finding, power transmission
– Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ;
Complaints about clutch and clutch mechanism and ⇒ Fault
finding, power transmission; Rep. Gr. 34 ; Complaints about
selector mechanism
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12 Rep. Gr.30 - Clutch

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2 Repairing clutch mechanism
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2.1 Overview
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Before disconnecting battery, obtain code for radio units having anti-theft coding.
l purpos
♦ With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting
and connecting battery .
nf
ercia
♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
orm
battery .
m
atio
om
♦ Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
n in
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I - Assembly overview - pedal
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f
en
ng
cluster ⇒ page 14
t.
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Cop py
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II - Assembly overview - hy‐ yri
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ht
draulics (LHD) ⇒ page 37 cop Vo
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III - Assembly overview - hy‐
AG.
draulics (RHD) ⇒ page 39
2. Repairing clutch mechanism 13

2.2 Assembly overview - pedal cluster
1 - Bulkhead
❑ With support for mount‐
ing bracket
2 - Seal
❑ Always renew
❑ Between mounting agen
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bracket and bulkhead olksw not
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❑ Self-adhesive orise nte
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❑ Bond to mounting aut ra
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bracket s
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3 - Mounting bracket
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❑ For mounting clutch
ab
ility
pedal
ot p
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❑ Is provided with damp‐
h re
ole,
ing in some equipment
spec
variants ⇒ page 15
t to the co
❑ Removing and installing
⇒ page 25
4 - Bolt
rrectne
5 - Over-centre spring
ss
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cial p
f
⇒ page 15
inform
mer
6 - Bearing bush
atio
om
7 - Pivot pin
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8 - Clutch pedal
t
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um
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⇒ page 20
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9 - Retainer
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❑ To remove and install,
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separate master cylin‐ Prote
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der from clutch pedal
⇒ page 20
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 25
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 33
❑ Can be checked using “guided fault finding” of vehicle diagnostic tester
❑ The clutch position sender -G476- is identified as clutch pedal switch -F36- in “guided fault finding”.
13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
14 - Supply hose
❑ Rubber
❑ From 12.05, plastic ⇒ page 38
15 - Hexagon nut, 25 Nm
❑ Self-locking

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6-speed manual gugearbox 02S - Edition 07.2009
ara
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❑ Qty. 3 aut
h
ra
ss c
❑ For mounting bracket on bulkhead
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pt
❑ Always renew
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16 - Hexagon nut, 25 Nm
ility
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❑ Always renew
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17 - Stop
ole,
spec
❑ For clutch pedal
t to the co
Mounting bracket with damping -arrows-
rrectness o
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2.3 Removing and installing over-centre

spring
Special tools and workshop equipment required
♦ Release tool -T10178-
2.3.1 Removing
Vehicles with knee airbag
Note
The installation location of the knee airbag is above the pedal

cluster.
– First check whether a coded radio is fitted. If so, obtain anti-

theft code.
2. Repairing clutch mechanism 15

Volkswagen 6 Speed Manual Gearbox 02s Workshop Manual
Full download: http://manualplace.com/download/volkswagen-6-speed-manual-gearbox-02s-workshop-manual/

– With ignition switched off, disconnect battery earth strap ⇒

Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove trim and cover below trim on drive side ⇒ General
body repairs, interior; Rep. Gr. 68 .
Vehicles with knee airbag
– Remove bracket for knee airbag together with crash bar ⇒
Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐
stalling knee airbag bracket .
Continuation for all
– Remove cable guide -2- from steering column.
– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep.
Gr. 80 ; Repairing heating .
Vehicles without knee airbag
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
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Attachment with
ss a2 bolts
u ra
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– Remove crash bar -1- (2 bolts).

nl
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itte
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ility
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, is n
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es, in part or in w
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Attachment with 1 bolt

– Remove crash bar -1- (1 bolt -2-).
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Volkswagen 6 Speed Manual Gearbox 02s Workshop Manual

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Volkswagen 6 Speed Manual Gearbox 02s Workshop Manual

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Service Department. Technical Information

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R007520

2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4 Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.2 Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Manual gearbox 02S -arrow 2-

Identification code and date of gearbox manufacture

The gearbox code also appears on the vehicle identification

1.2 Identification code, assembly allocation and capacities

Manual gearbox 6-speed 02S

♦ Specification for gear oil

Manufactured from 05.05 05.05 11.05

Engine 2.0 l - 110 kW 2.0 l - 110 kW 1.4 l - 125 kW

Ratio Final drive 62 : 17 = 3.647 63 : 16 = 3.938 62 : 17 = 3.647

Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l

Manual gearbox 6-speed 02S

2 Rep. Gr.00 - Technical data

Manual gearbox 6-speed 02S

Manual gearbox 6-speed 02S

Manufactured 05.06 from 05.06 09.06

Ratio Final drive 63 : 16 = 3.938 62 : 17 = 3.647 62 : 17 = 3.647

box completely dismantled)

♦ Allocation of clutch plate and pressure plate

Manual gearbox 6-speed 02S

Manual gearbox 6-speed 02S

4 Rep. Gr.00 - Technical data

2 Overview - power transmission

2. Overview - power transmission 5

6 Rep. Gr.00 - Technical data

1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

3. Calculating overall gear ratio “i” 7

4 General repair notes

4.1 Components n AG. Volkswagen AG

♦ When installing the manual gearbox, ensure that the dowel

sleeves between the engine and gearbox are correctly seated.

clean the contact surfaces. Contact surfaces must be free of

wax and grease.

catalogue “ETKA” . t to the co

♦ If the gearbox is repaired, fill with gear oil.

dismantled partially dismantled

4.1.2 O-rings, seals, gaskets and sealants

♦ Thoroughly clean housing joint surfaces before applying seal‐

8 Rep. Gr.00 - Technical data

4.1.3 Locking devices

4.1.4 Nuts and bolts

♦ Threads of bolts secured with locking fluid must be cleaned

with a wire brush. Then insert bolts with locking fluid -

AMV 185 101 A1- . spec

♦ Clean threaded holes in which self-locking bolts or bolts with

locking fluid have been inserted, e.g. with a thread chaser.

wards fitting tool.

♦ Lubricate all gearbox bearings with gear oil before installing.

♦ Tapered roller bearings fitted to one shaft must be renewed as

a set. Use same make of bearings.