VW 6 SPEED Manual Gearbox 02Q Workshop Service Repair Manual
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Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
6-speed manual gearbox 02Q
Edition 06.2010
Service
Service Department. Technical Information
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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
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R006920
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Calculating overall gear ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.8 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.10 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Removing pipe/hose line and bleeder from and installing on slave cylinder . . . . . . . . . . . . 40
3.2 Removing and installing slave cylinder with release bearing . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Removing and installing pipe/hose line or plastic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Repairing clutch - vehicles with turbo diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Determining clutch manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Removing and installing „Sachs“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3 Repairing „Sachs“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 Removing and installing „LuK“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.5 Repairing „LuK“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Repairing clutch - vehicles with petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.1 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Removing and installing gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 62
1.5 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 64
1.6 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.7 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 71
1.8 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 80
1.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
Contents i
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2 Removing and installing gearbox in vehicles with turbo diesel engine . . . . . . . . . . . . . . . . 85
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Removing and installing gearbox, vehicles with petrol engine . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 Checking gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.1 Overview - rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.3 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . 130
5.4 Removing and installing input shaft, output shafts, differential and selector rods . . . . . . . . 132
5.5 Assembly order, gearbox »without« retaining ring A for input shaft sealing cover . . . . . . . . 134
5.6 Assembly order, gearbox »with« retaining ring A for input shaft sealing cover . . . . . . . . . . 145
6 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
9 Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2 Output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.1 Assembly overview - output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . 185
2.2 Dismantling and assembling output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . 187
2.3 Adjusting output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3 Output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . 211
3.2 Adjusting output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
ii Contents
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00 – Technical data
1 Gearbox identification
The 6-speed manual gearbox 02Q is installed in the Jetta 2005 â–º,
in the Golf Variant 2007 â–º, in the Golf Variant 2010 â–º and in the
Jetta 2011 â–º in conjunction with a 4-cylinder engine.
Allocation ⇒ page 1
1.1 Location on gearbox
Code letters and date of manufacture -arrow 1- manual gearbox
02Q -arrow 2-
Manual gearbox 02Q -arrow 2-
Identification code and date of gearbox manufacture -arrow-
Example: GRF 25 11 3
I I I I
I I I I
Identification
code
Day Month Year (2003)
of manufacture
Additional data provide information about the production facility.
Note
The gearbox code also appears on the vehicle identification
plates.
1.2 Identification code, assembly allocation and capacities
Manual gearbox 6-speed 02Q
Identification code GRF GVT GXC
Manufactured from
to
05.05
11.05
05.05
11.05
07.06
07.06
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
1. Gearbox identification 1
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Manual gearbox 6-speed 02Q
Identification code GRF GVT GXC
Allocation Model Jetta 2005 â–º
Golf Variant 2007 â–º
Jetta 2005 â–º
Golf Variant 2007 â–º
Jetta 2005 â–º
Golf Variant 2007 â–º
Engine 2.0 l - 103 kW
turbo diesel
2.0 l - 147 kW
turbo FSI
2.0 l - 125 kW
turbo diesel
Ratio: Z
2
: Z
1 Final drive I
1)
69 : 20 = 3.450 71 : 18 = 3.944 71 : 18 = 3.944
Final drive II
2)
69 : 25 = 2.760 71 : 23 = 3.087 71 : 23 = 3.087
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• The following data can be found in the ⇒ Electronic parts catalogue „ETKA“ .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate
Manual gearbox 6-speed 02Q
Identification code HDV HVS KNQ
Manufactured from
to
05.05 07.06 02.08
11.08
Allocation Model Jetta 2005 â–º
Golf Variant 2007 â–º
Jetta 2005 â–º
Golf Variant 2007 â–º
Golf Variant 2007 â–º
Engine 2.0 l - 96 kW
turbo diesel
2.0 l - 100 kW
turbo diesel
2.0 l - 103 kW
turbo diesel
2.0 l - 125 kW
turbo diesel
1.9 l - 77 kW
turbo diesel
1.6 l - 77 kW
turbo diesel
Ratio: Z
2
: Z
1 Final drive I
1)
69 : 20 = 3.450 70 : 19 = 3.684 72 : 17 = 4.235
Final drive II
2)
69 : 25 = 2.760 70 : 24 = 2.917 72 : 22 = 3.273
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• The following data can be found in the ⇒ Electronic parts catalogue „ETKA“ .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate
Manual gearbox 6-speed 02Q
Identification code KNS KNU KNY
Manufactured from
to
11.07
10.08
11.07
02.09
02.08
10.08
Allocation Model Jetta 2005 â–º
Golf Variant 2007 â–º
Golf Variant 2010 â–º
Jetta 2005 â–º
Golf Variant 2007 â–º
Jetta 2005 â–º
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
2 Rep. gr.00 - Technical data
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Manual gearbox 6-speed 02Q
Identification code KNS KNU KNY
Engine 2.0 l - 100 kW
turbo diesel
2.0 l - 103 kW
turbo diesel
2.0 l - 147 kW
2.0 l - 155 kW
2.0 l - 125 kW
turbo diesel
Ratio: Z
2
: Z
1 Final drive I
1)
69 : 20 = 3.450 71 : 18 = 3.944 70 : 19 = 3.684
Final drive II
2)
69 : 25 = 2.760 71 : 23 = 3.087 70 : 24 = 2.917
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• The following data can be found in the ⇒ Electronic parts catalogue „ETKA“ .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate
Manual gearbox 6-speed 02Q
Identification code KRM KXZ KZS
Manufactured from
to
05.07
07.10
05.09 05.09
Allocation Model Jetta 2005 â–º
Golf Variant 2010 â–º
Jetta 2005 â–º
Golf Variant 2007 â–º
Jetta 2005 â–º
Golf Variant 2007 â–º
Jetta 2011 â–º
Engine 2.0 l - 103 kW
turbo diesel
2.0 l - 125 kW
turbo diesel
2.0 l - 155 kW
2.0 l - 147 kW
Ratio: Z
2
: Z
1 Final drive I
1)
69 : 20 = 3.450 70 : 19 = 3.684 70 : 19 = 3.684
Final drive II
2)
69 : 25 = 2.760 70 : 24 = 2.917 70 : 24 = 2.917
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• The following data can be found in the ⇒ Electronic parts catalogue „ETKA“ .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate
Manual gearbox 6-speed 02Q
Identification code LHD LNN NFN
Manufactured from
to
10.08 06.09 05.09
Allocation Model Jetta 2005 â–º
Golf Variant 2007 â–º
Golf Variant 2010 â–º
Jetta 2011 â–º
Golf Variant 2010 â–º Jetta 2005 â–º
Engine 2.0 l - 100 kW
turbo diesel
1.6 l - 77 kW
turbo diesel
2.0 l - 125 kW
turbo diesel
Ratio: Z
2
: Z
1 Final drive I
1)
69 : 20 = 3.450 72 : 17 = 4.235 70 : 19 = 3.684
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
1. Gearbox identification 3
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Manual gearbox 6-speed 02Q
Identification code LHD LNN NFN
Final drive II
2)
69 : 25 = 2.760 72 : 22 = 3.273 70 : 24 = 2.917
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• The following data can be found in the ⇒ Electronic parts catalogue „ETKA“ .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate
Manual gearbox 6-speed 02Q
Identification code NFP MDL
Manufactured from
to
05.10 11.09
Allocation Model Golf Variant 2010 â–º Jetta 2011 â–º
Engine 2.0 l - 103 kW
turbo diesel
2.0 l - 155 kW
Ratio: Z
2
: Z
1 Final drive I
1)
69 : 20 = 3.450 70 : 19 = 3.684
Final drive II
2)
69 : 25 = 2.760 70 : 24 = 2.917
Capacity of manual gearbox 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• The following data can be found in the ⇒ Electronic parts catalogue „ETKA“ .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
4 Rep. gr.00 - Technical data
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2 Overview - power transmission
Designation
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft for 5th, 6th and
reverse gears
6 - Output shaft for 1st through
4th gears
7 - Differential
Gears
-Arrows- indicate direction of travel.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
2. Overview - power transmission 5
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I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
6 Rep. gr.00 - Technical data
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$37.99
This workshop service repair manual is designed for the VW 6 Speed Manual Gearbox 02Q and is applicable to the following vehicle models:
- VW Golf Variant 2007 onward
- VW Jetta 2005 onward
The manual covers the 6-speed manual transmission 02Q model and includes the following contents:
- Technical data
- Clutch system
- 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
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch - vehicles with turbo diesel engine
- Controls, housing
- Removing and installing gearbox in vehicles with turbo diesel engine
- Removing and installing gearbox, vehicles with petrol engine
- Installing gearbox
- Specified torques
- Dismantling and assembling gearbox
- Repairing gearbox housing
- Repairing clutch housing
- Repairing selector unit
- Renewing oil seal for selector shaft
- Repairing selector forks
- Gears, shafts
- Input shaft
- Output shaft
- Final drive - differential
- Renewing flange shaft oil seals with gearbox installed
This comprehensive manual features detailed exploded views and step-by-step procedures with illustrations, making it useful for both professional mechanics and DIY enthusiasts. It is designed for repairs, maintenance, and servicing of the specified vehicle models.
