Technical data Gearbox identification The 6-speed manual gearbox 02S is installed in the Jetta 2005 ▸, in the Golf Variant 2007 ▸ and in the Golf Variant 2010 ▸ in con‐ junction with a 4-cylinder engine. Allocation ⇒ page 1...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Manual gearbox 6-speed 02S Identification code Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l box completely dismantled) Capacity of manual gearbox 1.9 l...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Manual gearbox 6-speed 02S Identification code • The following data can be found in the ⇒ Electronic parts catalogue “ETKA” .
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 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.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 4.1.3 Locking devices ♦ Do not overstretch retaining rings. ♦ Always renew retaining rings which have been damaged or overstretched.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 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.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Ensure that the pressure plate does not cant: loosen and tight‐ en bolts diagonally and in several gradual stages.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket. – To do this, remove lock washers -A- for damping.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Note The clutch pedal remains hooked to operating rod of master cyl‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Some cars have damping -arrow- on the clutch pedal mounting bracket. – Return it to installation position. Vehicles without knee airbag The crash bar -1- in front of clutch pedal -2- may be secured in different ways.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 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;...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket. – To do this, remove lock washers -A- for damping.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. – Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in‐...
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts –...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Continuation for all Note During the following work, ensure that no brake fluid lands on ♦ longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove bracket for knee airbag together with crash bar ⇒ Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – To do this, remove lock washers -A- for damping. – Pull off damping. – Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer. ♦ Length of spacer = about 40 mm (e.g.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove complete air filter housing if it is near battery ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Clamp off supply hose to master cylinder using hose clamp to 25 mm ∅ -3094- . – Release securing clip -2- with a screwdriver or a pointed object and pull out of master cylinder to stop.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 If the pipe/hose line was removed – Push pipe/hose line -1- or plastic line with seal -2- onto con‐ nection of master cylinder -4- until securing clip -3- engages audibly.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Some notches -arrows- are located in lower region of sump be‐ tween engine -A- and gearbox -B-. – Check outer contour of flywheel through these notches.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking ends of diaphragm spring • Wear to half the thickness of the diaphragm spring -arrows- is permitted. Checking spring connections and riveted connections –...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Note Renew pressure plate and clutch plate together only. Select ♦ clutch plate and pressure plate according to engine code and ⇒...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking position of adjusting mechanism with new pressure plates only • Both edges -A- of the adjuster ring must be located between the two notches -arrows B-.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Flywheel ❑ Removing and installing ⇒ Rep. Gr. 13 ❑ Ensure that centring pins fit tightly ❑ Keep contact surface for clutch lining free of grooves, oil and grease.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking ends of diaphragm spring • Wear up to half the thickness of the diaphragm spring is per‐ mitted. Checking spring connections and riveted connections –...
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing and installing gear knob and frame 1 - Emblem ❑ Can be carefully levered off gear knob of plastic...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Pull gaiter with frame for centre console upwards, inside out over gear knob. – Open clamp -arrow- and pull off gear knob together with gaiter.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Fitting position of cable tie for cables – Wind cable tie -arrow- around the selector cables in a figure eight and secure them as shown in figure.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Relay lever with clip -arrow 1- – Pull clip -arrow 1- off and remove relay lever together with ca‐ ble end-piece.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Levering gate selector cable end-piece off plastic relay lever • Relay lever has been removed. – Insert a flat-blade screwdriver -A- between bush -B- and relay lever.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Torque wrench -V.A.G 1331- ♦ Grease -G 000 450 02- – First check whether a coded radio is fitted. If so, obtain anti- theft code.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Releasing cable end-piece from gate selector cable – Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Clip -A- holds cables and heat shield together in position. – Install cable support bracket on gearbox and tighten bolts to specified torques ⇒...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Bend open tabs -arrows- of selector mechanism cover using a screwdriver and remove cover. – Remove gasket. – Pull off securing clips -2 and 3-. (Securing clips -1 and 4- have been discontinued.) Lever gear selector cable off gear lever...
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Adjust support beam on sliding piece using locking pin -arrow-. Number of holes visible = 5. – Lift gearbox using workshop crane and gearbox lifting tackle -3336- .
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 The clutch plate must slide easily to and fro on the input shaft. To install gearbox “02S”, set up gearbox support -3282- with ad‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque ⇒ page 96 – Align engine and gearbox in installation position using both spindles of support bracket -10-222A- .
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Install pendulum support with new bolts -arrows A-, -B- and -C- ⇒ Running gear, axles, steering ; Rep. Gr. 40 ; Repairing front suspension .
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking and topping up gear oil It is not possible to check the gear oil level by unscrewing the oil filler plug.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Clean gearbox. Caution To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Assembly sequence - Removing and in‐ stalling cover for gearbox housing and 5th and 6th gear Note Follow the working procedure described below if only the 5th ♦...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 • Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 • Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove selector fork for 5th and 6th gears as follows: – Cover openings with a cloth. – Engage 5th gear -arrows 1- and -2-.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Now remove 3rd bolt -arrow- for reverse shaft support bracket. – Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove bolts -A- from clutch housing side for securing clutch housing to gearbox housing. Note Do not remove nuts -B- for output shaft bearing support.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Screw M8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after gearbox housing is fitted.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Install selector shaft with selector shaft cover plate as follows: – Place selector plates in neutral. – Apply sealant -AMV 188 200 03- evenly to sealing surface of selector mechanism cover.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking 5th gear synchro-ring and 6th gear synchro-ring – Before installing synchromeshed gears and synchro-rings for 5th and 6th gear, press synchro-rings onto cones of synchro‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Drive on synchro-hub for 5th and 6th gear. Note When driving on, ensure that synchro-ring moves freely. – Heat inner race of cylindrical roller bearing for 6th gear syn‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Installation position of gear wheel for 6th gear: Groove -B- faces away from sleeve -A-. “Or” groove -arrow 1- near shoulder -arrow 2- faces away from sleeve -A- see previous figure).
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Selector unit ❑ Consists of selector shaft and selector shaft cover ❑ Components cannot be separated from each other 2 - -Schalter für Rückfahr‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing angled rod -A- from selector shaft cover – Remove outer part of angled rod. – Then carefully lever out angled rod using a screwdriver.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Installing springs with bent ends -A- The modified springs are installed on both sides. – Spring are installed only in conjunction with locking pieces which are hollow on the inner side.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 There are different versions. Seal -1- and sleeve -2- are two parts. Identification: notches along circumference of sleeve -arrow-. Renew seal ⇒...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1.3.2 Installing – Drive in new seal to stop, being careful not to cant seal. – Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1- .
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Adjustment overview Note If repairs have been carried out to the gearbox, it is necessary to adjust the input shaft, output shaft or differential only if compo‐...
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Installation position of thrust washer for tapered ring -1-. The shoulder -arrow- points towards spring -B-. Some gearboxes have lugs -A-.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 It is necessary to readjust the differential when the following com‐ ponents are renewed: ♦ Gearbox housing ♦ Clutch housing ♦...
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