VW Polo 2010-2012 6-Speed Manual Gearbox 02U Workshop Manual

Description

VW Polo 6-Speed Manual Gearbox 02U Workshop Manual

This VW Polo 2010-2012 6-Speed Manual Gearbox 02U Workshop Manual is a complete Volkswagen Service Department repair manual for the 02U transmission fitted to the Polo 2010 onward with the 1.2 l – 77 kW 4-cylinder engine. Codes MFV, MTH, NBU, NTD, PRP and PRN are all covered, with production dates, final drive ratio (59:15 = 3.933) and gearbox oil capacity (2.1 l) listed for each. Edition 06.2017.

File Details

• • Manual type: Workshop/Repair Manual
• • Brand/Model: Volkswagen Polo 2010 onward, 6-speed manual gearbox 02U
• • Language: English
• • Page count: 159 pages
• • File format: PDF
• • Edition: 06.2017

Chapters Covered

• • 00 – Technical Data: safety precautions for start-stop systems, gearbox identification and codes, power transmission overview, gear ratio calculation, general repair instructions (gaskets, seals, sealant, locking devices, nuts and bolts, mountings, shims, synchro-rings, gear wheels), electrical component fitting locations
• • 30 – Clutch: clutch actuation overview, pedal cluster assembly, clutch pedal switch F36, master cylinder mounting bracket, clutch pedal removal/installation (LHD and RHD variants), hydraulics assembly (LHD/RHD), master and slave cylinder removal/installation, bleeding the clutch system, clutch release mechanism, clutch repair, input shaft seal renewal
• • 34 – Controls, Housing: selector mechanism installation position and overview, gear knob and cover assembly, gear lever and selector housing repair, selector cable assembly, selector mechanism removal/installation and adjustment, gearbox removal and installation, specified torques, checking gear oil, full gearbox dismantling and assembly (housing cover, clutch housing, input/output shaft, differential, selector forks), gearbox housing and clutch housing repair, gearbox housing cover repair, selector unit repair, selector fork dismantling and assembly
• • 35 – Gears, Shafts: input shaft assembly overview and dismantling/assembly, output shaft assembly overview and dismantling/assembly
• • 39 – Final Drive – Differential: flange shaft oil seal renewal (left and right) with gearbox installed, differential assembly overview, dismantling and assembling the differential, adjusting the differential

Together these repair groups walk a technician through every stage of gearbox work on this transmission – from initial identification and diagnosis through to a full teardown and precision rebuild of the internal gear train and differential.

What This Workshop Manual Lets You Do

With this VW Polo 6-Speed Manual Gearbox 02U Workshop Manual in hand, you can diagnose gearbox codes correctly, remove and refit the complete gearbox assembly, rebuild the clutch actuation system, service the selector mechanism, and dismantle the gear train down to individual shafts and the differential unit. Following the specified torques, gear oil capacities and clearances in this manual protects the gearbox from premature wear and comeback repairs, since guessing at these figures risks damaging synchros, bearings, or the differential gear set. This 6-Speed Manual Gearbox 02U Workshop Manual downloads instantly as a PDF after purchase – no shipping wait, no missing pages – and opens on a phone, tablet, laptop or PC, or prints out for bench-side reference in the workshop.