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
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “VW Polo 2010-2012 6-Speed Manual Gearbox 02U Workshop Manual” are as follows:
+00 – Technical datap. 5
1 Safety precautions for vehicles with a start-stop systemp. 5
+2 Identification of gearboxp. 6
2.1 Location on gearboxp. 6
2.2 Identification code, assembly allocation, capacitiesp. 6
3 Overview – power transmissionp. 8
4 Calculating overall gear ratio “i”p. 10
+5 General repair instructionsp. 11
5.1 Gearboxp. 11
5.2 Gaskets and sealsp. 11
5.3 Sealantp. 11
5.4 Locking devicesp. 12
5.5 Nuts and boltsp. 12
5.6 Mountingsp. 12
5.7 Shimsp. 12
5.8 Synchro-ringsp. 13
5.9 Gear wheelsp. 13
5.10 Synchromeshed gearsp. 13
5.11 Clutchp. 13
+6 Electrical componentsp. 14
+6.1 Overview of fitting locations – electrical componentsp. 14
6.1.1 Overview of fitting locations – electrical components, manual gearboxp. 14
6.1.2 Overview of fitting locations – electrical components, clutch mechanismp. 14
+30 – Clutchp. 16
+1 Repairing clutch mechanismp. 16
1.1 Overview – clutch actuationp. 16
1.2 Assembly overview – pedal clusterp. 17
+1.3 Removing, installing and adjusting clutch pedal switch -F36-p. 19
1.3.1 Removing clutch pedal switchp. 19
+1.4 Removing and installing mounting bracket with master cylinderp. 20
1.4.1 Removingp. 21
1.4.2 Installingp. 22
+1.5 Removing and installing clutch pedal with over-centre spring, LHDp. 23
1.5.1 Removingp. 24
1.5.2 Installingp. 25
+1.6 Removing and installing clutch pedal with extension spring, LHDp. 26
1.6.1 Removingp. 27
1.6.2 Installingp. 28
+1.7 Removing and installing clutch pedal, RHDp. 29
1.7.1 Removingp. 30
1.7.2 Installingp. 31
1.8 Assembly overview – hydraulics (LHD)p. 32
1.9 Assembly overview – hydraulics (RHD)p. 34
+1.10 Removing and installing master cylinderp. 36
1.10.1 Removingp. 36
1.10.2 Installingp. 36
+1.11 Removing and installing slave cylinderp. 36
1.11.1 Removingp. 37
1.11.2 Installingp. 37
1.12 Bleeding clutch systemp. 37
2 Repairing clutch release mechanismp. 39
3 Repairing clutchp. 41
4 Renewing input shaft sealp. 45
+34 – Controls, housingp. 47
+1 Repairing selector mechanismp. 47
1.1 Installation position of selector mechanismp. 47
1.2 Overview of selector mechanismp. 48
1.3 Assembly overview – gear knob and coverp. 49
1.4 Removing and installing gear knob and coverp. 49
1.5 Repairing gear lever and selector housingp. 51
1.6 Assembly overview – removing and installing selector cablesp. 53
+1.7 Removing and installing selector mechanismp. 57
1.7.1 Removingp. 57
1.7.2 Installingp. 59
1.7.3 Specified torquesp. 60
+1.8 Adjusting selector mechanismp. 60
+2 Removing and installing gearboxp. 64
2.1 Removing gearboxp. 67
2.2 Installing gearboxp. 72
2.3 Specified torquesp. 76
3 Checking gear oilp. 78
+4 Dismantling and assembling gearboxp. 80
4.1 Overview – gearboxp. 80
4.2 Assembly overviewp. 81
4.3 Assembly overview – removing and installing cover for gearbox housing and 5th and 6th gearp. 82
4.4 Assembly overview – removing and installing clutch housingp. 84
4.5 Assembly overview – removing and installing input shaft, output shaft, differential, selector mechanism and selector forksp. 85
+4.6 Assembly sequencep. 86
4.6.1 Modifying gearbox support -3221-p. 90
4.6.2 Dismantlingp. 90
4.6.3 Installingp. 96
5 Repairing gearbox housing and clutch housingp. 103
6 Repairing gearbox housing coverp. 108
7 Repairing selector unitp. 111
8 Dismantling and assembling selector forksp. 114
+35 – Gears, shaftsp. 119
+1 Input shaftp. 119
1.1 Assembly overview – input shaftp. 119
1.2 Dismantling and assembling input shaftp. 122
+2 Output shaftp. 131
2.1 Assembly overview – output shaftp. 131
2.2 Dismantling and assembling output shaftp. 134
+39 – Final drive – differentialp. 141
+1 Renewing flange shaft oil seals with gearbox installedp. 141
+1.1 Renewing oil seal for left flange shaftp. 141
1.1.1 Removingp. 141
1.1.2 Installingp. 143
+1.2 Renewing seal for right flange shaftp. 143
1.2.1 Removingp. 144
1.2.2 Installingp. 145
+2 Differentialp. 147
2.1 Assembly overview – differentialp. 147
2.2 Dismantling and assembling differentialp. 149
+2.3 Adjusting differentialp. 155
2.3.1 Determining shim S2p. 159
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.
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