8 Speed Automatic Gearbox PDF

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Repair GroupsList of Workshop Manual Repair Groups
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Repair Group
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00 - Technical data
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30 - Clutch
32 - Torque converter
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37 - Controls, housing
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38 - Gears, control
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2013 Volkswagen AG, Wolfsburg D3E80480C6A

Amarok 2011 ➤
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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.3 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.4 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.1 Rules for safety when working on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.1 Rules for cleanliness when working on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.1 Allocation of gearbox to engine, gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.1 Assembly overview - torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.2 Proper handling of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Removing and installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Assembly overview - selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Emergency release from position »P« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Removing and installing cable support bracket for selector lever cable . . . . . . . . . . . . . . . . 21
1.8 Removing and installing gearbox selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Removing and installing gearbox carrier/gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1 Assembly overview - ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 Removing and installing ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Removing and installing ATF lines, ATF cooler/thermostat . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4 Removing and installing ATF lines, thermostat/gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5 Removing and installing ATF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.6 Cleaning ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Contents i
Amarok 2011 ➤
8-speed automatic gearbox 0CM - Edition 04.2013
6.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.2 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Assembly overview - sump/oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3 Removing and installing hydraulic impulse oil storage with accumulator solenoid N485 . . 60
2 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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Amarok 2011 ➤
00 – Technical data
1 Repair instructions
(VRL005441; Edition 04.2013)
⇒ “1.1 Tools”, page 1
⇒ “1.2 Gearbox”, page 1
⇒ “1.3 Gaskets and seals”, page 2
⇒ “1.4 ATF”, page 2
⇒ “1.5 Nuts and bolts”, page 2
⇒ “1.6 Electrical components”, page 3
⇒ “1.7 Contact corrosion!”, page 3
1.1 Tools
A summary of the special tools and workshop equipment used in
the workshop manual precedes each repair procedure and can
be found in “Special tools/Workshop equipment” binder.
Uncertainty often occurs with smaller bolts having low tightening
forces. Torque wrench 2...10 Nm - V.A.G 1783- can be used with
these bolts.
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♦ If gearbox covers have been unbolted or gearbox has no fluid,

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♦ First thoroughly clean connecting points and surrounding

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areas and then loosen bolts.

♦ When installing the gearbox, ensure that dowel sleeves be‐
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tween the engine and gearbox are correctly located.

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♦ Place removed parts on a clean surface. Cover parts to pre‐

vent soiling. Use plastic sheeting and paper. Use lint-free
cloths only!
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♦ If repair work cannot be performed immediately, carefully cov‐

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♦ Install only clean parts; do not remove new parts from pack‐
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♦ Do not run engine or tow vehicle with pan removed or when

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♦ After installing, check ATF level ⇒ page 51 .
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1. Repair instructions 1
Amarok 2011 ➤
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♦ When seals have been removed, hor check contact surface on eo
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♦ Before installing the seal, slightly moisten outer circumference
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♦ Only use ATF for automatic transmission components. Other
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♦ Open side of oil seal faces oil.
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♦ After installing, check ATF level ⇒ page 51 .
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1.4 ATF
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Use caution when handling oil. Dispose of used oil properly.

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Use only ATF available from the ⇒ Electronic Parts Catalogue
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Capacity ⇒ page 7 .
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1.5 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Threads of bolts secured with locking fluid must be cleaned
with a wire brush.
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Always renew self-locking bolts and nuts.
♦ Torque settings are specified for unoiled bolts and nuts.
2 Rep. gr.00 - Technical data

Amarok 2011 ➤
1.6 Electrical components

You have probably at some time received an electrical shock
when touching a metal object. This is due to the electrostatic
charge of the human body. This charge can disturb the function
of electrical components of the gearbox and of the selector mech‐
anism.
– Before working on electrical components, electrostatically dis‐
charge yourself (touch something that is earthed). Do not
touch connectors or »open« electronic components directly.
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1.7 Contact corrosion!
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Contact corrosion can occur if non-approved fasteners are used
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For this reason, fastening elements with special surface coating
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must be used.
Furthermore, rubber and plastic components as well as adhe‐
sives are made of non-conductive materials.
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If there are doubts about the suitability of fastening components,
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always use new parts ⇒ Electronic Parts Catalogue .

Note the following:
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♦ It is recommended to use only genuine parts, since only gen‐
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♦ Damage resulting from contact corrosion is not covered by the
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1. Repair instructions 3
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2 Safety instructions
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⇒ “2.1 Rules for safety when working on the gearbox”,
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2.1 Rules for safety when working on the
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To prevent personal injury and material damage to the vehicle,
observe the following:
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WARNING
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Risk of injury and accident by accidental engagement of gear

while engine is running.
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♦ Before working on vehicle with engine running, always
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Risk of poisoning from exhaust gases while engine is running.
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Danger of injury; the radiator fans can run at any time.

♦ Disconnect electrical connectors before starting work in
the area of the radiator cowl.
To prevent personal injury and damage to or destruction of elec‐

trical and electronic components, observe the following:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
Danger of destruction of electronic components when battery

is disconnected.
♦ Take the necessary measures when disconnecting the
battery.
♦ Disconnect battery only after the ignition has been switch‐
ed off.
– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .

Amarok 2011 ➤
Safety measures for vehicles with Start/Stop system
WARNING
Injury hazard as a result of automatic engine start in vehicles

with Start/Stop system
♦ In vehicles with the Start/Stop system activated (identifi‐
able by an indication in the dash panel insert) the engine
can start automatically if required.
♦ When working on the vehicle, therefore, ensure that the
Start/Stop system is deactivated (switch ignition off, then
switch ignition back on when required).
– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .

Observe the following if test and measuring instruments are re‐
quired during a road test:
WARNING
Accident hazard as a result of distraction and inadequate se‐

curing of test and measuring equipment.
Danger as a result of activation of front passenger airbag in
event of an accident. agen
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♦ Always strap test and measuring instruments in place on

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2. Safety instructions 5
Amarok 2011 ➤
3 General notes
⇒ “3.1 Rules for cleanliness when working on the gearbox”, page
6
3.1 Rules for cleanliness when working on

the gearbox
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Only use commercially available and lint-free cloths for clean‐
ing, e.g. the “WYPALL X70 / WORKHORSE” cloth from Kim‐
berly-Clark Professional.
♦ Seal open lines and connections immediately using clean
plugs or sealing caps from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use plastic foils or lint-free cloths.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
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Amarok 2011 ➤
4 Technical data
⇒ “4.1 Allocation of gearbox to engine, gear ratios”, page 7
⇒ “4.2 Capacities”, page 7
4.1 Allocation of gearbox to engine, gear ratios

Automatic gearbox 0CM
Gearbox Identification NPZ NPY NLG NLF
code
Allocation Model Amarok 2011 ► Amarok 2011 ► Amarok 2011 ► Amarok 2011 ►
Engine 2.0 l - 132
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Ratio 1st gear y Vo lks
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2nd gear
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3.143 3.143 ntee 3.143 3.143
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4th gear 1.667 1.667 1.667 1.667

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5th gear 1.285 1.285 1.285 1.285
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6th gear 1.000 1.000 1.000 1.000
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7th gear 0.839 0.839 0.839 0.839
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8th gear 0.667 0.667 0.667 0.667
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Reverse 3.300 3.300 3.300 3.300
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4.2 Capacities
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Caution
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Risk of malfunctions or failure of gearbox.

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♦ Only the ATF ordered through the replacement part sys‐

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Parts Catalogue .
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Capacities Lubricant
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Initial filling of gearbox by manufac‐ Prote
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ATF
turer depending on engine
Fill of ATF cooling system approx. 0.6 l
The ATF is obtainable as a spare part.

Container size 1.0 l - Part No. ⇒ Electronic Parts Catalogue
4. Technical data 7
Amarok 2011 ➤
30 – Clutch
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8 Rep. gr.30 - Clutch

Amarok 2011 ➤
32 – Torque converter
1 Torque converter
⇒ “1.1 Assembly overview - torque converter”, page 9
⇒ “1.2 Proper handling of torque converter”, page 9
⇒ “1.3 Removing and installing torque converter oil seal”,
page 10
⇒ “1.4 Draining torque converter”, page 11
⇒ “1.5 Removing and installing torque converter”, page 12
1.1 Assembly overview - torque converter
1 - Torque converter
❑ Removing and installing
⇒ page 12 agen
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5 - O-ring
6 - Bolt
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❑ 85 Nm
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1.2 Proper handling of torque converter

– Always secure converter.
An unsecured torque converter may slide out when the gearbox
is tipped.
1. Torque converter 9
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Therefore, always work with care.
1.3 Removing and installing torque convert‐

er oil seal
Special tools and workshop equipment required
♦ Oil seal extractor lever - VW 681-
10 Rep. gr.32 - Torque converter

Amarok 2011 ➤
Removing
– Apply oil seal extractor lever - VW 681- directly behind sealing
lip of seal to avoid damaging stop ring and lever out seal.
Installing
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Install in reverse order of removal, observing the following:
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– Apply ATF to circumference and sealing lipshoof ris oil seal. tee
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– Using suitable thrust piece , drive in torque converter seal to
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1.4 Draining torque converter
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♦ Used oil collection and extraction unit - V.A.G 1782-
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♦ Oil extraction probe - V.A.G 1358 A/1-

If oil has become fouled by abraded material or if a major overhaul
of gearbox is being performed, drain torque converter as follows:
1. Torque converter 11
Amarok 2011 ➤
– Extract ATF from torque converter using oil extractor -

V.A.G 1358 A- and oil extraction probe - V.A.G 1358 A/1-
or
– Extract ATF using waste oil collection and extraction unit -

V.A.G 1782- from torque converter.
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♦ Depth gauge
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Removing
– Remove gearbox ⇒ page 25 .
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Oil may escape when the torque converter is pulled out of the
gearbox.
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– Remove torque converter from gearbox.

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12 Rep. gr.32 - Torque converter

Amarok 2011 ➤
– Push torque converter into gearbox to stop.

The torque converter is properly installed when the gearbox can
be pushed against the engine flange »without force«.
– If this is not the case, fit the torque converter again. Then check
the installation dimension ⇒ page 13 .
Installation dimension
• The torque converter is correctly installed when the distance
-a- between the contact surfaces at the threaded holes of the
torque converter and the torque converter housing is at least
26.25 mm.
– Ensure that the torque converter does not slide »forwards«
during the installation of the gearbox.
Caution
If engine and gearbox are brought together with force because

the torque converter is improperly fitted, both gearbox and tor‐
que converter will be damaged.
The torque converter is properly installed when the gearbox can

be pushed against the engine flange »without force«.
Secure drive plate on torque converter.
– After installing gearbox, check ATF level and top up
⇒ page 51 . gen AG
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♦ ⇒ “1.1 Assembly overviewut-hotorque converter”, page 9 eo
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1. Torque converter
Amarok 2011 ➤
37 – Controls, housing
1 Selector mechanism
⇒ “1.1 Assembly overview - selector lever handle”, page 14
⇒ “1.2 Checking selector mechanism”, page 15
⇒ “1.3 Emergency release from position P ”, page 16
⇒ “1.4 Removing and installing selector lever handle”,
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⇒ “1.7 Removing and installing cable
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lever cable”, page 21

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⇒ “1.8 Removing and installing gearbox selector lever”,
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WARNING
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Before working on vehicle with engine running, move selector
lever into position “P” and apply handbrake.
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14 Rep. gr.37 - Controls, housing

Amarok 2011 ➤
1 - Clamp
❑ Renew after each re‐
moval.
❑ For attaching handle to
selector lever
2 - Handle with gaiter
❑ Removing ⇒ page 17
3 - Selector cover
❑ Is removed together
with handle.
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WARNING
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Before working on vehicle with engine running, move selector

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lever into position “P” and apply handbrake.

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• The starter must not operate in the selector lever positions “S”,
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“D”, “R” and “Tiptronic gate”.

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• When the vehicle is moving at speeds above 5 km/h and the

selector lever is shifted to position “N”, the solenoid for selector
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lever can be shifted into a driving range.

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• When the vehicle is moving at speeds below 2 km/h (almost

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solenoid for selector lever lock should only engage after about
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1. Selector mechanism 15
Amarok 2011 ➤
• Selector lever is locked and cannot be shifted out of “P” posi‐

tion with the lock button pressed on selector lever handle.
Solenoid for selector lever lock - N110- blocks selector lever.
– Press brake pedal and keep it pressed down.
• Solenoid for selector lever lock - N110- releases selector lever.
It is possible to shift into a driving gear. With lock button press‐
ed on selector lever handle slowly shift selector lever through
positions “R, N, D, S” starting at position “P”. Check whether
selector lever position display - Y6- in dash panel insert cor‐
responds to selector lever position.
Selector lever in “N” position, ignition switched on:
– Do not operate brake pedal.
• After a short waiting time: Selector lever is locked and cannot
be shifted out of “N” position despite lock button being pressed
on selector lever handle. Solenoid for selector lever lock -
N110- blocks selector lever.
– Operate brake pedal.
• Solenoid for selector lever lock - N110- releases selector lever.
“D” position can be engaged.
Selector lever in “D” position, ignition switched on:
– Shift selector lever into “Tiptronic gate”.
• Illuminated “D” symbol in selector lever position display - Y26-
must go out and “+” and “–” symbols must light up.
Selector lever position display
Simultaneous illumination of all selector lever position display
segments indicates gearbox emergencygen AG running mode.
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– Check and adjust selector
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♦ Selector lever cannot be moved out of “P” position when bat‐

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♦ Operating emergency release causes selector lever lock sol‐

spec
enoid - N110- to release lock when it is de-energised.

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– Unclip selector cover -1- from trim -arrows-.

rrectness of i
– Only raise trim far enough until emergency release is acces‐

sible.
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Amarok 2011 ➤
– Press emergency release lever downwards in

-direction of arrow- using your finger or a screwdriver and, at
the same time, push button of handle and shift selector lever
out of position “P”.
– Install selector cover.
1.4 Removing and installing selector lever

handle
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Removing
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– Shift selector lever to position “D”.
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– Unclip selector cover -1- from trim -arrows-.

– Pull connector off selector cover and pull gaiter over handle.
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Amarok 2011 ➤
– Remove clamp -arrow-.

– Pull handle off selector lever, without pressing button.
Note
Handle is removed together with selector cover.

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• Selector lever is in position “D”.
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♦ The button might be pressed into the handle. Do not install a

handle with the button pressed in.
nform
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♦ New handle is supplied with installation guard. Do not remove

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guard until just before installing. To remove, pull it out.
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If the button was pressed in by mistake, the installation position
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can be restored. To do this, push installation guard fully in whilst
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button is pressed, release button and pull installation guard out
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again. Button engages in installation position.

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– Press button in selector lever handle. Prote AG.
Note
If not installed correctly, button remains inserted in handle after

being pressed. Handle must be re-installed.
– Secure clamp -arrow- with hose clip pliers - V.A.G 1275- .

Amarok 2011 ➤
1.5 Removing and installing selector mech‐

anism
♦ Removal lever - 80 - 200-
Removing
– Remove transfer box ⇒ Power transmission; Rep. gr. 39 ;
Transfer box; Removing and installing transfer box .
– Remove selector lever handle ⇒ page 17 .
– Pull securing clip -arrow- in -direction of arrow- off selector
lever cable -1- and out of guide.
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– Press selector lever cable on ball head -arrow- off gearbox

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using removal lever - 80-200- . Then pull cable -1- in

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-direction of arrow- out of guide and lay to side.

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The number of connectors depends on the vehicle's equipment.

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Amarok 2011 ➤
– Unclip selector lever frame -1- -arrows- and disconnect all

connectors.
– Unscrew nuts -arrows- and remove selector mechanism

downwards.
Installing
– Tighten nuts of selector unit.
– Install transfer box ⇒ Power transmission; Rep. gr. 39 ;
– Install selector lever handle ⇒ page 17 .
Specified torque
Component Specified torque
Nuts of selector unit 8 Nm
1.6 Checking and adjusting selector lever

cable
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Checking
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– Move selector lever to “P” position.

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using removal lever - 80-200- .
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– Move selector lever from “P” to “D”.
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• Selector lever cable must move easily and smoothly.
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– Move selector shaft lever on gearbox to position “P”. Locking
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lever must engage in parking lock wheel so that both front
wheels are blocked (cannot be turned together in same direc‐
tion).
rrectness of i
• It must be possible to push selector lever cable onto selector
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shaft lever. Adjust selector lever cable if necessary.
– Carefully press selector lever cable onto selector shaft lever.
nform
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Do not bend selector shaft lever or selector can no longer be

precisely adjusted.
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– Remove selector lever cable from selector shaft lever.

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– Move selector shaft lever on gearbox to position “P”. Locking ht. rig
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lever must engage in parking lock wheel so that both front py by
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– Loosen bolt -2- and press selector lever cable -1- onto selector
shaft lever.
Note
Do not pull selector lever backwards or forwards when tightening

the bolt, otherwise setting could be falsified.
– Tighten bolt for selector lever cable.

Specified torque
Bolt for selector lever cable 12 Nm
1.7 Removing and installing cable support

bracket for selector lever cable
Amarok 2011 ➤
♦ Torque wrench - V.A.G 1331-
Removing
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– Press selector lever cable on ball head -arrow-
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off gearbox nte
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using removal lever - 80-200- . Then pull aut cable -1- in
h
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-direction of arrow- out of guide and lay
s to side.
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– Unscrew bolts -arrows- for rear propshaft -1- and remove

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propshaft from flange -2-.

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Amarok 2011 ➤
– Tie up propshaft -1- at a suitable location using wire -arrow-.
– Position engine and gearbox jack - V.A.G 1383 A- under trans‐

fer box.
– Remove securing bolts for gearbox cross member -1- and
gearbox mounting -arrows-.
– Remove gearbox crossmember with gearbox mounting.
Note
Lower gearbox carefully with engine and gearbox jack - V.A.G

1383 A- until cable support bracket bolts can be accessed more
easily.
– Lower gearbox.
– Unscrew bolts -arrows- from cable support bracket -1- and re‐
move cable support bracket.
Installing
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Bolts for cable support bracket 10 Nm

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Bolts for gearbox carrier on lad‐ 50 Nm +90°

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Bolts for gearbox carrier on 20 Nm +90°

spec
gearbox mounting1)
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Bolts for gearbox mounting on 50 Nm +90°

gearbox1)
rrectness of i
Bolts for propshaft1) 50 Nm +90°

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1) Renew.
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1.8 Removing and installing gearbox selec‐

m
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tor lever
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Removing
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– Remove sump ⇒ page 58 .

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– Remove mechatronic unit ⇒ page 62 .
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– Detach selector mechanism from gearbox ⇒ page 19 .
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Prote AG.
Amarok 2011 ➤
Note
Remove any residues of old locking pin from gearbox.
– Drive out locking pin with a drift.
– Pull gearbox selector lever and seal out of gearbox.

Installing
Note
♦ Remove any residues of old locking pin from gearbox.

♦ Renew seal and drive it in as far as stop using a suitable thrust agen
AG. Volkswagen AG d
oes
piece. Volksw not
gu
d by ara
♦ Drive in new locking pin so that it is flush. horise nte
eo
aut ra
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nl
pt
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erm
ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
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or c
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cted agen
Prote AG.

Amarok 2011 ➤
2 Gearbox
⇒ “2.1 Removing and installing gearbox”, page 25
⇒ “2.2 Renewing output shaft seal”, page 33
2.1 Removing and installing gearbox
Special tools and workshop

equipment required
♦ Fitting tool - 3046-
♦ Engine support - T50015-
♦ Lifting tackle - 2024 A-
♦ Support bridge - 30 - 211 A-
♦ Engine bung set - VAS
6122-
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
en
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Cop py
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rig ht
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by lksw
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Prote AG.
2. Gearbox 25
Amarok 2011 ➤

equipment required
♦ Torque wrench - V.A.G
1331-
♦ Torque wrench - V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
AG. Volkswagen AG d
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olksw not
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d by ara
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or eo
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aut ra
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un
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es, in part or in w
t to the co
rrectness of i
Note
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♦ Comply with rules for cleanliness when working on gearbox

⇒ page 6 .
nform
ercia
♦ Observe repair instructions ⇒ page 1 .

m
a
com
tion in
♦ Observe safety precautions ⇒ page 4 .

r
te o
thi
s
♦ Seal open lines and connections using clean plugs from en‐
iva
do
r
gine bung set - VAS 6122- .

rp
cum
fo
en
ng
t.
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op
– Raise vehicle ⇒ Maintenance ; Booklet 11 . C py
t. rig
gh ht
yri
– If fitted, remove engine/gearbox guard ⇒ General body re‐
p by
o Vo
by c lksw
pairs, exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing
Prote
cted AG.
agen
and installing engine/gearbox guard .
– Remove starter ⇒ Vehicle electrics; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Remove front silencer ⇒ Power unit; Rep. gr. 26 ; Exhaust
system; Exhaust pipes/silencers .
– Remove front propshaft ⇒ Transfer box and final drives; Rep.
gr. 39 ; Propshaft; Removing and installing front propshaft .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
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nte Amarok 2011 ➤
autho
8-speed automatic
e o gearbox
ra 0CM - Edition 04.2013
ss c
ce
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nl
pt
du
an
Note
itte
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erm
ab
ility
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It is not necessary to remove rear propshaft.
wit
, is n
h re
hole
– Unscrew bolts -arrows- for rear propshaft -1- and remove
spec
propshaft from flange -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
– Tie up propshaft -1- at a suitable location using wire -arrow-.
o
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Cop py
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co lksw
by
cted agen
Prote AG.
– Unlock connector -arrow- by turning it anti-clockwise in

-direction of arrow-.
– Unclip wiring harness from gearbox -1- -arrows- and lay to

side.
Caution
Do not loosen the bolt on the selector lever cable. Otherwise

the selector mechanism must be readjusted.
2. Gearbox 27
Amarok 2011 ➤


using removal lever - 80-200- . Then pull cable -1- in
-direction of arrow- out of guide and lay to side.
AG. Volkswagen AG d
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d by ara
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– Remove particulate
ss a filter bracket -1- from gearbox. To do this, c
unscrew bolts -arrows-.
ce
e
nl
pt
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erm
ab
Note
ility
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wit
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Only turn crankshaft in direction of engine rotation -arrow-.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Turn crankshaft -1- using an offset ring spanner -arrow- until

the torque converter bolts are accessible.
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
e
♦ Counterhold crankshaft with ring spanner when loosening tor‐

t
sd
iva
que converter.
o
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f
en
♦ The torque converter is secured with three bolts. Therefore

ng
t.
yi Co
turn crankshaft by 120° to access the bolts one after another. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Unscrew bolts -arrow- from torque converter -1-.
Note
Catch oil which runs out. Seal ATF lines and gearbox using clean
plugs from engine bung set - VAS 6122- .
AG. Volkswagen AG d
agen oes
olksw not
– Unscrew bolt -1- for ATF lines -arrows- from d bgearbox and dis‐
y V gu
ara
connect ATF lines. rise nte
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ab
pe
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ot
wit
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spec
es, in part or in w
t to the co
rrectness of i
– Unscrew securing bolt -arrow- for ATF lines -1-.
l purpos
nform
mercia
a
com
tion in
r
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iva
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Cop py
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– Unscrew bolt securing ATF double line -1- from bracket -2- and
co lksw
by
cted agen
lay line together with clamp -arrow- to side. Prote AG.
2. Gearbox 29
Amarok 2011 ➤
– Secure adapter - 2024 A/1- on subframe with fitting tool -

3046- .
– Secure engine support - T50015- and preload it slightly.
– Remove securing bolts for gearbox mounting -arrows-.

– Place engine and gearbox jack - V.A.G 1383 A- under gearbox
crossmember.
– Remove securing bolts for gearbox cross member -1-.
– Lower gearbox crossmember with engine and gearbox jack -
V.A.G 1383 A- and remove.
Note
Bolts 4 and 5 have already been removed during removal of start‐

er.
wage e
– Unscrew engine/gearboxy Vsecuring
olks bolts -1 through 10-s nexcept
ot g
ua
for one securing bolt.
rised b ran
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pt
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ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
– Position engine and gearbox jack - V.A.G 1383 A- with a soft

rrectness of i
foam surface -arrow- under gearbox -1- and also secure gear‐
box using a tensioning belt.
l purpos
– Remove last engine/gearbox connecting bolt.

nform
mercia
at
Note
om
ion
c
in t
or
Only remove the gearbox with the help of a second mechanic.

his
ate
do
priv
cum
or
– Press gearbox off engine (dowel sleeves) and pull out to rear.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Lower gearbox -1- carefully with engine and gearbox jack -

V.A.G 1383 A- .
– Use support bridge - 30 - 211 A- to secure torque converter in

gearbox and prevent it falling out.
Installing
Note
♦ Always renew bolts that are tightened with specified tightening

angle.
♦ Renew self-locking nuts and bolts.
♦ All cable ties which were opened or cut during removal must
be renewed at the same locations.
♦ Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
wage
problems and possible noises from the gearbox (rattling
olksof
e s no
yV t gu
gears which are not engaged) could occur. ise
d b ara
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Caution
ce
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un
pt
an
d
itte
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Please observe the following points during all installation work,
rm
in particular in the engine compartment, due to the space lim‐ ab

pe
ility
ot
itations: wit
, is n
h re
♦ Route lines of all kinds and electrical cables so as to re-
hole
spec
establish the original wiring.

es, in part or in w
t to the co
♦ Make sure there is adequate clearance from all moving or

hot parts.
rrectness of i
– If ATF is dirty or if an exchange gearbox is to be installed, clean

l purpos
ATF cooler and ATF lines ⇒ page 49 .

nform
ercia
– Reassemble all electrical connections, lines, hoses and con‐

nectors that were disconnected during removal.
m
a
com
tion in
Caution
r
te o
thi
s
iva
do
r
If engine and gearbox are brought together with force because

rp
cum
fo
the torque converter is improperly fitted, both gearbox and tor‐

en
ng
t.
yi
que converter will be damaged.
Co
Cop py
t. rig
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Vo
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by c lksw
– Before installing gearbox, ensure that torque converter is cted agen
Prote AG.
properly seated in gearbox ⇒ page 12 .
2. Gearbox 31
Amarok 2011 ➤
– Check installation dimension -a- ⇒ page 13

– Therefore, when securing gearbox to engine, check frequently
that the torque converter »moves freely« and is not being
pinched.
– Install starter ⇒ Vehicle electrics; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Install front silencer ⇒ Power unit; Rep. gr. 26 ; Exhaust sys‐ wage
es n
s
tem; Exhaust pipes/silencers . yV
olk ot g
ua
b
ed ran
– Install front propshaft ⇒ Transfer box and final drives; Rep. thoris tee
or
gr. 39 ; Propshaft; Removing and installing front propshaft au . ac
ss
ce
e
nl
pt
du
an
– If fitted, install engine/gearbox guard ⇒ General body repairs,
itte
y li
erm
exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing and
ab
ility
installing engine/gearbox guard . ot p
wit
, is n
After installing, check ATF level and top up if necessary
h re
hole
⇒ page 51 .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Specified torque
m
at
om
io
n
c
in t
or
his
Item 2, 3, 6: M12×70 80 Nm
ate
do
riv
Item 1, 10: M12×180×49 80 Nm

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en
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Item 7, 8: M10×50 45 Nm
n
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Item 9: M10×115×90 45 Nm t. C rig
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Item 4: M12×70 80 Nm cop Vo
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cted agen
Item 5: M12×60 80 Nm Prote AG.
Drive plate to torque converter 85 Nm

der frame1)
gearbox mounting1)
gearbox1)
Bolts for propshaft1) 50 Nm +90°

Amarok 2011 ➤
2.2 Renewing output shaft seal

equipment required
♦ Puller - T10055-
♦ Adapter - T10055/2-
♦ Sleeve - T10180-
♦ Thrust piece - T10186-
AG. Volkswagen AG d
agen oes
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pt
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ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
– Remove transfer box ⇒ Power transmission; Rep. gr. 39 ;
nform
ercia

m
at
– To pull out seal, screw sheet metal screw of about 4 mm di‐

om
io
ameter into seal -arrow-.

n
c
in t
or
his
e
♦ Screw in self-tapping screw so its is clamped between seal

at
do
riv
and metal cover.

p
cum
for
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♦ Do not screw in sheet metal screw too far to avoid damaging

n
t.
yi Co
op
bearing behind it. C py
ht. rig
rig ht
– Pull out seal using puller - T10055- .
py by
co Vo
by lksw
cted agen
Installing
Prote AG.
2. Gearbox 33
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Amarok 2011 ➤ ut ho eo
ra
a
8-speed automatic
ss gearbox 0CM - Edition 04.2013 c
ce
le
un
pt
an
– Especially coat sealing lips of new seal with ATF.
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– First put sleeve - T10180- on output shaft to prevent damage
mer
to seal.
atio
om
n
– Drive in new oil seal to stop using thrust piece - T10180- . Do
c
i
or
n thi
not cant oil seal in the process.
te
sd
iva
o
r
– Install transfer box ⇒ Power transmission; Rep. gr. 39 ;

p
cum
r
fo
en
ng
t.
yi Co
op
– Finally, check ATF level and top up ⇒ page 51 .
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
3 Assembly mountings
⇒ “3.1 Removing and installing gearbox carrier/gearbox mount‐
ing”, page 35
3.1 Removing and installing gearbox carri‐

er/gearbox mounting
♦ Engine and gearbox jack - V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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ce
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un
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d
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rm
ab
Removing
pe
ility
ot
wit
, is n
– Raise vehicle ⇒ Maintenance ; Booklet 11 .
h re
hole
spec
– Mark installation position of gearbox crossmember.
es, in part or in w
t to the co
– Unscrew securing bolts for gearbox mountings -arrows-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Assembly mountings 35
Amarok 2011 ➤
– Position engine and gearbox jack - V.A.G 1383 A- under gear‐

box.
Installing
– Insert gearbox crossmember back into previously marked po‐
sition.
Note
♦ Arrow on gearbox crossmember points in direction of travel.

♦ Carefully clean and degrease gearbox crossmember before
installation. Then carry out the following anti-corrosion meas‐
ures: AG. Volkswagen A gen G do
swa es
♦ Apply new primer and
by
new
Vol paint on all “bare metal” and
k not “dam‐
gu
aged” paint surfaces
ris
ed of gearbox crossmember (with a spray
ara
nte
can or brush).utho eo
r
sa ac
♦ After installation,
s
apply corrosion protection (wax) all over
ce
e
gearbox crossmember.
nl
pt
du
an
itte
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erm
ab
Specified torques
ility
ot p
wit
, is n

h re
hole

spec
es, in part or in w
der frame1)
t to the co

gearbox mounting1)
rrectness of i

gearbox1)
l purpos
1) Renew.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
e o Amarok 2011 ➤
ris nte
ho
aut 8-speed automatic gearbox 0CMr ac- Edition 04.2013
ss
ce
le
un
pt
an
d
4 Transporting gearbox
itte
y li
erm
ab
ility
ot p
⇒ “4.1 Transporting gearbox”, page 37
wit
is n
h re
4.1 Transporting gearbox
ole,
spec
t to the co
♦ Workshop hoist - VAS 6100-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
♦ Lifting tackle - 2024 A- ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Attach lifting tackle - 2024 A- as follows to lifting eyes of gear‐

box and transport using workshop hoist - VAS 6100- .
WARNING
Retaining hook and locking pins on lifting tackle must be se‐

cured with locking pins.
Input shaft side:

4th hole of hook rail in position 1 of lifting tackle -arrow A-.
Output shaft side:
First hole of hook rail in position 7 of lifting tackle -arrow B-.
4. Transporting gearbox 37
Amarok 2011 ➤
5 ATF circuit
⇒ “5.1 Assembly overview - ATF circuit”, page 38
⇒ “5.2 Removing and installing ATF cooler”, page 39
⇒ “5.3 Removing and installing ATF lines, ATF cooler/thermo‐
stat”, page 42
⇒ “5.4 Removing and installing ATF lines, thermostat/gearbox”,
page 45
olkswagen AG
en AG. V
⇒ “5.5 Removing and installing
olksATF filter”, page 47
wag does
not
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by ara
⇒ “5.6 Cleaning ATF circuit”,
ris
ed page 49 nte
ho eo
ut ra
5.1 Assembly overview - ATF circuitss
a c
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e
nl
pt
du
an
itte
Caution
y li
erm
ab
ility
ot p
Ensure vehicle is in a level position when checking, replenish‐
wit
, is n
ing and filling ATF. An improper ATF level hinders the function
h re
hole
of the gearbox.
spec
es, in part or in w
t to the co
1 - ATF cooler
rrectness of i
⇒ page 39
l purpos
2 - Bracket
nform
ercia
3 - Return line
m
at
❑ Insert to stop by hand

om
ion
with new O-ring.

c
in t
or
his
e
❑ Moisten O-rings with

at
do
riv
ATF.
p
cum
or

f
en
ng
t.
yi
⇒ page 42
Co
Cop py
t. rig
gh
4 - O-ring
ht
pyri by
Vo
co
❑ Renew after removal
by lksw
cted agen
Prote AG.
❑ Moisten O-ring with ATF
5 - Thermostat
6 - Clamp
7 - Bolt
❑ 20 Nm
8 - Bolt
❑ 8 Nm
9 - Double line.
❑ Insert to stop by hand
with new O-ring.
❑ Moisten O-rings with
ATF.
⇒ page 45
10 - Bolt
❑ 8.5 Nm

Amarok 2011 ➤
11 - Bolt
❑ 8 Nm
12 - Thermostat bracket
13 - Bolt
❑ 7 Nm
14 - Supply line
❑ Insert to stop by hand with new O-ring.
❑ Moisten O-rings with ATF.
❑ Removing and installing ⇒ page 42
15 - Bolt
❑ 2 Nm
5.2 Removing and installing ATF cooler

♦ Engine bung set - VAS 6122-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
♦ Drip tray - V.A.G 1306-
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. ATF circuit 39
Amarok 2011 ➤
Removing
Note
♦ Comply with rules for cleanliness when working on gearbox

⇒ page 6 .
♦ Observe safety precautions ⇒ page 4 .
♦ Seal open lines and connections using clean plugs from en‐
gine bung set - VAS 6122- .
– Remove front bumper cover ⇒ General body repairs, exterior;

Rep. gr. 63 ; Front bumper; Removing and installing front
bumper cover .
– Unscrew bolts -arrows- and remove front struts -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Lever off clips -arrows- and remove left air duct -1-.
es, in part or in w
t to the co
– Place dip tray - V.A.G 1306- under ATF cooler.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Unscrew right bolt -arrow- and disconnect ATF line -1- from
f
en
ng
t.
ATF cooler -2-.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Unscrew left bolt -arrow- and disconnect ATF line -1- from ATF
cooler -2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
– Unscrew bolt -arrow- from ATF cooler -1-.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unclip ATF cooler -2- from guide -arrow- on radiator -1-.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. ATF circuit 41
Amarok 2011 ➤
– Pull ATF cooler -arrow- upwards out of guide -1- and remove
ATF cooler.
Installing
Note
♦ Seals must always be renewed.

♦ Moisten seals with ATF prior to installation.
– Install front bumper cover ⇒ General body repairs, exterior;

bumper cover .
– Checking ATF level and topping up ⇒ page 51
Specified torques
♦ ⇒ “5.1 Assembly overview - ATF circuit”, page 38
♦ Front bumper, Assembly overview - front bumper ⇒ Front
bumper; Rep. gr. 63 ; Assembly overview - front bumper cov‐
er .
5.3 Removing and installing ATF lines, ATF

cooler/thermostat
AG. Volkswagen AG d
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ility
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hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
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te o
thi
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iva
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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byV gu
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aut ra
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Removing s
ce
e
nl
pt
du
an
itte
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Note
erm
ab
ility
ot p
wit
Seal open lines and connections using clean plugs from engine
, is n
h re
bung set - VAS 6122- .
hole
spec
es, in part or in w
t to the co
– Remove front bumper cover ⇒ General body repairs, exterior;
bumper cover .
rrectness of i
l purpos

– Place drip tray - V.A.G 1306- underneath.
nf
ercia
orm
– Remove connecting hose between charge air cooler and pres‐
m
atio
m
sure pipe.
o
n in
or c
thi
– Unscrew bolts -arrows- and remove front struts -1-.
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sd
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t.
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Cop py
ht. rig
rig ht
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Prote AG.
– Lever off clips -arrows- and remove left air duct -1-.
5. ATF circuit 43
Amarok 2011 ➤
– Unscrew bolt -arrow- and pull supply and return lines out of
thermostat.
wage es n
– Unscrew bolt -arrow- of return line -1-. yV
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erm
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spec
t to the co
– Unscrew bolt -arrow- of supply line -1-.
rrectness o
cial p
f inform
mer
atio
om
n
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Cop py
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Prote AG.

Amarok 2011 ➤
– Unscrew bolts -arrows- from bracket and remove lines -1-.

Installing
Note

Caution
If ATF cooler or ATF lines have been renewed, they must be

filled ⇒ page 53 .
olkswagen AG
en AG. V
olks
wag does
not
y V gu
db ara
– Install front bumper cover ⇒ General body
rise repairs, exterior; nte
Rep. gr. 63 ; Front bumper; Removing
aut
ho
and installing front eo
ra
bumper cover . ss c
ce
e
nl
pt
du
an
itte
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erm
ab
installing engine/gearbox guard .
ility
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Specified torques
wit
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hole
spec
es, in part or in w
♦ Front bumper, Assembly overview - front bumper ⇒ Front
t to the co
bumper; Rep. gr. 63 ; Assembly overview - front bumper cov‐
er .
rrectness of i
5.4 Removing and installing ATF lines, ther‐
l purpos
mostat/gearbox
nf
ercia
Special tools and workshop equipment required orm

m
atio

om
n in
or c
thi
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.
5. ATF circuit 45
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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aut ra
ss c
ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
mercia
at
om
io
Note
n
c
in t
or
his
te
Seal open lines and connections using clean plugs from engine
a
do
riv
bung set - VAS 6122- .

p
cum
for
en
ng
t.
yi Co
– If fitted, remove engine/gearbox guard ⇒ General body re‐ Cop py
t. rig
pairs, exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
– Place drip tray - V.A.G 1306- underneath.
– Unscrew bolt -arrow- of ATF double line -1- from thermostat.

Amarok 2011 ➤
– Unscrew bolt -1- of ATF double line -arrows- and pull ATF
double line out of gearbox.
– Unscrew bolt -arrow- of ATF double line -1- from gearbox.
– Unscrew bolt securing ATF double line -1- from bracket -2- and
remove line together with clamp -arrow-.
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Installing yV
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nl
Note
pt
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itte
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ab
ility
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, is n
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spec
es, in part or in w
Caution
t to the co
If ATF cooler or ATF lines have been renewed, they must be
filled ⇒ page 53 . rrectness of i
l purpos

nform
ercia

m
at
om

ion
c
in t
or
Specified torques
his
ate
do
riv

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en
ng
t.
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5.5 Removing and installing ATF filter Cop py
t. rig
gh ht
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cop Vo
by lksw
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Prote AG.
5. ATF circuit 47
Amarok 2011 ➤
Removing
AG. Volkswagen AG d
agen oes
olksw not
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Note d by gu
ara
rise nte
tho eo
♦ Comply withss rules
au
for cleanliness when working on gearbox r ac
⇒ page 6 .
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
– Position used oil collection and extraction unit - V.A.G 1782-
ot
wit
, is n
under gearbox.
h re
hole
– Remove ATF sump ⇒ page 58 . spec

es, in part or in w
t to the co
– Carefully pull ATF filter -arrow- downwards in
-direction of arrow- off mechatronic unit -1-.
Installing
rrectness of i

l purpos
nform
mercia
a
com
tion in
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– Fit O-ring -2- on ATF-Filter -1-.

n
t.
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Cop py
t. rig
gh ht
pyri by
Vo
Note
co lksw
by
cted agen
Prote AG.
On version A the solenoids are bonded in.
Version A

Amarok 2011 ➤
– Clean both solenoids -arrows-. Ensure solenoids are properly

seated with entire surface in recesses on ATF filter.
Version B
AG. Volkswagen AG d
agen oes
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au ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
– Clean both solenoids -arrows-. The solenoids must be firmly
wit
seated in guide.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
– Fit ATF filter to mechatronic unit.
n
c
in t
or
his
e
♦ The suction collar -1- of ATF filter must be inserted to stop into
at
do
riv
opening -2- of mechatronic unit.

p
cum
for
en
g
♦ Mounting -4- on the backside must engage in bolt -3- of me‐

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t.
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chatronic unit. Cop py
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– Install ATF sump ⇒ page 58 .
p by
co Vo
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– Fill ATF ⇒ page 53 .
Prote AG.
Specified torques
♦ ⇒ “1.1 Assembly overview - sump/oil strainer”, page 57
5.6 Cleaning ATF circuit

If ATF is dirty or if an exchange gearbox is to be installed, blow
out ATF cooler and ATF pipes with compressed air (not more than
10 bar).
WARNING
Wear eye protection.
– Thoroughly clean area around unions for gearbox to ATF line,

ATF line to thermostat and ATF line to ATF cooler.
5. ATF circuit 49
Amarok 2011 ➤
– Remove bolt -1- and pull ATF lines out of thermostat -2-.
– Unbolt ATF lines from and to ATF cooler at thermostat -2-. In
the process, hold against thermostat.
– Remove and drain ATF cooler ⇒ page 39 .
– Remove ATF lines -arrows- from gearbox.

– Push a hose onto one end of the ATF line between gearbox
and thermostat and secure with a hose clip. Hang other end
of hose in a suitable container.
– Blow compressed air through ATF line.
– Push hose onto other ATF line and repeat procedure. lkswage es n
o ot g
byV ua
– Moisten O-ring with ATF. ir se
d ran
tee
tho
or
– Install ATF pipes ⇒ page 42 . au ac
ss
ce
e
– Install ATF cooler ⇒ page 39 .

nl
pt
du
an
itte
Specified torques
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
gh ht
pyri by
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cted agen
Prote AG.

Amarok 2011 ➤
6 ATF
⇒ “6.1 Checking ATF level”, page 51
⇒ “6.2 Draining and filling ATF”, page 53
6.1 Checking ATF level

♦ ATF filling unit - V.A.G 1924-
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
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aut ra
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nl
pt
du
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itte
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erm
ab
ility
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es, in part or in w
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nf
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♦ Vehicle diagnostic tester

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Brief description
t.
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The ATF level must checked at a certain temperature with the
t. C rig
gh ht
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engine running. The ATF temperature is read on the ⇒ Vehicle p by
o Vo
by c
diagnostic tester. When test temperature has been reached, un‐
lksw
cted agen
Prote
screw plug for ATF inspection/filler hole located above sump.
AG.

Caution

of the gearbox.
Test conditions
• Gearbox must not be in emergency running mode.
• Vehicle must be standing absolutely level.
• Gearbox is set to position “P”.
6. ATF 51
Amarok 2011 ➤
• Extraction hose/extraction hoses of a switched-on exhaust

gas extraction system is/are connected.
• Heating and air conditioning system are switched off.
• ⇒ Vehicle diagnostic tester is connected.
• The ATF temperature should be between 30 ℃ and 35 ℃ at
the start of the test. If this temperature is exceeded, the gear‐
box first must cool off.
Note
♦ The ATF temperature is read on ⇒ Vehicle diagnostic tester.

G. Volkswage
♦ The further procedure is described inlksthe
wag⇒
en Vehicle
A
diagnostic
n AG d
oes
tester. o n ot g
yV ua
db ran
ise
♦ The ATF level is affected uby
tho the ATF temperature.
r tee
or
s a ac
♦ Checking the ATF levels when the ATF temperature is too low
ce
e
leads to overfilling.
nl
pt
du
an
itte
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♦ Checking the ATF level when the ATF temperature is too high
erm
ab
leads to underfilling.
ility
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wit
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♦ Both an excessive and an insufficient ATF level affects the
h re
function of the gearbox.
hole
spec
♦ The ATF level is checked on the ATF inspection/filler hole.
es, in part or in w
t to the co
♦ The ATF level is correct if ATF is slightly dripping out of ATF
inspection/filler hole at an ATF temperature of 35 °C to 45 °C
(50 °C for hot climate countries), due to the increased ATF
rrectness of i
level at higher temperatures.
l purpos
♦ Renew plug for ATF inspection/filler hole. nf

ercia
orm
Caution
m
atio
om
n in
or c
Risk of damage to gearbox.

thi
te
sd
iva

o
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rp
cu
tem can be used in automatic gearbox 0CM.

o
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en
ng
t.
yi Co
♦ Other oils will lead to malfunctions or failure of the gear‐ Cop py
t.
box.
rig
gh ht
pyri by
Vo
co
♦ Observe allocation as per ⇒ Electronic Parts Catalogue .
by lksw
cted agen
Prote AG.
♦ The adapter for filling ATF must be clean. The ATF must
not be mixed with other ATF oils!
At the test temperature of 35 °C:

– With engine running at idling speed, remove plug for ATF in‐
spection/filler hole -2- located above sump.

Amarok 2011 ➤
– Always renew plug and seal -arrow-.

If ATF drips out of drilling:
ATF does not need topping up.
– Wait until ATF reaches a temperature of 45 °C andwtighten
agen
AG.new
Volkswagen AG
does
plug for ATF inspection/filler hole. This concludes
yV
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gu
check. ised b ara
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If no ATF drips out of inspection hole: s aut or
ac
s
– ATF must be replenished.
ce
le
un
pt
an
d
– Shake oil bottle before opening. itte
y li
rm
ab
pe
ility
– With engine »running«, insert filling hook of ATF filling unit -
ot
wit
V.A.G 1924- into ATF inspection/filler hole.
, is n
h re
hole
spec
– Fill with ATF using ATF filling unit - V.A.G 1924- -arrow- until
es, in part or in w
ATF flows out of ATF inspection/filler hole.
t to the co
WARNING
rrectness of i
An ATF level which is too low or too high will impair the function
l purpos
of the gearbox.
nform
ercia
– Wait until an ATF temperature of 45 °C is reached.

m
a
com
tion in
– Tighten new plug.
r
te o
thi
s
iva
do
WARNING
r
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fo
en
ng
t.
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The following steps must only be performed if the ATF cooler
Co
Cop py
or the thermostat have been renewed. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– While the engine is running,
– wait until an ATF temperature of 90 ℃ is reached.
– Now ensure that this temperature is maintained for 5 minutes,
while the ATF cooler is filled.
– Stop engine and let ATF cool off to a temperature of 35 °C.
– Then check ATF level again.
Specified torques
ATF inspection plug 35 Nm
6.2 Draining and filling ATF

6. ATF 53
Amarok 2011 ➤
♦ ATF filling unit - V.A.G 1924-
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
♦ Vehicle diagnostic tester rised
nte
ho eo
ut
Draining ss a ra
c
ce
le
Prerequisites
un
pt
an
d
itte
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erm
ab
Caution
ility
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wit
is n
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ole,
spec
of the gearbox.
t to the co
♦ Engine off.
rrectne
♦ Vehicle level, all supports in lifting platform at same height.

s
♦ If noise insulation tray is present, it must be removed

s o
cial p
f i
♦ Selector lever in “P”.

nform
mer
♦ ⇒ Vehicle diagnostic tester is connected.

atio
om
n
c
♦ At start of work, ATF temperature must not be above 45 ℃.

i
or
n thi
te
sd
iva
o
pr
cum
r
Note
fo
en
ng
t.
yi Co
op
If ATF temperature is above 45 °C, let the gearbox cool off.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING
Do not start engine if there is no oil in gearbox.

Risk of eye injury.
♦ Wear eye protection!

Amarok 2011 ➤
Note
♦ Observe regulations for disposal.

♦ Renew ATF drain plug and seal.
♦ Renew plug for ATF inspection/filler hole.
Draining ATF:
under gearbox.
– Remove ATF drain plug -1- from sump.
– Drain ATF.
Adding ATF
• Tighten ATF drain plug in sump.
Caution

of the gearbox.
Caution
Risk of damage to gearbox. AG. Volkswagen AG d

agen oes
olksw not
V gu
by ara
d
ise nte
tem can be used in thoautomatic
r gearbox 0CM. eo
au ra
c
♦ Other oils will lead to malfunctions or failure of the gear‐
ss
ce
le
box.
un
pt
an
d
itte
y li
♦ Observe allocation as per ⇒ Electronic Parts Catalogue .

rm
ab
pe
ility
♦ The adapter for filling ATF must be clean. The ATF must
ot
wit
not be mixed with other ATF oils!

, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew plug for ATF inspection/filler hole -2- and insert filling
hook of ATF filling unit - V.A.G 1924- into ATF inspection/filler
hole.
rrectness of i
– With engine stopped, fill ATF up to overflow edge using ATF

l purpos
filling unit - V.A.G 1924- .

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. ATF 55
Amarok 2011 ➤
– Start engine and immediately fill more ATF until it flows out of
overflow edge -arrow-.
– Screw in plug for ATF inspection/filler hole hand-tight.
agen
AG. Volkswagen AG d
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olks ot g
– Run engine at idling speed. d byV ua
ran
ise tee
or
– With brake pressed, shift through au
tall selector lever positions
h or
ac
at idling speed and make sure each
ss position is engaged for at
least 10 seconds.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
– Keep constant engine speed of 2000 rpm for 30 seconds to
ility
ot
allow torque converter to be filled.
wit
, is n
h re
hole
– Finally, check ATF level and top up ⇒ page 51 .
spec
es, in part or in w
Specified torques
t to the co
rrectness of i
l purpos
ATF inspection plug 35 Nm
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
38 – Gears, control
1 ATF system
⇒ “1.1 Assembly overview - sump/oil strainer”, page 57
⇒ “1.2 Removing and installing sump”, page 58
⇒ “1.3 Removing and installing hydraulic impulse oil storage with
accumulator solenoid N485 ”, page 60
1.1 Assembly overview - sump/oil strainer
1 - Mechatronic unit
⇒ page 62 .
2 - Bolt
❑ Observe tightening se‐
quence ⇒ page 65
❑ 8 Nm wage
e ks s no
Vol t gu
3 - Seal ed
by ara
ris nte
❑ Renewuthafter removal
o eo
ra
sa c
4 - Hydraulic
s
impulse oil stor‐
ce
le
age with accumulator solenoid

un
pt
an
d
- N485- .
itte
y li
erm
ab

ility
ot p
⇒ page 60
wit
is n
h re
5 - Bolt
ole,
spec

t to the co
❑ 8 Nm
6 - Seal
rrectne

7 - ATF filter
ss o

cial p
f i
⇒ page 47
nform
mer
8 - Solenoids
atio
om
❑ Ensure solenoids are

n
c
i
or
properly seated on ATF

thi
te
sd
a
filter with their entire sur‐

iv
o
pr
face.
um
r
fo
en
ng
❑ Clean prior to installa‐

t.
yi Co
op
tion. C py
t. rig
gh ht
❑ Not available as a re‐ yri
p by
o Vo
placement part anymore. Cannot be separated from ⇒ Item 7 (page 57) .
c by lksw
cted agen
Prote AG.
9 - Seal
10 - Bolt
❑ 12 Nm
11 - Drain plug
❑ 12 Nm
1. ATF system 57
Amarok 2011 ➤
8-speed automatic gearbox 0CM
AG-. V
Edition 04.2013
olkswagenA n G do
wage es n
Volks ot g
12 - ATF pan ed
by ua
ran
ris tee
tho ⇒ page 58 or
au ac
ss
13 - Bolt
ce
le
un
pt
an
d
itte
y li
❑ Observe tightening sequence ⇒ page 65
erm
ab
ility
ot p
❑ 8 Nm
wit
is n
h re
14 - Seal
ole,
spec
t to the co
❑ ATF pump intake
15 - Connecting piece with seal
rrectne
❑ Oil supply for ATF pump
ss o
cial p
f inform
1.2 Removing and installing sump
mer
atio
m

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
under gearbox.
– Unscrew ATF drain plug and drain ATF ⇒ page 53 .
58 Rep. gr.38 - Gears, control

Amarok 2011 ➤
Note
Support gearbox using engine and gearbox jack - V.A.G 1383 A-

ensuring that sump can still be removed in the following work
procedure.
– Position engine and gearbox jack - V.A.G 1383 A- under trans‐

fer box.
– Unscrew bolts -arrows- of sump -1-.
G. Volkswagen AG d
– Remove sump -1- downwards in -directionlkof
swaarrow-.
gen A oes
not
o
yV gu
Installing sedb ara
nte
ri
ho eo
Install in reverse order of ut
removal,s aobserving the following: ra
s c
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ Renew ATF sump bolts and gasket.

ot
wit
, is n
h re
♦ In case of high mileage vehicles it is recommended to renew

hole
the ATF filter once the ATF sump has been removed
spec
es, in part or in w
⇒ page 47 .
t to the co
♦ Otherwise, the ATF filter must only be renewed when dam‐

aged.
rrectness of i
l purpos
nform
mercia
a
com
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1. ATF system 59
Amarok 2011 ➤
– Clean both solenoids -arrows-. Ensure solenoids are properly

seated with entire surface in recesses on ATF filter.
– Thoroughly clean sealing surface. Ensure that residues from
old gasket are removed completely.
– Ensure proper seating of ATF filter on mechatronic unit. Oth‐

erwise the ATF sump cannot be fitted properly.
♦ The suction collar -1- of ATF filter must be inserted to stop into
opening -2- of mechatronic unit.
♦ Mounting -4- on the backside must engage in bolt -3- of me‐
chatronic unit.
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– Tighten bolts in the specified sequence.

an
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erm
– Install gearbox crossmember with gearbox mounting.

ab
ility
ot p

wit
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Specified torques
hole
spec
es, in part or in w

t to the co
rrectness of i
l purpos
nf
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1.3 Removing and installing hydraulic im‐

orm
m
pulse oil storage with accumulator sole‐

atio
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or
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Note
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♦ The hydraulic impulse oil storage is not installed in all gear‐
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boxes.
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♦ Rules for cleanliness ⇒ page 6 .
Prote AG.

Amarok 2011 ➤
Removing
• Gearbox is installed.
Caution
Risk of damage to gearbox.

♦ The engine must not be started when there is no ATF in
the gearbox and the mechanic unit is removed.
– Shift selector lever to position “P”.
– Switch off ignition and remove ignition key.

– Remove ATF sump ⇒ page 58 .
– Remove ATF filter ⇒ page 47 .
– Carefully disconnect connector -arrow- from hydraulic impulse

oil storage -1-.
Caution
AG. Volkswagen AG d
agen oes
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Risk of damagingedgearbox
by
V
control unit (mechatronic gu unit)
ara
through electrostatic
horis discharge. nte
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♦ Before handling
ss electrical connector, the person handling c
it must “electrostatically discharge” himself/herself. To do
ce
le
un
pt
so, briefly touch e.g. an earth connection, a radiator in the

an
d
itte
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workshop or a lifting platform with the hand.

erm
ab
ility
ot p
♦ Do not touch contacts of gearbox connector with the hand.

wit
is n
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ole,
spec
– Unscrew bolts -arrows- from hydraulic impulse oil storage

t to the co
-1-.
– Remove hydraulic impulse oil storage.
rrectne
Installing
s

s o
cial p
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mer
Note
atio
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n
c
♦ Renew O-ring and bolts for hydraulic impulse oil storage.

i
or
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sd
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♦ Ensure that connecter is properly engaged and secured.

iv
o
pr
cum
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fo
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– Insert hydraulic impulse oil storage with new O-ring.

t.
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Cop py
. rig
– Observe tightening sequence of bolts ⇒ page 65 .
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rig by
copy Vo
– Connect connector to hydraulic impulse oil storage.
by lksw
cted agen
Prote AG.
– Install ATF filter ⇒ page 47 .
Specified torques
1. ATF system 61
Amarok 2011 ➤
2 Mechatronic unit
⇒ “2.1 Removing and installing mechatronic unit”, page 62
2.1 Removing and installing mechatronic

unit
♦ Guide pin - T40199-
lkswage es n
o ot g
byV ua
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ir se tee
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ab
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wit
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hole
spec
es, in part or in w
Removing
t to the co
Note
rrectness of i
l purpos

♦ Comply with rules for cleanliness ⇒ page 6 .
nf
ercia
orm
m
atio
m
WARNING
o
n in
or c
thi
e
Do not run engine or tow vehicle with pan removed or when

t
sd
iva
there is no ATF in gearbox.

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• Gearbox is installed.
t. C rig
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Vo
– Shift selector lever to position “P”.
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cted agen
Prote AG.
– Switch off ignition and remove ignition key.
– Remove ATF sump ⇒ page 58 .
– Remove ATF filter ⇒ page 47 .
Gearbox with hydraulic impulse oil storage
– Remove hydraulic impulse oil storage ⇒ page 60 .

Amarok 2011 ➤
Continuation for all vehicles
Caution
Risk of damaging gearbox control unit (mechatronic unit)

through electrostatic discharge.
♦ Before handling electrical connector, the person handling
it must “electrostatically discharge” himself/herself. To do
so, briefly touch e.g. an earth connection, a radiator in the
workshop or a lifting platform with the hand.
♦ Do not touch contacts of gearbox connector with the hand.
– Unlock connector -arrow- by turning it anti-clockwise in

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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erm
ab
ility
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wit
– Unscrew bolt and pull catch -1- of connector downwards in
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
– Pull connector housing -arrow- in -direction of arrow- out of

thi
te
gearbox -1-.
sd
iva
o
pr
cum
r
fo
en
ng
Caution
t.
yi Co
Cop py
ht. rig
Risk of damaging mechatronic unit.
rig ht
py by
co Vo
by lksw
cted
♦ Only the bolts with Torx T40 heads may be loosened.
agen
Prote AG.
♦ Only the marked bolts may be loosened.

♦ Loosening other bolts may affect the operation of the me‐
chatronic unit, or the mechatronic unit could come apart.
Note
♦ Bolt -16- has already been removed during removal of con‐

nector housing.
♦ Do not yet remove bolt -1-.
2. Mechatronic unit 63
Amarok 2011 ➤
– Unscrew bolts in sequence -18 through 2-. Pull out gearbox

output speed sender - G195- after bolt -17- has been loos‐
ened, in order to prevent the sender from being damaged.
– Screw in the 4 guide pins - T40199- hand-tight into holes
-2, 5, 13, 14-.
– Unscrew bolt -1-.
Caution
Risk of damaging senders on backside of mechatronic unit.

♦ Only lay down mechatronic unit with bolt head side facing
downwards.
– Remove mechatronic unit downwards.

1 - Electronic module with sensors
2 - Electronic gearbox control
3 - Hydraulic valve body
4 - Solenoid valves
5 - Gearbox connector
Installing
Install in reverse order of removal, observing the following: n AG. Volkswagen A
G do
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♦ Moisten seals with ATF before fitting. Do hnot ris use any
e
other nte
lubricants. ut o eo
ra
a c
ss
♦ Always renew a valve body which is fouled or defective.
ce
le
un
pt
an
d
itte
♦ Do not use fluffy cloths.

y li
rm
ab
pe
♦ Renew connecting piece with seals ⇒ Item 15 (page 58) .

ility
ot
wit
, is n
♦ Renew seal for oil passage between gearbox and mechatronic

h re
hole
unit ⇒ Item 14 (page 58) .

spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Renew bolts for mechatronic unit.

l purpos
♦ The guide pins - T40199- prevent the mechatronic unit from

canting during installation. This ensures that the ATF lines on
the backside of the mechatronic unit are not being damaged.
nform
ercia
♦ Thus, the aid of a 2nd mechanic is recommended when in‐

m
stalling the mechatronic unit with gearbox installed.

com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– The gearbox selector lever must be seated in the groove of

the slide block and of the selector slide -arrows-.
– Screw in new bolts -1, 3, 4- by hand until bolt heads
wage
n AG. Vmake
olkswagen AG
does
contact with mechatronic unit. yV
o lks not
gu b ara
ed
– Unscrew the 4 guide pins - T40199-
ho .
ris nte
e
t or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Install new connector housing (prior to installing bolt -16-).
es, in part or in w
Note retaining tabs -arrows-. The housing can only be fitted in
t to the co
one specific installation position. Then, lock securing clip.
rrectness of i
Note
l purpos
Do not tighten bolt -16- until after the securing clip has been prop‐
erly locked.
nform
mercia
at
– Tighten new bolts for mechatronic unit in sequence given.
om
ion
c
in t
or
his
ate
do
priv
c
Tightening sequence for mechatronic unit without hydraulic im‐
um
for
en
g
pulse oil storage

n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Tightening sequence for mechatronic unit with hydraulic impulse

oil storage
– Install ATF filter ⇒ page 47 .
– Adapt mechatronic unit using ⇒ Vehicle diagnostic tester.
Specified torques
2. Mechatronic unit 65

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2013 Volkswagen AG, Wolfsburg D3E80480C6A

2.1 Rules for safety when working on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Rules for cleanliness when working on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Proper handling of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

♦ If gearbox covers have been unbolted or gearbox has no fluid,

do not run engine or tow vehicle either.

♦ First thoroughly clean connecting points and surrounding

areas and then loosen bolts.

tween the engine and gearbox are correctly located.

♦ Place removed parts on a clean surface. Cover parts to pre‐

♦ If repair work cannot be performed immediately, carefully cov‐

aging until immediately before installing.

♦ Do not run engine or tow vehicle with pan removed or when

there is no ATF in gearbox.

1.3 Gaskets and seals AG. Volkswagen AG d

♦ Only use ATF for automatic transmission components. Other

♦ Open side of oil seal faces oil.

Use caution when handling oil. Dispose of used oil properly.

Drained ATF oil must not be reused.

1.5 Nuts and bolts

2 Rep. gr.00 - Technical data

1.6 Electrical components

always use new parts ⇒ Electronic Parts Catalogue .

uine parts are approved.

Risk of injury and accident by accidental engagement of gear

move selector lever into position “P” and apply handbrake.

Risk of poisoning from exhaust gases while engine is running.

Danger of injury; the radiator fans can run at any time.

To prevent personal injury and damage to or destruction of elec‐

Danger of destruction of electronic components when battery

– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .

4 Rep. gr.00 - Technical data

Safety measures for vehicles with Start/Stop system

Injury hazard as a result of automatic engine start in vehicles

– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .

Accident hazard as a result of distraction and inadequate se‐

♦ Always strap test and measuring instruments in place on

rear seat and have a 2nd person operate them.

3.1 Rules for cleanliness when working on

6 Rep. gr.00 - Technical data

4.1 Allocation of gearbox to engine, gear ratios

4th gear 1.667 1.667 1.667 1.667

5th gear 1.285 1.285 1.285 1.285

8th gear 0.667 0.667 0.667 0.667

Reverse 3.300 3.300 3.300 3.300

Risk of malfunctions or failure of gearbox.

♦ Only the ATF ordered through the replacement part sys‐

tem can be used in automatic gearbox 0CM ⇒ Electronic

The ATF is obtainable as a spare part.

8 Rep. gr.30 - Clutch

1.1 Assembly overview - torque converter

❑ Removing and installing y li

❑ Removing and installing

1.2 Proper handling of torque converter

Therefore, always work with care.

1.3 Removing and installing torque convert‐

10 Rep. gr.32 - Torque converter

♦ Oil extraction probe - V.A.G 1358 A/1-

– Extract ATF from torque converter using oil extractor -