7-Speed Dual Clutch Gearbox 0AM PDF

Service
Workshop Manual
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Service Department. Technical Information

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00 - Technical data
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30 - Clutch ot p
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34 - Controls, housing
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35 - Gears, shafts
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39 - Final drive - front differential
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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 © 2010 Volkswagen AG, Wolfsburg MEX5R008520

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code, engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Working with vehicle diagnostic testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Removing and installing the dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Adjusting position of engagement bearings “K 1 and K 2” . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 Renewing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Overview - selector mechanism in vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Removing and installing selector lever cable - vehicles up to 02.2009 . . . . . . . . . . . . . . . . 34
2.3 Overview of selector mechanism - vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 41
2.4 Removing and installing selector mechanism with selector lever and selector lever cable -
vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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2.7 Emergency release ho of selector lever . . . . . . . . . . . . . . . . . . . .e o. . . . . . . . . . . . . . . . . . . . . . 46
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2.8 Removing andssinstalling selector lever handle . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . 46
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2.9 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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3 Mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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3.1 Safety note on mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . 50
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3.2 Overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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3.3 Removing mechatronic unit for dual clutch gearbox J743 with gearbox installed . . . . . . . . 52
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3.4 Moving mechatronic unit for dual clutch gearbox J743 into “removal position” by hand . . 62
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3.5 Installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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3.6 View of selector forks with mechatronic unit removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.1 Information about gearboxes with different output shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.2 Removing gearbox, vehicles with 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Removing gearbox, vehicles with 1.6 l/75 kW MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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4.4 Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine . . . . . . . . . . . . . . . . . . . . . . 90

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4.5 Removing gearbox - vehicles with 1.6 l/77 kW TDI CR engine . . . . . . . . . . . . . . . . . . . . . . 97

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4.6 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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4.7 Torque settings “Gearbox to engine” and notes on assembly mounting . . . . . . . . . . . . . . 107
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5 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Contents i
1.1 Renewing oil seal for right stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.2 Renewing oil seal for left stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.3 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.4 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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ii Contents
00 – Technical data
1 Gearbox identification
KHN - Gearbox code letters

⇒ page 2
01.06.06 - Production date:

1 June 2006
14 - Factory code
14 15 - Time
0026 - Serial number
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1. Gearbox identification 1
2 Code, engine allocation

Allocation: gearbox codes for petrol engines
KHN, LKG, LKM KUT, LPL LSU
1.4 l/90 kW TSFI 1.4 l/118 kW TSI 1.6 l/75 kW MPI
Allocation: gearbox codes for diesel engines

KHM, LKL, LKF LQN, LST
1.9 l/77 kW TDI PD 1.6 l/77 kW TDI CR
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2 Rep. Gr.00 - Technical data

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1.7 l gear oil -G 052 171- 1 l central hydraulic oil and power
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steering oil -G 004 000-
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3. Capacities 3
4 General repair notes
4.1 Tools
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.
4.2 Gearbox
The gearbox has a hole in the housing.
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– Make sure no small parts drop into this hole during installation
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– Cover the hole with a cloth before installation work.

Make sure that no dirt can enter an “open” gearbox.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine. Do not tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ During installation, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ Place removed parts on a clean surface. Cover parts to pre‐
vent soiling. Use plastic sheeting and paper. Use lint-free
cloths only!
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
♦ If repair work cannot be performed immediately, cover opened
parts carefully.
4. General repair notes 5

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Do not mix “additives” in oil.

Oil which has been drained out cannot be added again.
Caution
Use caution when handling oil. Dispose of used oil properly.

One drop of oil will contaminate 600 litres of water.
4.4 Working with vehicle diagnostic testers

• Only work with vehicle diagnostic testers from Volkswagen.
♦ Vehicle diagnosis and service information system -VAS 5052
A-
♦ Vehicle diagnosis, testing and information system -VAS
5051B-
♦ Vehicle diagnostic tester -VAS 5053-
Various functions are available in the operating modes guided
functions and guided fault finding . The 3 most important
functions are:
♦ Adapting installation information
♦ Reading measured values for mandatory reporting
♦ Initiating basic adjustment
4.4.1 Adapting installation information

The mechatronic unit detects other control units in the vehicle by
means of signals on the data bus. Pressing the Adapt instal-
lation information lock button instructs the mechatronic unit
to forget all communication partners.

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♦ After work on the steering wheel paddle.
4.4.2 Reading measured values for mandato‐
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You must read these measured values before contacting your

Technical Service Center or your importer.
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Save the measured values in the diagnosis log so that all neces‐
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– Press the button DSG Mechatronic -J743- performing
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basic measurement only:
♦ if you are prompted to do so in “guided fault finding”

♦ after you have processed a fault entry
♦ after you have installed another gearbox
♦ after you have installed a clutch
♦ or after you have installed a mechatronic unit
4. General repair notes 7

30 – Clutch
1 Removing and installing the dual
clutch
Brief description
The clutch is installed “upwards” with the gearbox removed. The
mechatronic unit remains on the gearbox.
If one new clutch is installed, the positions of the engagement
bearings for “K 1” and “K 2” must be found and set. Then the clutch
is pressed onto the input shaft.
When installing a clutch, “most” mechanics push the clutch onto
the input shaft up to the stop. This is not the optimum position for
the clutch!
For this reason, pull the clutch slightly “upwards” against the re‐
taining ring after it has been installed.
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have a negative effect on the adjusting device.

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Transporting gearbox and securing to assembly stand

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⇒ page 111 .
Remove dual clutch ⇒ page 8 .
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Adjust the position of the engagement bearings “K 1 and K 2”

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Install dual clutch ⇒ page 22 .

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1.1 Removing dual clutch

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Special tools and workshop equipment required

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♦ Hook -3438-
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8 Rep. Gr.30 - Clutch

♦ Support device -T10323-
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♦ Assembly tool -T10356-
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♦ Thrust piece -T10376-
– Remove gearbox ⇒ page 73 .
1. Removing and installing the dual clutch 9

– Pull off both breather caps -arrows- and close using suitable
plugs to achieve an oil-tight seal.
Turn gearbox with clutch upwards.

For information about how to transport the gearbox securely and
attach it to the assembly stand ⇒ page 111 .
AG. Volkswagen AG d
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– Remove retaining ring of hub -arrow-.
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es, in part or in w
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ate
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– Remove hub with hook -3438- and a screwdriver.
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– Remove retaining ring of clutch -arrow-.
Note
♦ It is possible that the retaining ring is seated very tightly. The

cause may be that the clutch is pressing so hard against the
retaining ring that the ring is stuck.
♦ If you cannot get the ring out of the groove, press the clutch
down slightly. Never strike the clutch or shaft with a hammer!
Set up the tools that are shown in this illustration.
♦ Support bracket -T10323- fits on all 0AM gearboxes.
♦ Make sure that you place support bracket -T10323- in parallel
to the gearbox flange.
♦ Secure engine support with bolts -A-, as required with nuts.
♦ Always renew retaining ring.
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Clutch should only be pressed down yV
o slightly. Often, it is sufficient
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to rotate spindle against thrustir se
d piece -T10376- without pressing. uara
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This will “release” retainingtho ring. eo
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– Pull off clutch.
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ility
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t to the co
rrectness o
cial p
– Remove clutch together with puller -T10373- .

inform
mer
atio
om
n
c
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or
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– Remove small engagement bearing.

– Remove large engaging lever.
– Remove bolts and remove small engaging lever.
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– Remove retainer for engaging lever. rised ara
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Before installing clutch, please refer to ⇒ page 12 to ssee
au wheth‐ ra
c
er “clutch needs adjusting during assembly or not.” s
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Adjusting ⇒ page 12 .
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Install dual clutch ⇒ page 22 .
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es, in part or in w
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1.2 Adjusting position of engagement bear‐
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ings “K 1 and K 2”
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ercia
orm
♦ Gauge block -T10374-

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♦ Ruler -T40100-
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♦ Digital depth gauge e.g. -VAS 6594-
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♦ Adhesive -AMV 195 KD1 01-
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♦ Micrometer caliper
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Position of engagement bearings must be set after clutch and its
h re
hole
actuators have been renewed.
spec
es, in part or in w
♦ Retainer also belongs to actuator.
t to the co
There is no need to adjust anything if all the named parts have
only been removed and reinstalled.
rrectness of i
Conditions:
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• Only use tools in perfect condition.

• Contact surface of “gearbox on engine” must be free from “ir‐
nform
ercia
regularities”. This guarantees straight edge makes good con‐

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tion in
• Mechatronic unit is installed.
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Perform the following steps:
do
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Position of engagement bearings is comparable with clutch play
en
ng
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of a manual gearbox. In this 0AM dual clutch gearbox, there are
Co
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self. There are also tolerances within the dual clutch. These p by
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tolerances must be considered separately when adjusting.
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In the following procedure, you are first shown how to measure
all necessary dimensions “on gearbox”, in order to determine
what is the appropriate shim. Tolerances on gearbox and toler‐
ances in clutch determine thickness of shim.
First find a dimension “B”. This dimensions is required for both
clutches “K 1” and “K 2”.
Then find a dimension “A” for each clutch. The following 2 illus‐
trations show where to measure these dimensions.

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Golf Variant 2007 ➤ , Golf Variant 2010
ised b ➤ , Jetta 2005 ➤ , Jetta 2011 ➤uaran
r tee
7-speed dual clutch gearbox 0AM ut - Edition 07.2010
ho or
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“K 1”
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ate
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Perform the following steps “in sequence” and precisely.
Adjusting:
– Install parts of clutch as far as large engaging lever

⇒ page 22 .
Do not install small engagement bearing, do not insert any shim.

– Install retaining ring of outer input shaft -arrow-.
– Place a ruler -T40100- on its side on flange of clutch housing.

It should lie sideways on shaft end.
Note
Ruler -T40100- should remain in this position during subsequent

measurements. Do not turn over, do not remove.
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– Place digital depth gauge onto outer input shaft.

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– “Zero” depth gauge.

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– Measure distance from retaining ring.

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– Note down result and call it “B”.

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Example: “B” = 2.91 millimetres

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– Measure dimension “B” again on opposite side.
Note
Do not measure on ring joint. This could force ring away at that
point and falsify measuring result.
– Remove retaining ring again.

This ring is not allowed to be installed again!
– Calculate average of both measuring results.
Example:
Dimension “B” = B1+B22 = 2,91+3,02 = 2.96
This dimension “B” is needed in the following calculations.
In the following sample calculations, “B” should be 2.96 mm. The
dimension given for “B” is and example. The value for “B” may be
different in another gearbox.
AG. Volkswagen AG d
There are 2 clutches, therefore there are 2 setting procedureswageto
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Each measurement requires different preparatory ut
h measures, as
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well as a few calculations. Please comply with
ss athe following work‐ c
ing procedures.
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Start by calculating shim for clutch “K 1”.

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Do not insert any shim!
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ility
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– Place gauge block -T10374- on “large” engagement bearing.
hole
spec
– Press once onto gauge block -T10374- whilst turning.
es, in part or in w
t to the co
In this way, it is possible to observe how the engagement bearing
turns. This means gauge block -T10374- also “sits” correctly on
bearing.
rrectness of i
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– Place digital depth gauge “at top” onto outer input shaft.
iva
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Ruler -T40100- is already “on its side” on gearbox flange

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⇒ page 15 .
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– Measure distance from “shaft end” to gauge block -T10374- .
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erm
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ility
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is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t. rig
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Prote AG.

– To make sure this measurement is as accurate as possible,

position digital depth gauge twice at opposite sides.
This allows the value to be found even more accurately, because
the inaccuracy caused by “tilting” on the engagement bearing is
minimised.
– Calculate average of both measurements onto gauge block -
T10374- .
– Note down this value and call it “A1”.
Example:
Dimension “A1” = 2,61+2,812 = 2.71
Example: “A1” = 2.71 millimetres
Next calculation:
“A1” minus “B” plus height of gauge block -T10374- = Depth of
engagement bearing of clutch 1.
Height of gauge block -T10374- is always the same. It is: 51.81
mm.
Sample calculation:
2.71 mm minus 2.96 mm plus 51.81 mm = 51.56 mm.
You have now calculated value for how deep engagement bear‐
ing is actually seated inside gearbox.
Depth of bearing in each gearbox should be 50.08 millimetres.
Subtract nominal dimension “50.08 millimetres” from this actual
value. This gives result for actual gap of clutch 1.
– Continue the calculation:
Calculated value (in example: 51.56 mm) minus nominal dimen‐
sion = gap of clutch.
Sample calculation:
n AG . Volkswagen AG
51.56 mm minus “50.08 millimetres” = gap of clutch 1 =ks1.48
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Now tolerances in dual clutch must be introduced ise
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nte
lation. Procedure for this is very simple: uthor eo
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– Please read off value of clutch tolerances of “new” clutch.
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A value between minus 0.40 and plus 0.40 millimetres is provided

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with a new clutch.

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ility
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– Make a note of this value.

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Example 1: “- 0.40” is indicated on your clutch.

hole
spec
The previous calculation for “K 1”: “your calculated” gap minus

es, in part or in w
t to the co
value of clutch 1 =
1.48 mm minus 0.40 = 1.08 mm.
rrectness of i
Example 2: “+ 0.20” is indicated on your clutch.

l purpos
Then, the last calculation of “K 1” is as follows: 1.48 mm plus 0.20

= 1.68 mm.
nf
ercia
– Refer to table to find correct shim and install.

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Rep. Gr.30 - Clutch Prote AG.
Calculated shim thickness Shim to be installed (in milli‐

metres)
from to
0.31 0.90 0.8
0.91 1.10 1.0
olkswagen AG
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1.51 auth 1.70 1.6 ra
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1.71 1.90 1.8
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1.91 2.10 2.0
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2.11 2.30 2.2
ab
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ility
2.31 2.50 2.4
ot
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2.51 2.70 2.6
hole
spec
2.71 3.30 2.8
es, in part or in w
t to the co
– From the supplied shims, select the one that is required.
rrectness of i
WARNING
l purpos
Later on, only insert this 1 shim. Not 2 shims.

nform
mercia
With this, you have found “correct” shim for “K 1”. Please install
com
tion in
this shim during subsequent clutch installation.

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te o
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– Continue setting for clutch “K 2”.

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iva
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Calculate shim for clutch “K 2”.

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– Only insert small bearing.
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Do not insert any shim!
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cted agen
Prote AG.
Small engagement bearing only fits in one position due to 4

grooves.

– By “turning”, check whether small engagement bearing is in‐

stalled correctly and that grooves are seated correctly.
AG. Volkswagen AG d
agen oes
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ce
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pt
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– Place gauge block -T10374- on small bearing “with large
erm
ab
opening upwards”.
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Place digital depth gauge “at top” onto outer input shaft.
atio
om
n
c
– “Zero” depth gauge.
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
– Measure distance from “shaft end” into gauge block -T10374- .

– To make sure this measurement is as accurate as possible,

position digital depth gauge twice at opposite sides.
This allows the value to be found even more accurately, because
the inaccuracy caused by “tilting” on the engagement bearing is
minimised.
– Calculate average of both measurements onto gauge block -
T10374- .
– Note down this value and call it “A2”.
Example:
Dimension “A2” = 2,50+2,542 = 2.52
Example: “A2” = 2.52 millimetres
Next calculation:
“A2” minus “B” plus height ofggauge block
n AG. Volkswag-T10374-
en AG = Depth of
a e2.
engagement bearing ofVoclutch does
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Height of gauge oblock
ris
e -T10374- is always the same. On inside,
ran
tee it
is: 36.20 mm.auth or
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Sample calculation:
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d
2.52 mm minus 2.96 mm plus 36.20 mm = 35.76 mm.

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rm
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You have now calculated value for how deep engagement bear‐
pe
ility
ot
ing is actually seated inside gearbox.
wit
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Depth of bearing in each gearbox should be 34.35 millimetres.
hole
spec
es, in part or in w
Subtract nominal dimension “34.35 millimetres” from this actual t to the co

value. This gives result for actual gap of clutch 2.
– Continue the calculation:
rrectness of i
Calculated value (in example: 35.76 mm) minus nominal dimen‐

l purpos
sion = gap of clutch.

Sample calculation:
nform
ercia
35.76 mm minus “34.35 millimetres” = gap of clutch 2 = 1.41mm.

m
a
com
Now tolerances in dual clutch must be introduced into this calcu‐

ion in
lation. Procedure for this is very simple:

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te o
thi
s
iva
– Please read off value of clutch tolerance of “new” clutch.

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rp
cum
fo
A value between minus 0.40 and plus 0.40 millimetres is provided

en
ng
t.
yi
with a new clutch.
Co
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– Make a note of this value. rig ht
py by
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Example 1: “- 0.40” is indicated on your clutch. cted agen
Prote AG.
The previous calculation for “K 2”: “your calculated” gap minus

value of clutch 2 =
1.41 mm minus 0.40 = 1.01 mm.
Example 2: “+ 0.20” is indicated on your clutch.
Then, the last calculation of “K 2” is as follows: 1.41 mm plus 0.20
= 1.61 mm.
– Refer to table to find correct shim.

AG. Volkswagen AG d
agen oes
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Golf Variantrise 2007 ➤ , Golf Variant 2010 ➤ , Jetta a2005
d b ar
nte ➤ , Jetta 2011 ➤
7-speedaut dual clutch gearbox 0AM - Edition 07.2010 e or
ho
ac
ss
ce
Calculated shim thickness le Shim to be installed (in milli‐
un
pt
an
d
metres)
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rm
ab
from to
pe
ility
ot
wit
0.31 0.90 0.8
, is n
h re
0.91 1.10 1.0
hole
spec
es, in part or in w
1.11 1.30 1.2
t to the co
1.31 1.50 1.4
1.51 1.70 1.6
rrectness of i
1.71 1.90 1.8
l purpos
1.91 2.10 2.0

2.11 2.30 2.2
nform
ercia
2.31 2.50 2.4

m
a
2.51 2.70 2.6
com
tion in
2.71 3.30 2.8
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– From the supplied shims, select the one that is required.
um
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WARNING
t. C rig
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by
Later on, only insert this 1 shim. Not 2 shims. cted agen
Prote AG.
With this, you also have found “correct” shim for “K 2”. Please
install this shim during subsequent clutch installation. This shim
should be under small engagement bearing.
1.3 Installing dual clutch

♦ Support device -T10323-

♦ Assembly tool -T10356-
♦ Puller -T10373-
AG. Volkswagen AG d
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es, in part or in w
♦ Thrust piece -T10376-
t to the co
rrectness of i
l purpos
nform
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tion in
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♦ Adhesive -AMV 195 KD1 01-

t.
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Perform the following steps: opyri
gh by
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Caution
AG.
Do not oil or grease anything!
Before clutch is installed, position of engagement bearings “K 1

and K 2” must be set ⇒ page 12 .

– Insert plastic retainer of engaging lever and check for correct

seating.
– Install small engaging lever with clip.

Sleeve with its retaining plate fits only in one position.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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Only a few, “older gearboxes” do not have a clip.
erm
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ility
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“New” clutches always have one clip.
wit
is n
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– Check engaging lever is properly seated.
ole,
spec
– Screw on engaging lever with 2 new bolts.
t to the co
Torque setting: 8 Nm + 90°
rrectne
Note
ss o
Mounting for engaging lever and entire mechanism of engage‐
cial p
f i
ment bearing must be dry and free from oil or grease. If neces‐
nform
sary, clean these components with a cloth.
mer
atio
om
n
c
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or
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– Insert 2nd, “larger” engaging lever.
thi
te
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This “larger” lever is for clutch “K 1”.

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en
ng
– Check both engaging levers are seated correctly.

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Caution op Vo
by c lksw
cted agen
Prote AG.
Before continuing with assembly, check whether clutch needs
to be adjusted.
Do not continue with the assembly before the clutch has been
adjusted!
Adjust positions of engagement bearings ⇒ page 12 .

– Insert small engagement bearing with measured shim.

Shim should be under small engagement bearing. Therefore, in‐
sert shim first.
Small engagement bearing only fits in one position due to 4

grooves.
If clutch has been replaced, shim should also be under bearing.
AG. Volkswagen AG d
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d by ara
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or eo
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– By “turning” bearing, check whether it is installed correctly and

un
pt
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that grooves are seated correctly.

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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Secure shim using 3 drops of glue -AMV 195 KD1 01- .

nform
ercia
This prevents shim from slipping out of its seat when clutch is
m
a
com
inserted.
ion in
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Large shim is for clutch “K 1”, small one for clutch “K 2”.
thi
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– Turn back spindle of puller -T10373- .

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en
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t.
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Prote AG.

7-speed dual clutch gearbox 0AM - Edition
wag07.2010
en AG. V
olkswagen AG
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– Insert clutch. ris
ed
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– Use puller -T10373- to insert clutch
ss
a into gearbox. ra
c
ce
le
– Turn spindle “back” first.
un
pt
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ab
pe
ility
Note
ot
wit
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The clutch is self-adjusting. Shocks can have an effect on this
hole
spec
adjusting device. Therefore, please do not drop the clutch. Do not
es, in part or in w
left the clutch drop into the gearbox either when installing the
t to the co
clutch.
rrectness of i
– Press clutch on onto stop.
l purpos
Support bracket -T10323- fits on all 0AM gearboxes.

– Make sure that you place support bracket -T10323- in parallel
nform
ercia
to the gearbox flange.

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a
com
t
Secure engine support with bolts -A-, as required with nuts.
ion in
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– Push clutch down via spindle.
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Note
n
t.
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Place a hand on clutch whilst pressing on. You will be able to feel
gh ht
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a slight rattling. Rattling means the clutch is being pressed onto
cop Vo
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cted
its press seat. In the same way, you can also “feel” the stop when
agen
Prote AG.
the clutch has reached its seat.
Installation position of retaining ring: Joint of retaining ring is “nar‐

rower at top”.
If you can insert retaining ring -arrow-, clutch is correctly pressed

on to stop.
– Insert new retaining ring -arrow-.

– To enable clutch to find its installation position already, turn

clutch against puller -T10373- by hand.
• Now turn clutch by hand, without using a tool.
In this way, clutch slides against retaining ring. Do not use any
other tool.
Pressing on causes “clutch to locate at bottom” on input shaft.
Clutch should only be pulled up far enough for it to contact re‐
taining ring.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Then insert hub.
wit
, is n
h re
Hub has a “large” tooth and therefore only fits in one position.
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
“Large” tooth has a mark on -engine end- -arrow-.
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Insert retaining ring for hub -arrow-.

Installation position: Joint of ring must point towards “hub” on
clutch.
lkswage es n
o ot g
yV
– Turn clutch by hand and observe d“small” engaging lever whilst
b ua
ran
ir se
turning. tho tee
or
au ac
ss
ce
e
nl
pt
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
c
Engaging levers must remain “still” in their position whilst this is

or
thi
e
being done. They are not allowed to move up and down.

t
sd
iva
o
r
rp
cu
If an engaging lever moves up and down, then shim is not properly

o
m
f
en
ng
seated.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove clutch again in this case ⇒ page 8 .

– Look at shims -arrows- precisely.
• Shims must be correctly seated. They must not be damaged.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Remove plugs and put both breather caps -arrows- back on.
ce
le
un
pt
an
d
After the gearbox has been installed, you must initiate a basic itte
y li
erm
adjustment using the ⇒ Vehicle diagnosis, testing and information
ab
ility
system VAS 5051 ⇒ page 7 .
ot p
wit
is n
h re
ole,
spec
t to the co
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

34 – Controls, housing
1 Renewing gear oil olksw
agen
AG. Volkswagen AG d
oes
not
y V gu
b ara
The gearbox is filled for life. Therefore, there is no need to check rise
d
nte
the oil level of this gearbox. autho eo
ra
ss c
This explains why there is no oil level check.
ce
e
nl
pt
du
an
In case of leaks on gearbox, find out what is the cause and rectify
itte
y li
the faults.
erm
ab
ility
ot p
– Raise vehicle.
wit
, is n
h re
– Place drip tray under gearbox.
hole
spec
es, in part or in w
Then drain all gear oil and fill with new oil.
t to the co
– Then install the drain plug again.
If the gearbox is installed, you must remove the battery and bat‐
rrectness of i
tery tray to add oil.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Remove battery and battery tray -arrows- ⇒ Rep. Gr. 27 ;

f
en
ng
t.
Battery; Removing and installing battery .
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Move selector lever to position “P” position.
30 Rep. Gr.34 - Controls, housing

– Remove securing clip in -direction of arrow-.

Securing clips for selector lever cable must always be renewed.
– Remove Bowden cable from ball head.
– Use your hand to press lever to stop in direction of cable sup‐

port bracket.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Note installation position of lever and remove it from selector
es, in part or in w
t to the co
shaft.
– If you are unsure, refer to this illustration for guidance.
rrectness of i
– Unbolt cover.
l purpos
Only leaking covers must be renewed. If the cover was not leak‐
ing, it does not need to be renewed.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Pour 1.7 l of oil in through opening -arrow-.

f
en
ng
t.
yi Co
op
– Take care not to “spill” any. Gearbox must have precisely 1.7 C py
t. rig
litres of oil.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
Do not fill any more or any less oil. Malfunctions would result!
– Clean sealing surface on gearbox and on cover.
1. Renewing gear oil 31

AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
ara
ed
ris nte
o
Grease oil seal in cover with sealing grease -G 052 128
aut A1- .
h eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Always renew bolt of lever.
– Fit cover and lever again.
rrectne
Attach lever again in same position.
ss 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
op
– If you are unsure, refer to this illustration for guidance.
C py
ht. rig
rig ht
py by
– Press selector lever cable back onto ball head and install new co Vo
by lksw
securing clip.
cted agen
Prote AG.
A securing clip which has been removed is not allowed to be in‐

stalled again. The clip will have lost its internal tension and so it
might fall off.
– Therefore, when installing, always use a “new” securing clip.
– Adjust selector lever cable ⇒ page 43 .

2 Selector mechanism
WARNING
Before working on vehicle with engine running, move selector

lever into position “P” and apply handbrake.
2.1 Overview - selector mechanism in vehicles up to 02.2009

Selector mechanism from 03.2009 onwards ⇒ page 41 .
1 - Selector cover with handle

❑ Do not remove handle
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped ⇒ page 46 .
❑ Before removal of han‐
dle, pull lock button out
past its pressure point.
Secure locking button
with a cable tie or appro‐
priate wire against being
pressed in. This will pre‐
vent lock button from
being accidentally
pressed into the handle.
❑ Removing and installing
selector lever handle
⇒ page 46
2 - Selector mechanism with
selector lever
AG. Volkswagen AG d
❑ With selector lever lock agen oes
olksw not
solenoid -N110- d byV gu
ara
ise nte
❑ Emergency releasetho r eo
⇒ page 46 . ss au ra
c
❑ Brief instructions for re‐
ce
le
un
pt
moving and installing:

an
d
itte
y li
rm
ab
– Remove centre con‐

pe
ility
sole.
ot
wit
, is n
h re
– Remove Bowden cable

hole
spec
from gearbox
es, in part or in w
⇒ page 34 .
t to the co
– If necessary, disconnect
or remove parts of ex‐
rrectness of i
haust system ⇒ Rep.

Gr. 26 ; Removing and
l purpos
installing parts of exhaust system .

nform
ercia
– Remove heat shield beneath selector mechanism.

m
– Adjust selector lever cable after installing ⇒ page 43 .

com
tion in
r
te o
3 - Bolt with spring

thi
s
iva
do
❑ 3 Nm
r
rp
cum
fo
en
4 - Pin
ng
t.
yi Co
op
❑ Removing ⇒ page 34
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
33
Prote AG.
2. Selector mechanism
agen AG olksw
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta
wage 2005 ➤ , Jetta 2011
n AG. V does ➤
olks not
7-speed dual clutch gearbox 0AM - Edition
d by 07.2010
V gu
a
e ran
ris tee
❑ Do not grease autho or
ac
ss
5 - Locking plate
ce
e
nl
pt
du
❑ Always renew after removing
an
itte
y li
erm
ab
6 - Nut
ility
ot p
❑ 9 Nm
wit
, is n
h re
❑ Qty. 4
hole
spec
7 - Selector housing
es, in part or in w
t to the co
❑ With seal
8 - Selector lever cable
rrectness of i
❑ Bowden cable is not greased
l purpos
❑ Removing and installing ⇒ page 34

❑ Checking ⇒ page 43
nf
ercia
❑ Adjusting ⇒ page 43
orm
m
atio
9 - Securing clip
om
n in
c

or
thi
te
sd
a
10 - Hexagon flange nut

iv
o
r
rp
cu
❑ 8 Nm
o
m
f
en
ng
t.
yi
❑ Qty. 4
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted
Torque setting , selector lever to selector shaft ⇒ page 30 .
agen
Prote AG.
2.2 Removing and installing selector lever

cable - vehicles up to 02.2009
Note
Following installation, Bowden cable must be checked for ease

of movement and be adjusted.
Removing
– Move selector lever to position “S” position.


– Raise vehicle.
– To remove Bowden cable and/or selector mechanism, heat
shield under selector mechanism and, if necessary, parts of
exhaust system must now be removed ⇒ Rep. Gr. 26 ; Re‐
moving and installing parts of exhaust system .
– Remove -selector housing- beneath selector lever.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove locking plate of cable support bracket. Always renew

locking plate.
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
o
by c lksw
cted agen
Prote AG.
2. Selector mechanism 35
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
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
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
o
by c lksw
cted agen
Prote AG.
-Selector housing- is pushed forwards slightly on cable.

To remove cable, securing tab must be pushed forwards

-arrow 1-.
– At same time, push -pin- up with a screwdriver -arrow 2-.
– Please insert -screwdriver- from underneath whilst pushing

securing tab forwards.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Clarification:
♦ -Arrow 1- Push tab forwards
AG. Volkswagen AG d
♦ -Arrow 2- Push pin up lksw
agen oes
not
Vo gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove selector lever cable.

Remove selector housing from cable.
Installing
– Route selector lever cable without tension. Also insert into ca‐
ble support bracket on gearbox. Do not secure with securing
clips yet. Do not clip in ball head.

– Ensure that selector lever cable is properly routed during in‐

AG. Volkswagen AG d
stallation. lkswagen oes
n o ot g
yV ua
If the sheet metal is bent downwards,
ris
ed
b
it may cause noises. The ran
tee
cable will vibrate against the
uthosheet metal. or
sa ac
– Observe sheet metal.s Press it back up in the tunnel during
ce
e
nl
installation.
pt
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
Loosen adjustment screw -arrow-.
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
– Put selector housing onto cable. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Insert selector lever cable into selector mechanism.

– Insert cable into bearing and insert pin from above, down‐
wards through eye.
When you have checked freedom of movement of cable
⇒ page 43 , insert locking plate.
– Attach cable with new locking plate on cable support bracket

of selector mechanism.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove selector housing, heat shield and exhaust system ⇒

Rep. Gr. 26 ; Removing and installing parts of exhaust sys‐
tem .
– Check cable ⇒ page 43 .

AG. Volkswa7-speed
n gen A dual clutch gearbox 0AM - Edition 07.2010
G do
wage es n
Volks ot g
2.3 Overview of selector mechanism - vehicles from 03.2009 onwards
ris
ed
by ua
ran
tee
tho
or
au ac
ss
1 - Selector cover with handle
ce
le
un
pt
❑ Do not remove handle
an
d
itte
y li
without reason. For
rm
ab
emergency release, on‐
pe
ility
ot
ly the cover needs to be
wit
, is n
unclipped ⇒ page 46 .
h re
hole
spec
❑ Before removal of han‐
es, in part or in w
dle, pull lock button out
t to the co
past its pressure point.
Secure locking button
with a cable tie or appro‐
rrectness of i
priate wire against being
pressed in. This will pre‐
l purpos
vent lock button from

being accidentally
pressed into the handle.
nform
ercia

m
a
com
t
selector lever handle
ion in
⇒ page 46
r
te o
thi
s
iva
2 - Selector mechanism with
do
r
rp
c
selector lever and selector lev‐
um
fo
er cable
en
ng
t.
yi Co
op
❑ With selector lever lock C py
ht. rig
solenoid -N110- rig ht
py by
o Vo
❑ Bowden cable must not
by c lksw
cted agen
be greased
Prote AG.

⇒ page 42
❑ Checking ⇒ page 43
❑ Adjusting ⇒ page 43
3 - Bolt
❑ 8 Nm
4 - Hexagon flange nut
❑ 8 Nm
❑ Qty. 4
5 - Selector housing
6 - Securing clip
2.4 Removing and installing selector mech‐

anism with selector lever and selector
lever cable - vehicles from 03.2009 on‐
wards
Selector mechanism and selector lever cable are not allowed to
be separated from one another. Both are removed together. In
the engine compartment, it may be necessary to provide instal‐
lation space. Often, it is necessary to remove air filter.
In the interior, it may be necessary to remove centre console.
Note
Following installation, Bowden cable must abe

genchecked
AG. Volkswfor
ageease
n AG d
oes
of movement and be adjusted. yV
olksw not
g b ua
ed ran
oris tee
th or
– Move selector lever to position “P” position. au ac
ss
ce
le
– Remove selector lever handle ⇒ page 46 .

un
pt
an
d
itte
y li
– Remove centre console ⇒ Rep. Gr. 68 .
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove 4 bolts.
nform
ercia
– Raise vehicle.
m
a
com
tion in
– Remove heat shield beneath selector mechanism. This makes

r
te o
subsequent removal of selector mechanism easier.

thi
s
iva
do
r
To do so, remove parts of exhaust system if necessary ⇒ Rep.

rp
cum
fo
Gr. 26 ; Removing and installing parts of exhaust system .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


– Remove selector mechanism.

Install in reverse order of removal.
– Before you put on ball head: check cable ⇒ page 43 .
– Install all parts of exhaust system which were removed ⇒ Rep.
Gr. 26 ; Removing and installing parts of exhaust system .
– Install heat shield ⇒ Rep. Gr. 66 .
– Adjust selector lever cable after installing ⇒ page 43 .
2.5 Checking selector lever cable

Brief description
Selector lever cable must be removed from gearbox so that its
freedom of movement can be checked. Put removed end down
so it does not rub against anything.
Then the selector lever must be moved and after that, the Bowden
cable must be reattached to the gearbox.
Then the selector lever cable must be adjusted ⇒ page 43 .
Do not grease connections of cable!
Checking
– Remove cable from lever on gearbox.
– Move selector lever repeatedly from “P” to “S” and back to “P”.
• Selector lever must move easily.
swage es n
– Reinstall cable with “loosened” adjustment screw. byV
olk ot g
ua
d ran
ir se
If you remove the securing clip, you must always install thao “new” tee
or
securing clip. au ac
ss
ce
le
– Adjust cable ⇒ page 43 .

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
2.6 Adjusting selector lever cable

ss 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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Torque wrench -V.A.G 1331-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
The selector lever cable must always be adjusted whenever
y li
erm
ab
♦ The selector lever cable has been removed from the gearbox.
ility
ot p
wit
is n
♦ The engine and/or gearbox has been removed and installed.
h re
ole,
spec
♦ Parts of the assembly mounting have been removed and in‐
stalled.
t to the co
♦ The cable itself or the selector mechanism has been removed
and installed.
rrectne
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
ss o
Adjusting
cial p
f inform
– Move selector lever in vehicle to “P” position.
mer
atio
m
Adjuster screw -arrow- must be “loosened”.

o
n
c
i
or
n thi
– Shift lever on gearbox to position “P”.
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The gearbox lever must be pressed “completely to right side of

vehicle” in the direction of selector lever cable support bracket.

This figure shows you the view of gearbox from “behind”. -P- in
direction of cable support bracket.
AG. Volkswagen AG d
agen oes
olksw not
– Install Bowden cable with loosened adjusting
d by V
screw -arrow- gu
ara
and new securing clip. rise nte
tho eo
au ra
ss c
WARNING
ce
le
un
pt
an
d
itte
y li
Be sure that the parking lock is engaged.
rm
ab
pe
ility
ot
wit
, is n
h re
– To do this, turn both front wheels simultaneously “under the
hole
spec
car” in the same direction until the parking lock can be head
es, in part or in w
to engage.
t to the co
• The parking lock is engaged when both front wheels cannot
be turned in the same direction at the same time.
rrectness of i
– Gently push handle of selector lever forwards and backwards
but under no circumstances must you shift out of “P”.
l purpos
In this way the inner cable of the Bowden cable finds it optimal
nform
position.
mercia
a
com
t
– Tighten adjusting screw -arrow- to 13 Nm.
ion in
r
te o
This completes the adjustment.

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.
2.7 Emergency release of selector lever

Do not remove handle. agen
AG. Volkswagen AG d
oes
olksw not
V
– Unclip selector cover and hold to side.ed by gu
ara
ris nte
o
– Depress brake pedal or set handbrake.
aut
h eo
ra
ss c
Vehicles up to 02.2009
ce
le
un
pt
an
– Press yellow plastic part -arrow- from right to left. d
itte
y li
erm
ab
– Or press on the pin of the solenoid.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
Vehicles from 03.2009 onwards
i
or
n thi
te
sd
a
– Press onto yellow plastic part -arrow-.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.8 Removing and installing selector lever

handle
It is possible with all handles that lock button is pressed into han‐
dle. Do not install a handle with the locking button pressed in.
– Before removal, pull lock button out past its pressure point.
– Secure locking button with a cable tie or wire against being
pressed in.
– Unclip cover.

– Push sleeve upwards to release handle.

– Lock the handle again after installing. To do this, press the
sleeve under the handle back down.
– You only have to remove transport guard from “new” handles.

The locking button is already in installation position.
– Pull connector from cover.
– Pull off handle upwards.
– Lock the handle again after installing. Press the sleeve under
the handle back down.
In vehicles with lock button at front on handle -arrow-

Lock button -arrow- is not allowed to be pressed in when handle
is being fitted and removed.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– However, should this happen, unclip handle trim upwards.

– Press small lever for pull rod -arrow- back into groove before
installing handle.
2.9 Checking selector mechanism

Faults which can be detected electrically can be determined with
guided fault finding . In the case of mechanical faults, skill
is required to localise and repair a faulty system or defective
“part”.
It must not be possible to start the engine in the selector lever
positions “R”, “D” or “S”.
When selector lever is shifted to position “N” at speeds above 5
km/h, solenoid for selector lever lock must not engage and block
selector lever. Selector lever can be shifted into a driving range.
When travelling at speeds below 5 km/h (almost stationary) and
shifting into selector lever position “N”, solenoid for selector lever
lock should only engage after about 1 second. Selector lever can‐
not be shifted out of “N” position until brake pedal is depressed.
swa
gen AG
. Volkswagen AG
does
k not
Vol gu
Selector lever in “P” position and ignition switched
se
d b on
y ara
nte
ri
ho eo
• Brake pedal not depressed: aut ra
ss c
Selector lever is locked and cannot be shifted out of “P” position
ce
e
nl
pt
du
with the lock button pressed. Solenoid for selector lever lock
an
itte
blocks selector lever.

y li
erm
ab
ility
• Brake pedal is depressed:

ot p
wit
, is n
Solenoid for selector lever lock releases selector lever. It is pos‐

h re
hole
sible to shift into a driving gear. Slowly shift selector lever from
spec
“P” through to “S”, checking whether selector lever position in

es, in part or in w
t to the co
dash panel insert corresponds to selector lever position.

Selector lever in “N” position and ignition switched on
rrectness of i
• Brake pedal not depressed:

l purpos
Selector lever is locked and cannot be shifted out of “N” position

with the lock button pressed. Solenoid for selector lever lock
blocks selector lever.
nf
ercia
orm
• Brake pedal is depressed:

m
atio
om
n in
Solenoid for selector lever lock releases selector lever. It is pos‐

or c
sible to shift into a driving gear.

thi
te
sd
iva
o
r
Selector lever in position “Tiptronic”

rp
cu
o
m
f
en
ng
– Shift selector lever into Tiptronic gate.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
48
cted agen
Prote
Rep. Gr.34 - Controls, housing
AG.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
is
Golf
ed b Variant 2007 ➤ , Golf Variant 2010ara ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
nte
r
ut
ho 7-speed dual clutch gearbox
eo
ra 0AM - Edition 07.2010
s a c
s
Symbols must change from “P R N D S” to “7 6 5 4 3 2 1”.
ce
le
un
pt
an
d
itte
Ignition and light switched on
y li
rm
ab
pe
ility
The respective symbol in the shift mechanism cover lights up.
ot
wit
, is n
Selector lever position display
h re
hole
spec
Simultaneous illumination of all selector lever position display
es, in part or in w
segments indicates gearbox emergency running mode.
t to the co
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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3 Mechatronic unit for dual clutch gear‐

box -J743-
Safety note on mechatronic unit for dual clutch gearbox -J743-
⇒ page 50
Overview - mechatronic unit ⇒ page 51
Remove mechatronic unit for dual clutch gearbox -J743-
⇒ page 52 .
Move mechatronic unit for dual clutch gearbox -J743- into “re‐
moval position” by hand ⇒ page 62 .
Install mechatronic unit for dual clutch gearbox -J743-
⇒ page 65 .
View of selector forks with mechatronic unit removed
⇒ page 72
3.1 Safety note on mechatronic unit for dual clutch gearbox -J743-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

WARNING
Do not work on pressure accumulator. The accumulator is un‐

der pressure and is not allowed to be opened.
3.2 Overview - mechatronic unit
1 - Bolt
❑ 10 Nm
❑ M8 x 35
❑ Always renew
Note
2 - Bolt
❑ 10 Nm
❑ M8 x 90
❑ Always renew
3 - Mechatronic unit for dual
clutch gearbox -J743-
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Take care with the breather when handling the mechatronic unit.
m
– When doing any work on the mechatronic unit, please remove

com
tion in
cap -arrow- from breather and seal with a suitable plug.

r
te o
thi
Protective cover -0AM 325 120- is well suited.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Mechatronic unit for dual clutch gearbox J743 51

3.3 Removing mechatronic unit for dual

clutch gearbox -J743- with gearbox in‐
stalled
This description only applies to installed gearboxes. If gearbox
has been removed, first remove clutch then mechatronic unit.
♦ Move mechatronic unit for dual clutch gearbox -J743- into “re‐
moval position” by hand ⇒ page 62 .
♦ Assembly lever -T10407-
♦ Drip tray for workshop hoist -VAS 6208- AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Vehicle diagnostic tester
Perform the following steps: rrectness of i
l purpos
In order to remove the mechatronic unit, sufficient space must be

available in front of the gearbox. Depending on the vehicle, parts
nform
ercia
must be removed which do not have anything to do directly with

the gearbox. For example, the air filter housing and, if present,
m
a
com
charge air lines or coolant lines.

ion in
r
te o
Any retainers fitted on the cover of the mechatronic unit must also
thi
s
iva
be removed.
do
r
rp
cum
fo
The vehicle diagnostic tester brings the mechatronic unit into the
en
ng
t.
correct position for removal. All gear actuators are moved “into
yi Co
op py
neutral”. . C rig
ht ht
rig by
py
In this position, insert assembly lever -T10407- between release
co Vo
by lksw
cted
lever and gearbox housing. This makes it possible to remove load
agen
Prote AG.
from plungers of mechatronic unit so that they may be removed
by hand from cups of engaging levers.
Mechatronic unit can be removed and inserted. When installing,
make sure clutch plungers are correctly seated in cups of engag‐
ing levers.
Therefore, please follow description below step by step.

lkswage es n
o ot g
yV
Note d b ua
ran
ir se tee
tho
u or
♦ The clutch is self-adjusting. Shocks can have an
ss effect on this
a ac
adjusting device. Even if the mechatronic unit has been re‐
ce
e
nl
pt
moved, the “sudden removal” of the assembly lever -T10407-
du
an
itte
from under the engaging levers can have a negative effect on
y li
erm
ab
the adjusting mechanism.
ility
ot p
♦ In order to remove the mechatronic unit, sufficient space must
wit
, is n
h re
be available in front of the gearbox. In some vehicles, parts
hole
must be removed which do not have anything to do directly
spec
with the gearbox. Remove any charge air lines or coolant lines
es, in part or in w
t to the co
that may be present.
♦ Any retainers fitted on the cover of the mechatronic unit must
also be removed.
rrectness of i
♦ A “new” mechatronic unit is correctly filled with oil.
l purpos
♦ Do not drain oil. A “removed” mechatronic unit is sent back

with its oil in.
nf
ercia
orm
m
atio
m
Mechatronic unit remains filled with oil.

o
n in
or c
Removing:
thi
te
sd
iva
o
– Raise vehicle. All 4 supports of lifting platform must be at same
r
rp
cu
o
m
height.
f
en
ng
t.
yi Co
op
– Move selector lever to position “P” position. C py
t. rig
gh ht
yri
– Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview
p by
co Vo
by lksw
- noise insulation . Prote
cted AG.
agen
– Connect vehicle diagnostic tester and then select “7-speed

dual clutch gearbox”, Moving gear actuator into -neu-
tral- position under Guided functions .
– Switch off ignition.

– Raise vehicle.
– Remove complete air filter housing.
♦ Vehicles with petrol engines ⇒ Rep. Gr. 24 ; Removing and
installing air filter
♦ Vehicles with diesel engines ⇒ Rep. Gr. 23 ; Removing and
– Remove battery and battery tray ⇒ Rep. Gr. 27 ; Battery;
Removing and installing battery .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Golf Variant 2007
ut
h ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta
o eo
ra
2011 ➤
a
7-speed duals clutch gearbox 0AM - Edition 07.2010
s c
ce
le
un
pt
In some vehicles, a cover is fitted over the engaging levers.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– If this cover is fitted, remove it.
spec
– Remove starter ⇒ Rep. Gr. 27 ; Removing and installing
t to the co
starter .
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
– Release mechatronic unit connector by pulling in . Cop py
-direction of arrow- and pull off connector.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Drain gear oil, then reinstall drain plug ⇒ page 30 .
– Pull cap off breather and close using a suitable plug to achieve
an oil-tight seal.
Note
Protective cover -0AM 325 120- is well suited.
– Remove all retainers and brackets from front of gearbox.

– Using a screwdriver, carefully unclip gearbox input speed

sender 3 -G641- from housing in -direction of arrow-.
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
– Unscrew bolts of mechatronic unit for dual clutch gearbox -
erm
ab
J743- “in diagonal sequence”.
ility
ot p
wit
, is n
“There are 4 long and 3 short bolts.”
h re
hole
spec
Do not remove more than 7 bolts!
es, in part or in w
t to the co
– Please look carefully to check which bolts you are unscrewing.
Do not unscrew any cover bolts.
rrectness of i
l purpos
nform
mercia
The gearbox is shown here again from the side to make this sit‐
at
om
io
uation clearer.
n
c
in t
or
his
The mechatronic unit must be removed. The cover does not have
ate
do
riv
to be removed.
p
cum
for
Therefore, do not remove more than 7 bolts!
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The next step is “difficult”:

Now press both engaging levers of dual clutch “away” from plung‐
ers of mechatronic unit. Otherwise, levers will jam mechatronic
unit at plungers and prevent mechatronic unit from being re‐
moved.
– Please read through this description all the way to the end first.
This will help you to perform the following steps “correctly”.
Both levers must now be carefully pressed away from the plung‐
ers.
– First take a look at -reddish-brown- engaging lever in this pic‐
ture.

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
– Insert assembly lever -T10407- to its right.

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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
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
– Far enough until groove lines up with housing rib -arrow-.

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
No further.
– Assembly lever -T10407- should make contact with gearbox
housing with its entire “rear face”.
Caution
• Housing rib and groove of lever must be flush with one

another. Do not insert tool as far as stop.
– Apply a bit of force to tip of lever when turning.

This stops lever from slipping out when turning.

Turn assembly lever -T10407- anticlockwise. In this way, engag‐

ing levers are pressed away from plungers -direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
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
Do not take out assembly lever -T10407- . It must remain inserted

l purpos
between engaging lever and gearbox housing for the entire proc‐
ess.
nform
ercia
– If necessary, press assembly lever -T10407- against gearbox

using a screwdriver.
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
o
by c lksw
cted agen
Prote AG.

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
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
If lever slips off, this indicates you applied a bit of leverage to

thi
te
sd
a
handle whilst turning.

iv
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.

– Apply a bit of force to tip of lever when turning.

This stops lever from slipping out when turning.
– Remove mechatronic unit.
G. Volkswagen
– Make sure no oil runs
lksw
agout
en A of breather. AG doe
sn
o ot g
yV u
Mechatronic unit
ris
ed bis to be sent for reconditioning with aits
ran oil in.
t ee
ho
aut or
ac
ss
ce
e
nl
pt
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
If mechatronic unit “jams” and cannot be removed: 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
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Sometimes, the mechatronic unit cannot be removed. In this

case, the gear actuator is “caught” at the “top left” of the gearbox
housing.
In this case, mechatronic unit is not allowed to be removed with
significant force.
– First reposition mechatronic unit on gearbox housing and se‐
cure it with one bolt.
– Move mechatronic unit into “removal position” by hand
⇒ page 62 .
Installing mechatronic unit ⇒ page 65 .
3.4 Moving mechatronic unit for dual clutch gearbox -J743- into “removal posi‐
tion” by hand
Sometimes, the mechatronic unit cannot be removed. In this
case, the gear actuator is “caught” at the “top left” of the gearbox
housing -arrow-.

• Only if you cannot set the mechatronic unit to removal position

with the vehicle diagnostic tester , you must move the unit by
hand to this position.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
The “sticking” gear actuator -arrow- can be pressed by hand into

its “removal position”. To do this, push a selector fork behind the

t to the co
parking lock cover. How to do this is described in the following

work procedure:
rrectne
– First reposition mechatronic unit on gearbox housing and se‐

cure it with one bolt.
ss

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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


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
– Use your hand to press lever to stop in direction of cable sup‐
erm
ab
ility
port bracket.
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
– Remove lever of selector shaft.

orm
m
– Unbolt cover. atio

om
n in
or c
thi
e
Caution
t
sd
iva
o
r
rp
cu
o
The mechatronic unit will not be “stuck” after the next step. That
m
f
en
ng
t.
means that it could fall out. If not already done: Secure me‐
yi Co
op
chatronic unit on gearbox with a bolt to prevent it from falling
C py
t. rig
gh
down.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Working through opening, push selector fork to side

-direction of arrow-.
(Press to left in direction of travel.)
This presses back “sticking” gear actuator and mechatronic unit
can be removed.
– Please do not assemble parking lock until you have filled oil.

– Grease oil seal in cover with sealing grease -G 052 128 A1- .
– Fit cover and lever again.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Press selector lever cable back onto ball head and install new
es, in part or in w
securing clip.
t to the co
– Securing clips for selector lever cable must always be re‐
newed.
rrectness of i
– Add gear oil after completing work on mechatronic unit. Fill oil
l purpos
into gearbox ⇒ page 30 .

– Adjust selector lever cable ⇒ page 43 .
nform
ercia
– Place plug on removed mechatronic unit.

m
a
com
tio
This way, the mechatronic unit can be sent sealed in oil-tight con‐
n in
dition.
r
te o
thi
s
iva
do
r
rp
3.5 Installing mechatronic unit for dual

um
fo
en
ng
t.
clutch gearbox -J743-
yi Co
Cop py
t. rig
gh ht
Special tools and workshop equipment required yri
p by
o Vo
by c lksw
cted
♦ Guide pin -T10406-
agen
Prote AG.

Note
♦ A “new” mechatronic unit is correctly filled with oil.

♦ Do not drain oil. A “removed” mechatronic unit is sent back
with its oil in.
Installing
• All selector forks must be “in neutral” prior to installation of
mechatronic unit
Note
Make sure that all selector forks are located in -N-, “in the middle”, and therefore that the gearbox is in neutral.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
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ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
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or
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ate
do
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for
en
– Therefore, check each of 4 selector forks by hand.

ng
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Prote AG.

Every selector fork has 3 positions: “gear selected - neutral - gear

selected”.
– Also, move each fork into each position in succession. Then
disengage all gears and return selector forks to middle position
“neutral”.
Note
“Neutral, neutral, neutral”, or gearbox will not function!
You can turn the front gear slightly for assistance. This makes it
“easier” to shift the forks.
– Please clean sealing surface where mechatronic unit will
make contact later on.
Oil residues on sealing surface will later result in a misdiagnosis
of “leaking”.
AG. Volkswagen AG d
agen
– Screw in guide pin -T10406- hand-tight. Volksw oes
not
gu
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db ara
rise nte
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un
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pe
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ot
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hole
spec
es, in part or in w
t to the co
Make sure that all 4 gear actuators project 25 millimetres -a-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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Cop py
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lkswage es n
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ab
Caution
ility
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wit
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Handle with care. When levering the plungers out of the me‐
h re
chatronic unit, make sure that you do not brace yourself on the
hole
spec
sensors.
es, in part or in w
t to the co
– Please clean sealing surface of mechatronic unit.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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or c
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Golf Variant 2007 ➤ , Golf
agenVariant 2010 ➤
AG. Volkswagen AG, dJetta 2005 ➤ , Jetta 2011 ➤
oes
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ol
0AM
gu - Edition 07.2010
b a
ed ran
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– Watch out for seal on mechatronicauunit.
th or
ac
ss
Seal must be pushed in all around.
ce
le
un
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an
d
– Look at sender. Clip must not be damaged.
itte
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rm
ab
pe
– Put on mechatronic unit.
ility
ot
wit
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– When gripping and putting on, make sure selector forks are
h re
not inadvertently pressed out of their position.
hole
spec
es, in part or in w
– Also observe engaging levers and plungers on mechatronic
t to the co
unit.
rrectness of i
l purpos
nform
mercia
a
com
tion in
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– Screw in 7 new bolts and tighten until finger-tight.
do
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cum
fo
– Remove guide pins -T10406- again.
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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Prote AG.
– Make sure that plungers meet up correctly in cups of engaging

levers.
– Pull out plungers by hand until they are seated in cups.
Plungers can be moved into position with a hook bent from a piece
of welding wire (local manufacture).
– Now check seat of plungers again.
Plungers that are not seated correctly will damage mechatronic

unit.
– Tighten mechatronic unit diagonally to 10 Nm.

– Turn assembly lever -T10407- clockwise and remove it.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Install gearbox input speed sender 3 -G641- .
an
d
itte
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ab
– Look at sender. Clip must not be damaged.
pe
ility
ot
wit
• Sender lug must be fully and firmly in contact with gearbox
, is n
h re
housing. If sender is “loose” or clip is broken, renew mecha‐
hole
spec
tronic unit.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove plug and put breather cap -arrow- in place.

m
a
– Join connector of mechatronic unit.
com
tion in
r
te o
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Cop py
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pyri by
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Prote AG.
– Attach all retainers and brackets to front of gearbox.


Now add gear oil ⇒ page 30 .
– Install starter ⇒ Rep. Gr. 27 ; Removing and installing starter .
– Fit charge air or coolant hoses as necessary.

– Install battery and battery tray ⇒ Rep. Gr. 27 ; Battery; Re‐
moving and installing battery .
– Install complete air filter housing.
♦ Vehicles with petrol engines ⇒ Rep. Gr. 24 ; Removing and
♦ Vehicles with diesel engines ⇒ Rep. Gr. 23 ; Removing and
– If necessary, top up coolant ⇒ Rep. Gr. 19 a;gDraining
en AG. V and
olkswagen AG
does
filling coolant . olksw not
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d b ara
se nte
– Install noise insulation⇒ Rep. Gr.
thori 50 ; Assembly overview - eo
noise insulation . sa
u ra
c s
ce
e
– Carrying out basic adjustment ⇒ page 7 .

nl
pt
du
an
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erm
ab
ility
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– Place plug on “removed” mechatronic unit if necessary.

wit
, is n
h re
This way, the mechatronic unit can be sent sealed in oil-tight con‐
hole
dition.
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
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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Prote AG.

7-speed dual clutch gearbox 0AM - Edition 07.2010 en AG. Volkswagen AG
ag does
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3.6 View of selector forks with mechatronic unit removed by ara
ed nte
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th
au ra
c
ss
N - Idling/gearbox neutral po‐
ce
e
nl
pt
sition “in the middle”
du
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itte
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R - Reverse gear
ab
ility
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❑ If reverse gear is engag‐
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ed, extended plunger of
h re
mechatronic unit catch‐
hole
spec
es behind gearbox es, in part or in w
housing.
t to the co
– Therefore, move me‐
chatronic unit into re‐
rrectness of i
moval position by hand
⇒ page 65 .
l purpos
1 - Gear
nform
ercia
2 - Gear
m
at
om
3 - Gear
ion
c
in t
or
4 - Gear
his
ate
do
riv
5 - Gear
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6 - Gear
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rig
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Prote AG.

4 Removing and installing gearbox

Information about gearboxes with different output shafts
⇒ page 73
Vehicles with petrol engines
1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine
⇒ page 74
1.6 l/75 kW MPI engine ⇒ page 81 AG. Volkswagen AG d
agen oes
olksw not
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Vehicles with diesel engine ed b ara
nte
ris
ho eo
1.9 l/77 kW TDI PD engine ⇒ page 90 aut ra
c
ss
1.6 l/77 kW TDI CR engine ⇒ page 97
ce
e
nl
pt
du
an
itte
4.1 Information about gearboxes with differ‐
y li
erm
ab
ent output shafts
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Gearbox with different output shafts.
hole
spec
A - Stub shafts “to 11.2008”
es, in part or in w
t to the co
B - Flange shafts “from 12.2008”
Vehicles with stub shafts on gearbox
rrectness of i
To remove gearboxes with stub shafts, it is necessary to remove
l purpos
stub shafts. Only shafts with straight joints can be put back onto
the output shafts safely. Therefore, these drive shafts must be
removed.
nf
ercia
or
Vehicles with flange shafts on gearbox
m
m
atio
om
For gearboxes with flange shafts, the drive shafts must be unbol‐
n in
or c
ted from the gearbox. This way, the gearbox can be removed. In
thi
te
sd
individual cases, it is necessary to remove right-hand flange shaft
iva
o
r
from gearbox. This gives you enough clearance for removing

rp
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gearbox.
f
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Cop py
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Prote AG.
Secure both drive shafts to suspension struts using tensioning
straps -T10038- .
4. Removing and installing gearbox 73

4.2 Removing gearbox, vehicles with 1.4 l/90 kW TFSI engine and 1.4 l/118 kW
TSI engine gen AG
. Volkswagen AG
d
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olks not
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Special tools and workshop
ho
ris nte
eo
equipment required au t ra
c
ss
♦ Support bracket -10 - 222
ce
e
nl
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du
A-
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itte
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erm
ab
♦ Adjustment plate -3282/59-
ility
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♦ Adapter -10 - 222 A /8-
wit
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h re
hole
♦ Insert tool, 18 mm -T10179-
spec
es, in part or in w
♦ Gearbox support -3282-
t to the co
♦ Socket -T10061-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.
♦ Engine and gearbox jack -V.A.G 1383 A-
Brief description
The gearbox is removed downwards separately, without engine.
The battery, air filter and starter are removed “from above”.

Noise insulation beneath engine/gearbox, lower cover in frontagleft

en AG. V
olkswagen AG
does
wheel housing and pendulum support are removed “from Volkbelow”.
sw not
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Perform the following steps: rise tee
tho or
au ac
– Raise vehicle. All 4 supports of lifting platform
ss must be at same
height.
ce
e
nl
pt
du
an
itte
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erm
ab
Only in vehicles with stub shafts
ility
ot p
wit
, is n
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hole
Note
spec
es, in part or in w
t to the co
After loosening centre bolt, do not lower vehicle to ground again.
– Step on the brake pedal while a 2nd mechanic loosens the two
rrectness of i
drive shaft bolts -arrow-.
l purpos
– Remove both front wheels.

Continuation for all vehicles
nform
mercia
– Remove complete air filter housing ⇒ Rep. Gr. 24 ; Removing
at
om
i
and installing air filter .
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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yri by
– Remove battery and battery tray ⇒ Rep. Gr. 27 ; Battery; cop Vo
by lksw
cted agen
Prote AG.

starter .

Cable may also be pushed slightly backwards out of cable support
bracket and removed later when gearbox is lowered. But then
observe cable when lowering gearbox.

– Release mechatronic unit connector by pulling and pull off

connector.
– Now remove all upper connecting bolts between engine and
gearbox.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
These tools are appropriate for this. ut
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
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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
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

A bolt is located in the starter motor hole. Bit -T10061- can be

used instead of an 18 mm socket.
- noise insulation .
– Remove front part of wheel housing ⇒ Rep. Gr. 66 ; Assembly
overview - front wheel housing .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
– Remove pendulum support.

ot p
wit
, is n

h re
hole
spec
– Remove both drive shafts ⇒ Rep. Gr. 40 ; Removing and

es, in part or in w
installing drive shafts .

t to the co
Only in vehicles with flange shafts

rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– If fitted, remove the heat shield over the right-hand drive shaft.
o
n in
or c
Tightening torque ⇒ Rep. Gr. 40 ; Repairing drive shafts

thi
te
sd
iva
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unbolt only left suspension link from swivel joint -arrows-.

– Swing left drive shaft into wheel housing onto longitudinal
member. This will keep the shaft out of the way during further
work.
The surface protection of the shafts must not be damaged. Plastic
cable ties or a pair of tensioning straps -T10038- are therefore
very good for this.

straps -T10038- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Remove right flange shaft of gearbox.

wit
, is n
h re
Bolt has a 6 mm hexagon socket. Bolt can also be removed and

hole
spec
installed with socket -V.A.G 1669- .

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
– Unbolt exhaust system bracket from subframe.

or c
thi
te
sd
iva
o
r
rp
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove front exhaust pipe so that lower bolts can be removed

-arrows-.
– Remove engine cover from cylinder head.
– If there are hose and cable connections in area ofolengine
ksw
age sup‐ es n
ot g
port eye for support bracket -10-222 A- , remove
db
y these now.
V ua
ran
e
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Support engine and gearbox with support bracket -10-222 A-
hole
spec
but do not raise.
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
a
Remove all bolts -1- and -2- for bracket.

iv
o
r
rp
cu
o
m
– Then lower engine and gearbox slightly using spindles of sup‐
f
en
ng
t.
port bracket -10 - 222 A- so that bracket can be removed.
yi Co
Cop py
ht. rig
At most, 5 turns are sufficient to remove bracket. rig ht
py by
co Vo
by lksw
In many cases, the spindle does not need to be lowered further cted agen
Prote AG.
for the later removal of the gearbox.
To remove gearbox 0AM, set up gearbox support -3282- with ad‐

justment plate -3282/59- and push onto engine and gearbox
support -V.A.G 1383 A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate -3282/59- .
– Screw in support elements as illustrated on adjustment plate
-3282/59- .
– Position engine and gearbox jack -V.A.G 1383 A- under vehi‐
cle.
• Arrow on adjustment plate -3282/59- points in direction of trav‐
el.
– Align gearbox support -3282- parallel to gearbox.
– Screw pin -3282/29- into “rear” hole for pendulum support.

– Place both remaining attachments onto gearbox as shown.

When doing this, place sheet metal of drift under gearbox
housing and not under mechatronic unit.
– Secure gearbox with tensioning strap -T10038- . olkswage es n
ot g
byV ua
– Raise gearbox and engine support -V.A.G 1383 A- from belowrised ran
tee
to support gearbox. utho
or
a ac
ss
The gearbox is separated from the engine in this position.
ce
le
un
pt
an
– Remove remaining engine/gearbox connecting bolts.
d
itte
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rm
ab
– Press gearbox off engine, “observing selector lever cable” and
pe
ility
lower gearbox.
ot
wit
, is n
h re
hole
spec
Note es, in part or in w
t to the co
♦ Distance between engine flange and gearbox flange should
be about 50 mm before gearbox is lowered.
rrectness of i
♦ Be careful of all lines and coolant hoses when lowering gear‐
l purpos
box.
nform
ercia
– Renew needle bearing in crankshaft -arrow- ⇒ Rep. Gr. 13 ;

Crankshaft, pulling needle bearing from crankshaft and driving
m
a
com
ti
in .
on in
r
te o
thi
s
iva
⇒ page 111 .
do
r
rp
cum
fo
Installing gearbox ⇒ page 104 .
en
ng
t.
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op
If gearbox is to be sent:
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
In some cases, there are retainers on the front of the gearbox.

– Remove retainers if installing a “new” gearbox, because there
are no retainers on a “new” gearbox.
– Install right flange shaft of gearbox with flange shafts
⇒ page 118 .

4.3 Removing gearbox, vehicles with 1.6 l/75 kW MPI engine

equipment required
A-
♦ Adapter -10 - 222 A /8-
♦ Socket -T10061-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
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ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
♦ Bracket -T10346-
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.

♦ Adapter -10 - 222 A /3-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
Brief description
com
tion in

r
te o
thi
s
iva
do
r
rp
cum
fo
Noise insulation beneath engine/gearbox, lower cover in front left

en
ng
t.
yi
wheel housing and pendulum support are removed “from below”.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
height.
starter .

– Remove securing clip in -direction

wage
n AG. Vof arrow-. does
olkswagen AG
ks not
Vol g
Securing clips for selector
ed
by lever cable must always be renewed.
ua
ran
is tee
or
– Remove Bowden
au
th cable from ball head. or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
connector.
rrectness of i
l purpos
gearbox.
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
These tools are appropriate for this. ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
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.
yi Co
Cop py
ht. rig
A bolt is located in the starter motor hole. Bit -T10061- can be rig ht
py by
used instead of an 18 mm socket.
co Vo
by lksw
cted agen
Prote AG.

– Disconnect left and right-hand drive shafts from flanges on
gearbox.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Unbolt only left suspension link from swivel joint -arrows-.

ot
wit
, is n
h re

hole
spec
es, in part or in w
work.
t to the co

very good for this.
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
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.


straps -T10038- .

AG. Volkswagen A
Bolt has a 6 mm hexagon ksocket.
swa
gen Bolt can alsoGbe
doeremoved
s no and
y Vol 1669- .
installed with socket d-V.A.G t gu
b ar
e an
ris tee
Torque setting:u30
tho Nm or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unbolt exhaust system bracket from subframe.
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.
– Remove front exhaust pipe so that lower bolts can be removed
yi Co
op
-arrows-.
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.

– Bolt bracket -T10346- to rear of the 3 mounting holes for bat‐

tery tray.
– To do this, use a collar bolt M 6 or a securing bolt for battery
AG. Volkswagen AG d
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♦ Adapter -10 - 222 A /8-
♦ Adapter -10 - 222 A /3-
• Place adapters -10 - 222 A /8- on upper longitudinal carriers,
directly before the raised portion (-arrow 1-) next to bolt
(-arrow 2-).

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lustration).
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bracket on spindles. en AG. V
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Remove all bolts -1- and -2- for
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– Raise gearbox and engine support -V.A.G 1383 A- from below
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lower gearbox.
Note

box.

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AG n AG d
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– Renew needle bearing in crankshaft -arrow- by ⇒ Rep. Gr. 13 ;
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4.4 Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine

equipment required
A-
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♦ Adapter -10 - 222 A /16-

♦ Hook -10 - 222 A /2-
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♦ Shackle -10 - 222 A /12-
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Brief description
height.
Note
After loosening centre bolt, do not lower vehicle to ground again.

– Step on the brake pedal while a 2nd mechanic loosens the two
drive shaft bolts -arrow-.
– Remove both front wheels.

Removing and installing battery . n AG. Volkswagen AG do
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– Remove starter ⇒ Rep. Gr. 27 by V; Removing and installing
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connector. C py
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– Now remove all upper connecting bolts between engine and cop Vo
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These tools are appropriate for this.

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- noise insulation . pyri by
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– Remove both drive shafts ⇒ Rep. Gr. 40 ; Removing and
installing drive shafts .
Only in vehicles with flange shafts

– Unscrew left suspension link from swivel joint.

work.
very good for this.

straps -T10038- .

installed with socket -V.A.G 1669- . agen
AG. Volkswagen AG d
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Torque setting: 30 Nm ed
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– If there are hose and cable connections in area of engine sup‐
port eye for support bracket -10 - 222 A- , remove these now.
– Remove filler pieces from upper edges of both wings.

but do not raise.
AG. Volkswagen AG d
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Secure shackle -10 - 222 A /16- to gearbox by housing.
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port bracket -10 - 222 A- or adapter -10 - 222 A /16- so that

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rm
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AG . Volkswage
– Align arms of gearbox support
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– Raise gearbox and engine support -V.A.G 1383 A- from below

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lower gearbox. by c lksw
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Note

box.
– Renew needle bearing in crankshaft -arrow- ⇒ Rep. Gr. 13 ;

Crankshaft, pulling needle bearing from crankshaft and driving
in .
⇒ page 111 .


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⇒ page 118 . ise
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4.5 Removing gearbox - vehicles with 1.6 l/77 kW TDI CR engine
spec
t to the co
equipment required
rrectne
A-
ss o
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inform
mer
♦ Socket -T10035-
atio
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♦ Socket -T10061-
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♦ Adapter -10 - 222 A /3-
♦ Adapter -10 - 222 A /18-
AG. Volkswagen AG d
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Brief description
spec
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starter .
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connector.
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gearbox.
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These tools are appropriate for this.

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AG.
Rep. Gr.34 - Controls, housing
– Unscrew left suspension link from swivel joint.

work.
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straps -T10038- .

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installed with socket -V.A.G 1669- . Volksw not
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– If there are hose and cable connections in area of engine sup‐
port eye for support bracket -10-222 A- , remove these now.
– Remove filler pieces from upper edges of both wings.

but do not raise.
AG. Volkswagen AG d
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nform
mercia
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tion in
r
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• Place adapters -10 - 222 A /8- on upper longitudinal carriers,

s
iva
do
directly before the raised portion (-arrow 1-) next to bolt

r
rp
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(-arrow 2-).
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port bracket -10 - 222 A- so that bracket can be removed.
In many cases, the spindle does not need to be lowered further

-3282/59- .
cle.
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agen
of
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– Raise gearbox and engine support -V.A.G 1383 A- from below rrectness of i
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nf
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m
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be about 50 mm before gearbox is lowered. C py
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♦ Be careful of all lines and coolant hoses when lowering gear‐ cop Vo
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta g2011
n AG.➤
Volkswagen AG
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– Renew needle bearing in crankshaft -arrow- ⇒ Rep. Gr. ut13h ;
o
or
Crankshaft, pulling needle bearing from crankshaft andsdriving
sa ac
in .
ce
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nl
pt
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⇒ page 111 .
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nf
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– Install right flange shaft of gearbox with flange shafts
m
atio
m
⇒ page 118 .
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4.6 Installing gearbox
– Please read these important work steps before installing gear‐
box.
– In some cases, there are brackets on the front of the removed
gearbox. Attach these brackets to the “new” gearbox.


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Gearbox with flange shafts -B-
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h re
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spec
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Note
There is no need to renew oil seal for flange shaft when doing
rrectness of i
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– Remove right-hand flange shaft of gearbox in order to install

gearbox.
nform
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Gearbox with flange shafts, torque setting ⇒ page 118 .

m
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tio

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by lksw
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– If it has not already been done, renew needle bearing in crank‐

shaft -arrow- ⇒ Rep. Gr. 13 ; Crankshaft, pulling needle
bearing from crankshaft and driving in .
– Check for proper seating of both dowel sleeves between en‐
gine and gearbox.
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insert it in cable support bracket “early”.
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ab
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t to the co
– Readjust gearbox support until engine and gearbox are
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rrectne
– Turn crankshaft slightly if necessary.
ss o
– After fitting starter motor, check that both breather caps are in
cial p
f in
place -arrows-!
form
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– Securing clip for selector lever Bowden cable -arrow- must be

renewed.
A securing clip which has been removed is not allowed to be in‐
stalled again. The clip will have lost its internal tension and so it
might fall off.
– Therefore, when installing, always use a “new” securing clip.

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ir se Golf Variant 2007 ➤ , Golf Variant
tee 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
t or
au 7-speed dual ac clutch gearbox 0AM - Edition 07.2010
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– Ensure that selector lever cable is properly routed during in‐
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ility
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es, in part or in w
installation.
t to the co
– Always adjust selector lever cable ⇒ page 43 .
rrectness of i
– Carrying out basic adjustment ⇒ page 7 .
l purpos
Torque settings for gearbox installation ⇒ page 107 .
nform
ercia
4.7 Torque settings “Gearbox to engine”

and notes on assembly mounting
m
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com
tion in
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The “next chapters” list the torque settings for gearbox installa‐
te o
thi
tion.
s
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rp
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There is also information about the “left” assembly mounting.
fo
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Threaded connections that are not directly assigned to the gear‐
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The pendulum support on the subframe is part of the running
gear.
Consequently, further descriptions can also be found in ⇒ Run‐
ning gear, axles, steering; Rep. Gr. 40 .
Left assembly mounting
– Renew all bolts on left assembly mounting.
– First screw in all bolts by hand.
– First bolt bracket to gearbox -1- with 40 Nm + 90° further turn.

AG . Volkswage
– The bracket can be moved within its seat with ksw
agaenscrewdriver AG does
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when bolts -2- are tightened. Torque setting
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V of -bolts 2-: 60 Nm
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c
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Pendulum support to subframe and gearbox ⇒ Rep. Gr. 40 ;
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Assembly overview - subframe, anti-roll bar, suspension links .
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Gearbox to engine:
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♦ 1.4 l/90 kW TFSI engine ⇒ page 108
hole
spec
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♦ 1.4 l/118 kW TSI engine ⇒ page 108
t to the co
♦ 1.6 l/75 kW MPI engine ⇒ page 108
♦ 1.9 l/77 kW TDI PD engine ⇒ page 109
rrectness of i
♦ 1.6 l/77 kW TDI CR engine ⇒ page 110
l purpos
4.7.1 Engines: 1.4 l/90 kW TFSI, 1.4 l/118 kW TSI, 1.6 l/75 kW
nf
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orm
m
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M12 - 80 Nm
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4.7.2 Engine: 1.9 l/77 kW TDI PD
M12 - 80 Nm
❑ If 18 mm insert -T10179-
is used: 65 Nm.
M10 - 40 Nm
- Arrows point towards dowel
sleeves
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4.7.3 Engine: 1.6 l/77 kW TDI CR
M12 - 80 Nm
❑ If 18 mm insert -T10179-
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M10 - 40 Nm
- Arrows point towards dowel
sleeves
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– Pull off both breather caps -arrows- and close using suitable
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Secure gearbox on gearbox support -VW 353-
5. Transporting gearbox and securing to assembly stand 111

Lift gearbox into assembly stand.

The gearbox is lifted “into assembly stand” together with gearbox
support -VW 353- . n AG. Volkswagen A G do
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35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
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1. Currently, no repairs can be made to gears and shafts 113

39 – Final drive - front differential

1 Oil seals
Gearbox with stub shafts -A-.
Right ⇒ page 114
Left ⇒ page 116
Gearbox with flange shafts -B-.
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Left-hand side ⇒ page 116
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♦ Hexagon key -T10107 A- or socket and extended bit -V.A.G

1669-

114 Rep. Gr.39 - Final drive - front differential

♦ Sealing grease -G 052 128 A1-

♦ Drip tray
Note
♦ Do not remove both drive shafts from gearbox at the same

time. If you do so, it will no longer be possible to hold the op‐
posite front wheel fixed for removing or installing the bolts of
the stub shafts.
♦ Do not remove both stub shafts from gearbox at the same time.
If the differential bevel gears turn, it is difficult to reinstall the
securing bolts for the stub shafts.
– Remove drive shaft ⇒ Rep. Gr. 40 ; Removing and installing

drive shafts .
– Remove bolt -arrow- in stub shaft with socket -T10107 A- or
socket -V.A.G 1669- .
– Pull out stub shaft.
– Pry seal out using assembly lever.
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– Lightly oil outer
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– Half fill space between sealing lip and dust lip with sealing
, is n
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hole
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– Drive in new seal to stop, being careful not to cant seal.

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If necessary, it is possible to press a new dust ring onto the stub

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– Reinstall drive shaft ⇒ Rep. Gr. 40 ; Removing and installing
Prote AG.
drive shafts .
– Renew gear oil ⇒ page 30 .
– Install noise insulation; torque settings ⇒ Rep. Gr. 50 ; As‐
sembly overview - noise insulation .
1. Oil seals 115

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♦ Multipurpose tool -771-
♦ Puller hooks -771/37-


♦ Drip tray
Note
♦ Do not remove both drive shafts from gearbox at the same

time. If you do so, it will no longer be possible to hold the op‐
posite front wheel fixed for removing or installing the bolts of
the stub shafts.
♦ Do not remove both stub shafts from gearbox at the same time.
If the differential bevel gears turn, it is difficult to reinstall the
securing bolts for the stub shafts.
– Remove drive shaft ⇒ Rep. Gr. 40 ; Removing and installing

drive shafts .
– Remove bolt -arrow- in stub shaft with socket -T10107 A- or
socket -V.A.G 1669- .
– Pull out stub shaft.
– Pull out stub shaft oil seal with multi-purpose tool -VW 771-
and puller hooks -VW 771/37-. wage
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rrectness of i
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– Drive in new seal to stop, being careful not to cant seal.

If necessary, it is possible to press a new dust ring onto the stub
shaft using drift sleeve -40 - 20- . Do not use a hammer.
– Insert stub shaft.
– Tighten new countersunk bolt for stub shaft to 30 Nm.
– Reinstall drive shaft ⇒ Rep. Gr. 40 ; Removing and installing
drive shafts .
1.3 Renewing seal for right flange shaft

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♦ Tensioning strap -T10038-

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♦ Do not remove both flange shafts from gearbox at the same
es, in part or in w
t to the co
time. If the differential bevel gears turn, it is difficult to reinstall
the securing bolts for the flange shafts.
♦ Remove drive shaft from gearbox and lay to side. Drive shaft
rrectness of i
is fixed onto suspension strut with tensioning belt -T10038- .
l purpos
♦ You do not need to remove the centre bolt of the drive shaft.
nform
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– Remove drive shaft heat shield from engine -arrows-, if fitted.

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Unbolt drive shaft from gearbox.

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– Pull out flange shaft.
– Pry seal out using assembly lever.
– Lightly oil outer circumference of new oil seal.
– Half-fill space between sealing lip and dust lip of new seal with
sealing grease -G 052 128- -arrow-.
1. Oil seals 119

– Drive in new seal to stop with thrust piece -3305- , being careful
not to cant seal.
– Insert flange shaft.
– Tighten new countersunk bolt to 30 Nm. When doing this,
press flange shaft against gearbox so that bolt engages in
thread.
– Fit drive shaft back on ⇒ Rep. Gr. 40 ; Removing and installing
drive shafts .
1.4 Renewing oil seal for left flange shaft

Right side ⇒ page 118
♦ Multipurpose tool -VW 771-
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♦ Hexagon key -T10107VoA-
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es n
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m
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Drive shaft is fixed onto suspension strut with tensioning belt
-T10038- .
♦ You do not need to remove the centre bolt of the drive shaft.

– Remove left wheel housing liner⇒ Rep. Gr. 66 ; Assembly
overview - front wheel housing liner .
– If present: Unbolt front left vehicle level sender -G78- from

suspension link.
Torque setting for removing and installing ⇒ Rep. Gr. 40 ; front
left vehicle level sender -G78- .
– Turn steering wheel to left lock and remove left drive shaft from
flange shaft ⇒ Rep. Gr. 40 ; Removing and installing drive
shafts .
1. Oil seals 121

– Only unscrew left suspension link from swivel joint.
AG. Volkswagen AG d
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– Unscrew nut -1- from coupling rod -3- ⇒ Rep. Gr. 40 ; As‐ d by V gu
ara
sembly overview - subframe, anti-roll bar, suspension links oris.e nte
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h
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– Pull off coupling rod and turn anti-roll bar -2- upwards sslightly.
s c
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– Swing left drive shaft into wheel housing. un
pt
an
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– Raise drive shaft as high as possible and secure. Take care
rm
ab
pe
not to damage paint on drive shaft in the process.
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– Remove left flange shaft of gearbox.
rrectness of i
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– Pull out flange shaft.
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te o
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– Remove flange shaft oil seal.

– Lightly oil outer circumference of new oil seal.

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Golf Variant yV
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– Half-fill space between sealing
ss lip and dust lip of new seal with c
sealing grease -G 052 128- -arrow-.
ce
le
un
pt
an
d
itte
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ility
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is n
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ole,
spec
t to the co
rrectnes
– Drive in new seal to stop with thrust piece -3305- , being careful
s o
cial p
f
not to cant seal.
inform
mer
– Insert flange shaft.
atio
m
– Tighten new countersunk bolt to 30 Nm. When doing this,

o
n
c
i
or
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press flange shaft against gearbox so that bolt engages in
thi
te
thread.
sd
iva
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– Fit drive shaft back on ⇒ Rep. Gr. 40 ; Removing and installing

fo
en
ng
drive shafts .
t.
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– Fit suspension link and coupling rod back on ⇒ Rep. Gr. 40 ;

Removing and installing drive shafts .
1. Oil seals 123

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7-speed dual clutch gearbox 0AM

Service Department. Technical Information

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Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R008520

2.9 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3 Mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.2 Overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.5 Installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.6 View of selector forks with mechatronic unit removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.1 Information about gearboxes with different output shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.4 Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine . . . . . . . . . . . . . . . . . . . . . . 90

4.5 Removing gearbox - vehicles with 1.6 l/77 kW TDI CR engine . . . . . . . . . . . . . . . . . . . . . . 97

4.6 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.1 Renewing oil seal for right stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

KHN - Gearbox code letters

01.06.06 - Production date:

2 Code, engine allocation

Allocation: gearbox codes for diesel engines

2 Rep. Gr.00 - Technical data

4 General repair notes

4 Rep. Gr.00 - Technical data

– Cover the hole with a cloth before installation work.

4. General repair notes 5

The cover prevents dirt getting in.

Do not mix “additives” in oil.

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

4.4 Working with vehicle diagnostic testers

4.4.1 Adapting installation information

6 Rep. Gr.00 - Technical data

4.4.2 Reading measured values for mandato‐

You must read these measured values before contacting your

important adjustments are taught in again, or reset to program‐

basic measurement only:

♦ if you are prompted to do so in “guided fault finding”

4. General repair notes 7

The clutch is self-adjusting. Shocks can have an effect on this ab

clutch. Even if the mechatronic unit has been removed, “pulling

have a negative effect on the adjusting device.

Transporting gearbox and securing to assembly stand

Adjust the position of the engagement bearings “K 1 and K 2”

Install dual clutch ⇒ page 22 .

1.1 Removing dual clutch

Special tools and workshop equipment required

8 Rep. Gr.30 - Clutch

♦ Support device -T10323-

♦ Thrust piece -T10376-

– Remove gearbox ⇒ page 73 .

1. Removing and installing the dual clutch 9

Turn gearbox with clutch upwards.

10 Rep. Gr.30 - Clutch

– Remove retaining ring of clutch -arrow-.

♦ It is possible that the retaining ring is seated very tightly. The

– Remove clutch together with puller -T10373- .

1. Removing and installing the dual clutch 11

– Remove small engagement bearing.

– Remove bolts and remove small engaging lever.

♦ Gauge block -T10374-

12 Rep. Gr.30 - Clutch

Position of engagement bearings must be set after clutch and its

actuators have been renewed.