CUTIE DSG 2 TOURAN 1.6 DIESEL - PDF Versiunea 1 PDF

Service
Workshop Manual
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ,
Golf 2009 ➤ , Golf Plus 2005 ➤ ,
Golf Plus 2009 ➤ , Passat 2006 ➤ ,
Passat CC 2009 ➤ , Polo 2010 ➤ ,
Scirocco 2009 ➤ , Touran 2003 ➤
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7-speed dual clutch gearbox 0AM
Edition 12.2016
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
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 © 2016 Volkswagen AG, Wolfsburg K0058895220

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
7-speed dual clutch gearbox 0AM - Edition 12.2016
Contents
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00 - Technical data .ed. b.y V. . . . . . . . . . . . . . . . . . . . .t g.ua.ra. . . . . . .................... 1
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1 Identification
utho of gearbox . . . . . . . . . . . . . . . . . . . . . . . e. o.r . . . ........................ 1
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2 ss Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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3 Code, engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3.1 Polo 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3.2 Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3.3 Golf 2004 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3.4 Passat CC 2009 ►; CC 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.5 Passat 2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.6 Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.7 Golf Plus 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.8 Golf Plus 2005 ►, Cross Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.9 Scirocco 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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5.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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5.3 Anti-friction bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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5.4 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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5.5 Working with tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1 Removing and installing dual clutch, gearboxes made up to 05.2011 . . . . . . . . . . . . . . . .
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1.1 Assembly overview - dual clutch, gearboxes made up to 05.2011 . . . . . . . . . . . . . . . . . . 11
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1.2 Removing dual clutch, gearboxes made up to 05.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made up
to 05.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Installing dual clutch, gearboxes made as of 05.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Removing and installing dual clutch, gearboxes made from 06.2011 onwards . . . . . . . . . . 37
2.1 Assembly overview - dual clutch, gearboxes made as of 06.2011 . . . . . . . . . . . . . . . . . . . . 37
2.2 Removing dual clutch, gearboxes made as of 06.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made as
of 06.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4 Installing dual clutch, gearbox date from 06.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3 Removing and installing oil seals at clutch end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.1 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 Selector mechanism in vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1 Overview of selector mechanism up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2 Removing and installing selector lever cable up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Selector mechanism from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Overview of selector mechanism in vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 80
4.2 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 Selector lever in “P” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2 Selector lever in “N” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.3 Selector lever in position “Tiptronic” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.4 Ignition and light switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.5 Selector lever position indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Contents i
5.6 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

6 Safety note on mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . 89
7 Overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8 Removing mechatronic unit for dual clutch gearbox J743 ; gearbox is installed . . . . . . . . 92
9 Moving mechatronic unit for dual clutch gearbox J743 into »removal position« by hand . . 104
10 Installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . 106
11 View on selector forks; mechatronic unit is removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
12 Renewing clutch actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
13 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
13.1 Notes on different vehicles, different gearboxes . . . . . . . . . . . . A . . ..V.o.lk.sw. a.g.en. . . . . . . . . . . 120
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13.2 Removing gearbox, Golf 2009 ► and Golf Plus 2009 ►, 1.2 olkl
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.d .by. V. . . . . . . . . . . . . . . . . . . . . . . . . g.u.ar.a 122
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13.3 Removing gearbox, Golf 2009 ►, 1.8 l - 118 kW petrol tho
ri engine . . . . . . . . . . . . . . . . . . . . . . 130 eo
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a77 kW petrol engine . . . . . . . . . . . . . . . . 136r ac
13.4 Removing gearbox, Polo 2010 ►, 1.2 l - 63 and ss
13.5 Removing gearbox, Polo 2010 ►, 1.4 l - 63 kW petrol engine . . . . . . . . . . . . . . . . . . . . . . 141
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13.7 Removing gearbox, Polo 2010 ►, 1.6 l - 66 kW diesel engine . . . . . . . . . . . . . . . . . . . . . . 152
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13.9 Removing gearbox with flange shafts; Touran 1.4 l - 103, 110 and 125 kW petrol engine (and
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110 kW Eco-Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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13.10 Removing gearbox, Touran 1.6 l - 77 kW TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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13.11 Removing gearbox, Touran 1.9 l - 77 kW TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
13.12 Removing gearbox, Passat 2006 ► 1.4 l - 110 kW Eco-Fuel engine . . . . . . . . . . . . . . . . . . 183
13.13 Removing gearbox, Passat 1.4 l - 90 and 110 kW petrol engine . . . . . . . . . . . . . . . . . . . . 189
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13.14 Removing gearbox, Passat 1.8 l - 90 and 118 kW petrol engine . . . . . . . . . . . . . . . . . . . . 193
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13.15 Removing gearbox, Golf Plus 2009 ►, 1.4 l - 90 kW and 118 kW petrol engine . . . . . . . . 199
13.16 Removing gearbox, Golf Plus 2009 ►, 1.6 l - 75 kW petrol engine . . . . . . . . . . . . . . . . . . 206
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13.17 Removing gearbox, Scirocco 2009 ►, 1.4 l - 118 kW TSI engine . . . . . . . . . . . . . . . . . . . . 212
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13.18 Removing gearbox, Golf 2009 ►, 1.6 l - 75 kW petrol engine . . . . . . . . . . . . . . . . . . . . . . 218
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13.19 Removing gearbox, Golf 2009 ►, 1.4 l - 90 or 118 kW petrol engine . . . . . . . . . . . . . . . . . . 225
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13.20 Removing gearbox, Golf 2004 ►, Golf Plus 2005 ► and Cross Golf 1.4 l - 90, 118 kW TSI
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13.21 Removing gearbox, Golf Plus 2009, 1.6 l - 77 kW diesel engine . . . . . . . . . . . . . . . . . . . . 239
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13.22 Removing gearbox, Golf 2009 1.6 l and 1.9 l - 77 kW diesel engine . . . . . . . . . . . . . . . . . . 245
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13.23 Removing gearbox, Golf 2004 and Golf Plus 2005 1.9 l - 77 kW TDI engine . . . . . . . . . . 251
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13.24 Removing gearbox, Passat CC 2009 ►, CC 2010 ►, Passat 2011 ► 1.4 l - 90, 110, 118 kW cop Vo
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petrol engine and 1.4 l - 110 kW Eco-Fuel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 cted agen
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13.25 Removing gearbox, Passat CC 2009►, CC 2010►, 1.8 l - 90 and 118 kW petrol engine . . 264
13.26 Removing gearbox, Golf Cabriolet 2012 ►, 1.4 l - 90 or 118 kW petrol engine . . . . . . . . . . 270
13.27 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
13.28 Torque settings »Gearbox to engine« and notes on assembly mounting . . . . . . . . . . . . . . 279
14 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
15 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
15.1 Renewing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
15.2 Draining and filling hydraulic fluid for mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

1 Notes on gearbox disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
1.1 Overview: gearbox disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
2 Dismantling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3 Assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
4 Dismantling and assembling gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5 Dismantling and assembling clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
6 Dismantling and assembling outer input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
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7 ...................................................................... 325
8 Dismantling and assembling output shaft 1 - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
8.1 Dismantling output shaft 1 partially . . . . . . . . . . . . . . .n A .G. ..V.o.lk.sw. a. g.e.n A
.G................ 329
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8.2 Dismantling output shaft 1 completely . . . . . . V.o.l . . . . . . . . . . . . . . . . . . o.e.s n. o.t .g . . . . . . . . .
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8.3 Assembling output shaft 1 . . . . . . . . . . . i.se.d.b. . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an. t . . . . . . 333
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8.4 Dismantling and assembling locking collars aut
ho and synchro-hubs of output shaft 1 . . . e. o. . . .
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9.1 Dismantling output shaft 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
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9.2 Assembling output shaft 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
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9.3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 . . . . . . . . 346
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10.1 Dismantling output shaft 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hole
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10.2 Assembling output shaft 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
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10.3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 . . . . . . . . . . 351
11 Notes on gearbox adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
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11.1 Calculating shims for clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
12 Calculating shims for gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
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13 Parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
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13.1 Removing and installing cover for parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
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13.2 Removing and installing parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

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39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
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1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

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1.1 Renewing oil seal for right stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
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1.2 Renewing oil seal for left stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

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1.3 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
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1.4 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents iii
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iv Contents
00 – Technical data
1 Identification of gearbox
(VRL009832; Edition 12.2016)
KHN - Gearbox code letters n AG. Volkswagen AG do

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1. Identification of gearbox 1
2 Overview - power transmission

The 7-speed dual clutch gearbox 0AM is configured as a 5-shaft
gearbox. There are two input shafts and three output shafts.
A1 - Input shaft 1
A2 - Input shaft 2
B1 - Output shaft 1
B2 - Output shaft 2
B3 - Output shaft 3
C - Front final drive
K1 - Dual clutch 1
K2 - Dual clutch 2
M - Engine
T1 - Sub-gearbox 1
cardiagn.com
❑ with gears 1, 3, 5 and 7
T2 - Sub-gearbox 2
❑ with gears 2, 4, 6 and
reverse gear R
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2 Rep. gr.00 - Technical data

3 Code, engine allocation
3.1 Polo 2010 ►

Always take account of the gearbox code if spare parts are re‐
quired for a repair.
Allocation: gearbox codes for petrol engines
LWX, MGQ, MGV, MLN, NTY, PKV, MPP, NAY,
MLG, MPN, MPU, NBD, PMR, PWC NTW, NQH,
NAX, NBD, NQN, NUC, PMP, PKT,
NQG, NTV, PKZ, PMV, PWA
PKS, PMN, PWG
PVZ
1.4 l - 63 kW 1.2 l - 63, 66, 1.4 l - 1.4 l - 132 kW
77 kW 103 kW
Allocation: gearbox codes for diesel engines

»KJB«, MLM, MPT,
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NBC, NQM, NUB, PKY,
PMU, PWF
1.6 l - 66 kW swage
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Always take account of the gearbox code
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LPL, LKP, LWW, LQM, LWW, MGM, LKP, LPL, LWW,
ot
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MGM, MLD, MPK, MLD, MPK, NAU, MGM, MLD, MPK,
, is n
h re
MUV, NAU, NAZ, NQA, NTP, PKM, NAU, NQA, NTP,
hole
NQA, NTP, NTX, PMH, PVU, QQT, PKM, PMH, PVU,
spec
es, in part or in w
PKU, PKM, PMH, QGV QGV, QQT
t to the co
PMQ, PVU, PWB,
QGV, QHC, QQT,
QQZ rrectness of i
1.4 l - 103 kW 1.4 l - 110 kW Eco- 1.4 l - 125 kW
Fuel
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LQN, MLE, MPL, KHM, LKF, LKL,

m
NAV, NQE, NTT, LPH, LSR, MGJ

com
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PKQ, PML, PVX,

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QGY, QQW
thi
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1.6 l - 77 kW TDI 1.9 l - 77 kW TDI

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3.3 Golf 2004 ►

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KHN, LKG, LKM,
LWZ, MGK
1.4 l - 90 kW FSI

KHM, LKL, LKF,
LPH, LSR, MGJ
3. Code, engine allocation 3

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7-speed dual clutch gearbox
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Allocation: gearbox
au codes
th for diesel engines or
ac
ss
1.9 l - 77 kW TDI
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»KHN«, LKG, LKP MLD, MPK, LKN, LPK,
LKM NAU, NQC LSS, MLC,
MGL
rrectness of i
1.4 l - 90 kW 1.4 l - 1.4 l - 1.8 l - 112,
l purpos
FSI 110 kW 118 kW 118 kW
3.5 Passat 2006 ►
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LKG, LKM, LKP, LQM, MLD LKN, LPK, LWW
um
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KHN, LPJ, LSS, MLC,
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LQK, LWZ, MLG
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1.4 l - 90 kW 1.4 l - 110, 1.8 l - 112, 1.4 l -
agen
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FSI 118 kW 118 kW 110 kW
Eco-Fuel
3.6 Golf 2009 ►

MLJ, MPQ, NBA, MGU, MLJ, MPQ, »LKG«, LKM,
NQK, NTZ NBA, NQK, NTZ LPJ, LWZ, MGK,
MLB, MPH, NBA,
NQK, NTZ
1.2 l - 63 kW FSI 1.2 l - 77 kW FSI 1.4 l - 90 kW FSI

»KUT«, LKP, LKJ, »LPN«, LYG, LKJ, LSS, MGL, MPJ
LPL, LWW, MGM, LSU, MGP, MLF,
MLD, MPK, MSL, MPM, NAW, NQF,
MUV, NAU, NAZ, NTU
NQA, NQJ, NTP,
NTX
1.4 l - 118 kW TSI 1.6 l - 75 kW 1.8 l - 118 kW

LYG, LST, LKQ,
KTZ, LQN, MGN,
MLE, MPL, NKA,
NQE, NTT
1.6 l - 77 kW
3.7 Golf Plus 2009 ►



MGU, »LKM«, LPJ, LYG, LKJ, LPN, »LKP«,
MLJ, LWZ, KHN, LKG LSU, MGP, MLF, LPL, LWW,
MPQ, MGK, MLB, MPH, MPM, NAW, KUT, MGM,
NBA, NBA, NQK, NTZ, NQF, NTU, PMM, MLD, MPK,
NQK, PMS, PKW, PWD PKR, PVY MYR, NAU,
NTZ, NQA, NTP,
PMS, PMH, PKM,
PKW, PVU
PWD
1.2 l - 63, 1.4 l - 90 kW FSI 1.6 l - 75 kW TSI 1.4 l -
77 kW 118 kW TSI
TSI

KHM, LKQ, LPM, LKL, LKF, KHM
LST, LQN, MGN,
MLE, MPL, NKA,
NQE, NTT, PML,
PKQ, PVX
1.6 l - 77 kW TDI 1.9 l - 77 kW
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3.8 Golf Plus 2005 ►, Cross Golf
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»KHN«, LKG, LKM »KUT«, LKP horis nte
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»LKG«, LKM, NAS, »KUT«, LKP, LKJ,
s
NBA, NQK, NTZ, LPL, LQM, LWW,
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PWD MYQ, MYR, NAU,
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NAZ, NQA, NQJ,

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NTP, NTX, PKM,

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1.4 l - 90 kW FSI 1.4 l - 118 kW TSI

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3. Code, engine allocation 5

4 Capacities
The 7-speed dual clutch gearbox has two separate and different
oil systems. One for the gear oil section -arrow A- and one for the
hydraulic fluid section -arrow B-.
Capacities Gear oil section
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Lubricant Gear oil for dual clutch gearbox 0AM
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Part number ⇒ Electronic Parts Catalogue
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Capacities Hydraulic fluid section in mechatronic unit for
spec
dual clutch gearbox - J743-
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Initial filling 0.9 l
Changing No change necessary
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Lubricant Hydraulic fluid
Part number ⇒ Electronic Parts Catalogue
“ETKA”
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Further information in the part number designates the container
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Risk of damage to gearbox.

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♦ Only the gearbox oil for the 7-speed dual clutch gearbox
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♦ Other oils will lead to malfunctions or failure of the gear‐
box.
♦ It is not possible to check the fill level of the hydraulic fluid
section of the mechatronic unit for dual clutch gearbox -
J743- . Before repairs, the breather of the mechatronic unit
for dual clutch gearbox - J743- must be sealed so that no
oil can escape.
♦ If any oil escapes from the hydraulic fluid part of the me‐
chatronic unit for dual clutch gearbox - J743- , it is not
possible to replenish it or check the level!
♦ If oil escapes from the gear oil section, it can only be rec‐
tified by changing the gear oil. It is not possible to check
the fill level.
♦ If the level of oil/fluid is too high or too low in either of the
parts, the function of the gearbox will be impaired.

5 General repair instructions
5.1 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.
5.2 Gearbox
cardiagn.com
The gearbox has a hole in the housing.
– Make sure no small parts drop into this hole during installation
work.
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5. General repair instructions 7

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– Cover the hole with a cloth before installation work.

Always 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.
♦ When installing, check for proper seating of dowel sleeves be‐
tween engine and gearbox.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. 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, carefully cov‐
er opened components.

In some vehicles, a cover is fitted over the engaging levers.

The cover prevents dirt getting in.
Specified torque: 8 Nm
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Never interchange outer bearing races of tapered roller bearings.
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Never press ball bearings out or in using balls. Both these will
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cause irreparable damage to the bearings during operation of the

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5.4 Oil
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spec
The “0AM” gearbox has two oil circuits. One oil fill is for gears and
shafts. A 2nd oil fill is for mechatronic unit for dual clutch gearbox
t to the co
- J743- .
Both oils are Genuine parts ⇒ page 6 .
rrectne
Do not mix »additives« in oil.

s
Oil which has been drained out cannot be added again.

s o
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Caution
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Be careful when working with oil. Dispose of drained oil ac‐

c
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or
cording to regulations. Remember: one drop of oil will contam‐

thi
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5.5 Working with tester
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♦ Vehicle diagnostic and service information system - VAS 5052
A-
♦ Vehicle diagnosis, testing and information system - VAS
5051B-
Various functions are available in the operating modes Guided
functions and Guided fault finding . The 3 most important
are:
♦ Adapting installation information
♦ Reading measured values for mandatory reporting
♦ Initiating basic adjustment
5. General repair instructions 9

5.5.1 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 button instructs the mechatronic unit to
forget all communication partners.
All »active partners« are detected once again the next time the
ignition system is switched on.
You cannot »generate« any faults using this function. Please al‐
ways perform the Adapt installation information function
after the following activities:
♦ After a selector lever has been installed.
♦ After another control unit has been installed, e.g. engine, ABS
or gateway.
♦ After work on the steering wheel paddle.
5.5.2 Reading measured values for mandato‐

ry reporting
You must read these measured values before contacting your
cardiagn.com
Technical Service Centre or your importer.
Save the measured values in the diagnosis log so that all neces‐
sary gearbox data will be available for fault analysis.
5.5.3 Initiating basic adjustment

This teaches important settings into the mechatronic unit. Even
important adjustments are taught in again, or reset to program‐
med points. These include, for example, the synchronisation
points and »reference points« for the engaging lever and gear
actuator.
WARNING agen
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Do not carry out basic adjustment without a reason unless re‐ rised b ara
nte
quested to do so! ut
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– Press the button DSG Mechatronic -J743- performing
an
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♦ if you are prompted to do so in “guided fault finding” wit

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♦ after you have processed an event memory entry
ole,
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♦ after you have installed a dual clutch

t to the co
♦ or after you have installed a mechatronic unit

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30 – Clutch
1 Removing and installing dual clutch,
gearboxes made up to 05.2011agen AG. Volkswagen AG do
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Removing and installing dual clutch, gearboxesdmade
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06.2011 onwards ⇒ page 37 orise tee
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Overview: ss ac
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♦ ⇒ “1.1 Assembly overview - dual clutch, gearboxes made up
pt
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to 05.2011”, page 11 itte
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hole
spec
K 1 and K 2, gearboxes made up to 05.2011”, page 17
es, in part or in w
t to the co
♦ ⇒ “1.4 Installing dual clutch, gearboxes made as of 05.2011”,
page 30
rrectness of i
1.1 Assembly overview - dual clutch, gear‐
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boxes made up to 05.2011
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Caution
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Risk of damage from clutch adjustment device.

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♦ The clutch is self-adjusting. Shocks can have an effect on
te
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this adjusting device. Do not allow clutch to fall into gear‐
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box during installation.
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1. Removing and installing dual clutch, gearboxes made up to 05.2011 11

1 - Retaining ring
❑ Always renew after re‐
moving.
2 - Hub
3 - Retaining ring
moving.
4 - Large engaging lever for “K n AG. Volkswagen AG do
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❑ Always renew if dual ss
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5 - Small engaging lever for »K
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hole
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6 - Bolts
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moving.
❑ 8 Nm +90°
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7 - Support
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❑ For engaging lever

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clutch is renewed.
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at
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8 - Bar
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❑ For small engaging lev‐

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❑ No present in some old‐

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9 - Sealing ring
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Prote AG.
❑ For inner input shaft

❑ Renewing ⇒ page 63
10 - Sealing ring
❑ For outer input shaft
11 - Outer input shaft
12 - Shim “SK 1”
❑ Determining thickness ⇒ page 17
13 - Shim “SK 2”
❑ Determining thickness ⇒ page 17
14 - Small engagement bearings for »K 2«
❑ Always renew if dual clutch is renewed.
15 - Dual clutch
❑ Removing ⇒ page 13
❑ Installing ⇒ page 30
12 Rep. gr.30 - Clutch

1.2 Removing dual clutch, gearboxes made

up to 05.2011
Special tools and workshop equipment required
♦ hooks - 3438-
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♦ Set of plugs for engine - VAS 6122-
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♦ Support bridge - T10323-
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♦ -T10356/5- from assembly tool - T10356A-

♦ Tapered roller bearing puller - T10373A-
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♦ Press tool - T10376-
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♦ 1 x sealing cap - 0AM 325 120 A- and 1 x sealing cap - 02M
n
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409 120- , as an alternative to engine bung set - VAS 6122-

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Requirement:
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• Gearbox removed and secured to engine and gearbox jack

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⇒ page 287 . Cop py
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• Mechatronic unit for dual clutch gearbox - J743- built into py by
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– Pull off both breather caps -arrows- and close using clean
plugs from engine bung set - VAS 6122- to achieve an oil-tight
seal.
WARNING
For some gearboxes the breather cap on the mechatronic unit

is destroyed during removal and must be renewed.
It is not possible to check the fill level of the hydraulic fluid sec‐
tion of the mechatronic unit. Before repairs, the breather of the
mechatronic unit must be sealed so that no oil can escape.
Oil that escapes from the hydraulic fluid section of the mecha‐
tronic unit cannot be replenished, nor can the oil level be
checked. If there is any oil leakage, renew mechatronic unit.

lkswage es n
o ot g
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ir se
CC 2010th ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009e o➤ , Golf Plus 2005 ➤ ...
o te
u r
ss
a
7-speed dual clutch gearbox a0AM c - Edition 12.2016
ce
le
un
pt
– Turn gearbox on engine and gearbox jack upwards together
an
d
itte
y li
with clutch.
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
The clutch is pulled off upwards. The mechatronic unit remains
es, in part or in w
t to the co
on the gearbox.
rrectness of i
l purpos
nform
ercia
– Remove retaining ring of hub -arrow-.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
cardiagn.com
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove hub with hook - 3438- and a screwdriver.
– Remove retaining ring -arrow- for clutch.

If retaining ring cannot be removed:
Note
♦ If the retaining ring cannot be removed it is because the clutch

has »clamped« the retaining ring at the bottom.
♦ In this case, push the clutch down slightly (see following de‐
scription) and release the load on the retaining ring. Never
strike the clutch or shaft with a hammer!
♦ Always renew retaining ring.

– Position support bracket - T10323- parallel to gearbox flange

as shown in illustration.
– If necessary, balance out gaps using -T10356/5- , for example.
– Screw in bolts -A- hand-tight.
Note
Secure bolts -A- with nut as required.
Caution
Risk of damage to clutch and other components!

• Push down clutch using only very light force.
– To press down, turn spindle against thrust piece - T10376- .
cardiagn.com
Continuation once retaining ring has been removed:
– Insert puller - T10373A- into
wage
clutch
n AG and
. Volkswagenbore
AG doout clutch.
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d by ara
e nte
ris
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ss
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un
pt
an
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Remove clutch together with puller - T10373A- .

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
16
by c lksw
cted
Rep. gr.30 - Clutch
agen
Prote AG.
– Remove small engagement bearing.

– Remove large engaging lever.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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nl
pt
du
an
itte
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erm
ab
– Undo bolts and remove small engaging lever.
ility
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wit
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h re
hole
Note
spec
es, in part or in w
t to the co
Only a few, »older« gearboxes do not have a clip.
rrectness of i
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l purpos
nf
ercia
orm
m
atio
m
– Remove retainer for engaging lever.

o
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.
1.3 Adjusting position of engagement bear‐

ings for clutches “K 1” and “K 2”, gear‐
boxes made up to 05.2011
WARNING
If the dual clutch is renewed, the following components must

also be renewed:
♦ Both engaging levers with engagement bearing.
♦ Retainer for engaging lever.
♦ Shims for engagement bearing.
After the dual clutch and corresponding components have
been renewed, the position of the engagement bearings for
“K 1 and K 2” must always be readjusted.

Note
G. Volkswagen AG d
♦ There is no need to adjust anything if all the components men‐
lksw
agen
A
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tioned have only been removed and reinstalled. o not
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♦ The retaining ring must be renewed in each case.ut
ho eo
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ss
ce
Brief description
e
nl
pt
du
an
itte
♦ Position of engagement bearings is comparable with clutch
y li
erm
ab
play of a manual gearbox. There are tolerances in this 7-speed
ility
ot p
dual clutch gearbox 0AM in the engagement system of the
wit
, is n
gearbox and in the gearbox itself. Within the dual clutch there
h re
are tolerances as well. These tolerances must be taken into
hole
spec
account separately during adjustment.
es, in part or in w
t to the co
♦ The following procedure first describes how to measure all
necessary dimensions on the gearbox so that the appropriate
shim can be selected. In addition are the tolerances in the
rrectness of i
clutch that the manufacturer has already calculated. Toleran‐
ces on gearbox and tolerances in clutch determine thickness
l purpos
of shim.
cardiagn.com
♦ Adhere to the sequence of work steps.
nf
ercia
or
Overview of clutch actuation
m
m
atio
om
n in
or c
1 - Small engaging lever for »K
thi
te
sd
a
2«
iv
o
r
rp
cu
o
m
f
en
ng
clutch is renewed.
t.
yi Co
Cop py
t.
2 - Shim for »K 2«
rig
gh ht
pyri by
Vo
o
by c
3 - Engagement bearings for
lksw
cted agen
Prote
»K 2«
AG.

clutch is renewed.
4 - Large engaging lever for “K
1”
❑ With large engagement
bearing
clutch is renewed.
5 - Shim for “K 1”
6 - Bolts
moving.
❑ 8 Nm + 90°
7 - Bar
❑ Not present in some old‐
er gearboxes
clutch is renewed.
8 - Support
clutch is renewed.


♦ Depth gauge, digital 300 mm - VAS 6594-
♦ Gauge block - T10374-
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
♦ Ruler - T40100-
t to the co
rrectne
cardiagn.com
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Requirement:
en
ng
t.
yi Co
op
• The gearbox flange must be level to assure good contact with C py
t. rig
the ruler.
gh ht
pyri by
Vo
co lksw
by
• Mechatronic unit for dual clutch gearbox - J743- must be in‐ cted agen
Prote AG.
stalled.
• Specified torques
⇒ “1.1 Assembly overview - dual clutch, gearboxes made up
to 05.2011”, page 11 .
Note
If a further tightening angle is specified for certain bolts, these

must be renewed.
Caution

• Retainer for engaging lever and entire mechanism of en‐
gagement bearing must be dry and free of oil or grease.

Step 1: prepare dual clutch for measurement

– Insert retainer for engaging lever.
– Fit small engaging lever with clip and secure with 2 new bolts.
Torque setting: ⇒ page 12 . n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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Note utho
or
a ac
ss
ce
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un
pt
an
d
itte
y li
cardiagn.com
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Insert large engaging lever.
– Check both engaging levers are seated correctly.
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
– Install old retaining ring of outer input shaft.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Step 2: determine dimension “B” for clutch “K 1” and “K 2”
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
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rm
ab
pe
ility
ot
wit
, is n
– Place ruler - T40100- upwards across end of shaft onto gear‐
h re
hole
cardiagn.com
box flange.
spec
es, in part or in w
t to the co
Caution
rrectness of i
Risk of false measurements.
♦ The ruler - T40100- should remain in this position for the
l purpos
following measurements. Do not turn over, do not remove.
nform
mercia
a
com
tion in
r
te o
thi
– Place digital 300 mm depth gauge - VAS 6594- on top of ruler

s
iva
do
- T40100- and position depth gauge rod on outer input shaft.

r
rp
cum
fo
en
g
– Set depth gauge to “0”.

n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Position depth gauge rod on retaining ring, as show in dia‐

gram.
– In this position, determine dimension “B1” to retaining ring.
• Example: dimension “B1” = 2.92 mm

– In the opposite position, determine dimension “B2” to retaining

ring.
Note
Do not measure on retaining ring joint. The retaining ring could

be pushed away and falsify the reading.

AG. Volkswagen AG d
agen oes
– Calculate mean value from dimension
yV
olks
w
“B1” and “B2”. not
gu
b ara
ed nte
Formula: (B1 + B2)/2 oris eo
th
au ra
c
Example: ss
ce
le
un
pt
• 2.92 + 3.002 = 2.96 mm
an
d
itte
y li
rm
ab
• Result: Dimension “B” = 2.96 mm
pe
ility
ot
wit
– Remove and dispose of retaining ring.
, is n
h re
hole
spec
Step 3: determine dimension “A 1” for engagement bearing of
cardiagn.com
es, in part or in w
clutch “K 1”
t to the co
Caution
rrectness of i
l purpos
♦ Do not insert any shim!
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.
– Place end gauge - T10374- on large engagement bearing with

large opening upwards.
– To ensure that end gauge - T10374- sits properly on engage‐
ment bearing, press down and turn end gauge.
• Engagement bearing will turn with end gauge - T10374- .

en AG. V7-speed dual
G clutch gearbox 0AM - Edition 12.2016
olkswagen A
ag does
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y Vol gu
– Place digital 300 mm depthsgauge d b - VAS 6594- on top of ruler ara
i e nte
and position depth gauge thorod
r on outer input shaft. eo
au ra
c
• Ruler - T40100- is lying
s upwards across end of shaft on gear‐
s
ce
e
box flange.
nl
pt
du
an
itte
y li
erm
ab
Caution
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
– Position depth gauge rod on end gauge - T10374- , as show

in diagram.
nf
ercia
o
– In this position, determine dimension “A 1a” to end gauge -
rm
m
T10374- .
atio
om
n in
c
• Example: Dimension “A 1a” = 2.61 mm

or
thi
e
cardiagn.com
t
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.

– In the opposite position, determine dimension “A 1b” to end

gauge - T10374- .
• Example: Dimension “A 1b” = 2.81 mm
– Calculate mean value from dimension “A 1a” and “A 1b”.
Formula: (A1a + A1b )/2
Example:
• 2.61 + 2.812 = 2.71 mm
• Result: Dimension “A 1” = 2.71 mm
Step 4: Determine installation depth of clutch engagement bear‐
ing “K 1”
Note
On the basis of dimension “A 1” and dimension “B”, the actual

installation depth of the clutch engagement bearing “K 1” is now
calculated based on the following calculus.
cardiagn.com
Dimension “A 1”
– Dimension “B”
+ Exterior height end gauge - T10374- (51.81 mm; fixed val‐
ue)
= Actual installation depth of clutch engagement bearing “K
1”
Example:
• 2.71 mm - 2.96 mm + 51.81 mm = 51.56 mm
• Result: Installation depth of clutch engagement bearing “K 1” wage
es n
= 51.56 mm yV
olks ot g
u b ara
ed
Step 5: Determine clearance of clutch “K 1” thoris nte
e or
au ac
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
With the actual value and specification for the engagement bear‐ ab
ility
ot p
ing installation depth, the clearance of clutch “K 1” is now deter‐ wit

, is n
mined using the following calculus. h re

hole
spec
es, in part or in w
Actual value of engagement bearing installation depth

t to the co
– Specification of engagement bearing installation depth

(50.08 mm; fixed value)
rrectness of i
= Clearance of clutch “K 1”
l purpos
Example:
• 51.56 mm – 50.08 mm = 1.48 mm
nf
ercia
or
• Result: Clearance of clutch “K 1” = 1.48 mm

m
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
y V gu
d b ara
ise nte
CC 2010 th➤o , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤
r e,o Golf Plus 2005 ➤ ...
u ra
ss a 7-speed dual clutch gearbox 0AM c - Edition 12.2016
ce
le
un
pt
Step 6: Determine tolerance of clutch “K 1”
an
d
itte
y li
erm
ab
– Read clutch tolerance value from new clutch.
ility
ot p
• Example: Read off clutch tolerance value on clutch
wit
is n
h re
“K 1 = +0.2”, as shown in diagram.
ole,
spec
Step 7: Determine thickness of shim “SK 1” urposes, in part or in wh
t to the co
Note
rrectne
On the basis of the clearance value and clutch tolerance “K 1”,
the thickness of shim “SK 1” is now calculated using the following
ss
calculus.
o
cial p
f inform
mer
Clearance of clutch “K 1”
atio
om
–/+ Clutch tolerance of clutch “K 1”
n
c
i
or
n thi
= Calculated thickness of shim “SK 1”
te
sd
iva
o
pr
c
Example:
um
r
fo
en
ng
t.
yi
• 1.48 mm + 0.20 mm = 1.68 mm
Co
op py
cardiagn.com
t. C rig
gh
• Result: Calculated thickness of shim “SK 1” = 1.68 mm
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– From the shims supplied, measure the required shim and have
it ready for installation.
Calculated thickness of shim Available shims
mm Thickness in mm
0.31 … 0.90 0.80
0.91 … 1.10 1.00
1.11 … 1.30 1.20
1.31 … 1.50 1.40
1.51 … 1.70 1.60
1.71 … 1.90 1.80
1.91 … 2.10 2.00
2.11 … 2.30 2.20
2.31 … 2.50 2.40
2.51 … 2.70 2.60
2.71 … 3.30 2.80
Example:
• Chosen shim thickness = 1.60 mm =
Caution
Risk of damage to gearbox

♦ Mark shim “SK 1” and have it ready for assembly.
♦ For adjustment, only this shim “SK 1” may be inserted.


clutch “K 2”
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
rrectne
– Only insert small engagement bearing.
ss
cardiagn.com
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.
Small engagement bearing only fits in one position due to 4

grooves.
– By turning -arrows-, check whether small engagement bearing

is properly installed and that grooves are seated correctly.
Caution


– Place end gauge - T10374- on small engagement bearing with

large opening upwards.
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
and position depth gauge rod on outer input shaft.
t to the co
• Ruler - T40100- is lying upwards across end of shaft on gear‐
box flange.
rrectne
Caution
ss
cardiagn.com
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
in diagram. Cop py
t. rig
gh ht
yri
– In this position, determine dimension “A 2a” to end gauge - p by
co Vo
by lksw
T10374- . cted agen
Prote AG.


gauge - T10374- .
AG. Volkswagen AG d
• Example: Dimension “A 2b” = 2.54 mm lksw
agen oes
not
Vo gu
by ara
– Calculate mean value from dimension “A 2a” and “Aris2eb”.
d
nte
tho eo
u ra
Formula: (A2a + A2b)/2 ss a c
ce
e
nl
pt
Example:
du
an
itte
y li
• 2.50 + 2.542 = 2.52 mm
erm
ab
ility
ot p
• Result: dimension “A 2” = 2.52 mm
wit
, is n
h re
Step 9: calculate installation depth of clutch engagement bearing
hole
spec
“K 2”
es, in part or in w
t to the co
Note
rrectness of i
On the basis of dimension “A 2” and dimension “B”, the actual
l purpos
installation depth of the clutch engagement bearing “K 2” is now

calculated based on the following calculus.
nf
ercia
cardiagn.com
or
Dimension “A 2”
m
m
atio
m
o
n in
or c
thi
+ Interior height end gauge - T10374- (36.20 mm; fixed val‐
te
sd
a
ue)
iv
o
r
rp
cu
o
= Actual installation depth of clutch engagement bearing “K
m
f
en
ng
t.
2” Cop
yi Co
py
t. rig
gh
Example:
ht
pyri by
Vo
co lksw
by
• 2.52 mm - 2.96 mm + 36.20 mm = 35.76 mm cted agen
Prote AG.
• Result: Installation depth of clutch engagement bearing “K 2”

= 35.76 mm
Step 10: calculate clearance of clutch “K 2”
Note
With the actual value and specification for the engagement bear‐
ing installation depth, the clearance of clutch “K 2” is now deter‐
mined using the following calculus.
Actual value of engagement bearing installation depth

– Specification of engagement bearing installation depth
(34.35 mm; fixed value)
= Clearance of clutch “K 2”
Example:
• 35.76 mm – 34.35 mm = 1.41 mm
• Result: clearance of clutch “K 2” = 1.41 mm

Step 11: calculate clutch tolerance of clutch “K 2”

• Example: Read off clutch tolerance value on clutch “K 2 = –
0.2”, as shown in diagram.
Step 12: determine thickness of shim “SK 2”
Note
On the basis of the clearance value and clutch tolerance “K 2”,

the thickness of shim “SK 2” is now calculated using the following
calculus.
Clearance of clutch “K 2”
Example:
• 1.41 mm – 0.20 mm = 1.21 mm
cardiagn.com
• Result: calculated thickness of shim “SK 2” = 1.21 mm
Calculated thickness of shim Available shims AG. Volkswagen AG d
mm Thickness
lkswin mm
agen oes
no
o t gu
yV
0.31 … 0.90 ris
ed b 0.80 ara
nte
0.91 … 1.10 tho 1.00
eo
au ra
c
ss
1.11 … 1.30 1.20
ce
le
un
1.31 … 1.50 1.40 pt

an
d
itte
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erm
1.51 … 1.70 1.60 ab

ility
ot p
1.71 … 1.90 1.80 wit

is n
h re
1.91 … 2.10 2.00
ole,
spec
2.11 … 2.30 2.20

t to the co
2.31 … 2.50 2.40

2.51 … 2.70 2.60
rrectne
2.71 … 3.30 2.80

Example:
ss o
cial p

inform
mer
• Chosen shim thickness = 1.20 mm

atio
om
n
c
i
or
Caution
thi
te
sd
iva
o
pr
Risk of damage to gearbox

um
r
fo
en
ng
t.
♦ Mark shim “SK 2” and have it ready for assembly.
yi Co
Cop py
ht. rig
♦ For adjustment, only this shim “SK 2” may be inserted. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Adjustment is now complete, and the »small« engagement lever

has been installed. The next step now is to install the clutch again.
– Install clutch ⇒ page 30 .

1.4 Installing dual clutch, gearboxes made

as of 05.2011
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o eo
♦ Tapered roller bearing
auth puller - T10373A- 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
co lksw
by
cted agen
Prote AG.

• Specified torques
⇒ “1.1 Assembly overview - dual clutch, gearboxes made up
to 05.2011”, page 11 .
Installing
WARNING

also be renewed:
♦ Retainer for engaging lever.
“K 1 and K 2” must always be readjusted ⇒ page 17 .
Note
cardiagn.com
♦ Renew all bolts tightened with further tightening angle.
♦ The following four work steps are only necessary if the position
of the engagement bearings did not have to be adjusted.
– Insert retainer for engaging lever.

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
– Install small engaging lever with bracket.

rrectness of i
Note
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.

– Bolt on engaging lever with 2 new bolts.

Specified torques: ⇒ page 12
AG. Volkswagen AG d
agen oes
– Insert large engaging
Vol lever.
ksw not
gu
by ara
ed
– Check both oengaging
ris levers are seated correctly. nte
eo
th
s au ra
c
s
Caution
ce
e
nl
pt
du
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• The positions of the engagement bearings must be set
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wit
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correctly.
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Adjustment can only be carried out before the clutch is installed
es, in part or in w
⇒ page 17 . t to the co
Do not continue with assembly until the setting is correct!
If no new parts have been installed, insert removed shims.
rrectness of i
For adjustment, only one shim per engagement bearing may

l purpos
be installed.
• Clutch parts must be free of oil and grease.
nf
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– Insert small engagement bearings with measured shim for “K

or
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2”.
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Shim should be under small engagement bearing. Therefore, in‐

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sert shim first.

t.
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Prote AG.
• Small engagement bearing only fits in one position due to 4

grooves.

– By turning -arrows-, check whether small engagement bearing

is properly installed and that grooves are seated correctly.
– Fix »large« shim for “K 1” in place with 3 drops of adhesive -

AMV 195 KD1 01- .
This prevents shim from slipping out of its seat when clutch is
inserted.
– Turn back spindle of puller -T10373- .
Caution
cardiagn.com
– Install clutch with puller - T10373A- in gearbox, as shown in

diagram. . Volkswag n AG en AG
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es, in part or in w
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– If necessary, balance out gaps using -T10356/5- from assem‐
bly tool - T10356- , for example.
Note
– Press on clutch as far as it will go.
Note
Place a hand on the clutch when pressing it on. A slight »rattling«

will be felt. Rattling indicates that the clutch is being pressed onto
its press seat. This also enables detection of the limit stop once
the clutch has been seated correctly.
cardiagn.com
– Take hold of new retaining ring with retaining ring pliers, as
shown in the illustration.
wage
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Vol t
• Installation position:
ed
by narrow surface of retaining ring
gu
aon
ra top.
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es, in part or in w
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– Inserting retaining ring -arrow-.

rrectness of i
Note
l purpos
If the retaining ring cannot be inserted, the clutch has not been
pressed in onto its limit stop.
nf
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or c
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– To move clutch to operating position hold spindle of puller -
Co
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T10373A- with one hand, and use the other hand to pull clutch
t. C rig
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in direction of rotation -arrow- against retaining ring. p by
co Vo
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Note agen
AG. Volkswagen AG d
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♦ Pressing makes the clutch sit at the bottom against ris the limit
e d ara
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stop on the input shaft. This is not the optimumuposition.
tho eo
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♦ Clutch should only be pulled up far enough for it to contact
s
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nl
retaining ring.
pt
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Note
wit
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Only turn by hand. In this way, clutch slides against retaining ring.
Do not use any other tool. es, in part or in w
t to the co
– Insert hub.
rrectness of i
• Hub has »large tooth« -arrow- and only fits in one position.
l purpos
• »Large tooth« has a mark at engine end.
nf
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or
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– Insert retaining ring -arrow- of hub.
py by
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• Joint of retaining ring must point towards »hub« of clutch.
Prote AG.

– Turn clutch by hand and observe small engaging lever whilst

turning.
• While the clutch is being turned, it must be ensured that the
cardiagn.com
small engaging lever remains absolutely still. It must be en‐
sured that it does not move up and down.
AG. Volkswagen AG d
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Note
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♦ If an engaging lever moves up and down, the shim is not prop‐

ility
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erly seated.
wit
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♦ In this case, remove clutch again ⇒ page 13 .

ole,
spec
♦ Check shims -arrows-.

t to the co
♦ The shims must be properly seated and must not be damaged.

rrectness
– Remove two plugs and put breather caps -arrows-on.

o
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f inform
mer
WARNING
atio
om
n
c

or
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– Dispose of excess shims.
Co
Cop py
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gh
– After installation of gearbox, perform Complete reset by
ht
pyri by
Vo
o
means of Guided functions ⇒ Vehicle diagnostic tester.
c by lksw
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Prote AG.

2 Removing and installing dual clutch,

gearboxes made from 06.2011 on‐
wards
Removing and installing dual clutch, gearboxes made up togen AG. Volkswagen AG d
a
05.2011 ⇒ page 11 Vol
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Overview: oris tee
th or
au
♦ ⇒ “2.1 Assembly overview - dual clutch,ss gearboxes made as ac
of 06.2011”, page 37
ce
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nl
pt
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♦ ⇒ “2.2 Removing dual clutch, gearboxes made as of 06.2011”,
itte
y li
erm
page 39
ab
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♦ ⇒ “2.3 Adjusting position of engagement bearings for clutches
wit
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K 1 and K 2, gearboxes made as of 06.2011”, page 43
h re
hole
spec
♦ ⇒ “2.4 Installing dual clutch, gearbox date from 06.2011”, page
es, in part or in w
56
t to the co
2.1 Assembly overview - dual clutch, gear‐
rrectness of i
boxes made as of 06.2011
cardiagn.com
l purpos
Caution
nform
ercia

m
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at
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♦ A clutch that has fallen onto a hard surface or shows signs
um
for
en
g
of damage must not be reinstalled.

n
t.
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Cop py
t. rig
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Vo
co lksw
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cted agen
Prote AG.
2. Removing and installing dual clutch, gearboxes made from 06.2011 onwards 37
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ a,gGolf
en AGPlus
. Volks2005 ➤G ...
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1 - Hinge mounting au
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ac
❑ For large engaging lever ss
ce
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“K 1”
nl
pt
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❑ Cannot be renewed.
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ab
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2 - Ball pin
ot p
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er “K 2”
hole
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es, in part or in w
t to the co
clutch is renewed.
3 - Shim “SK 1”
rrectness of i
❑ Determining thickness
⇒ page 43
l purpos
4 - Shim “SK 2”
nf
ercia
o
⇒ page 43
rm
m
atio
m
5 - Small engagement bear‐

o
n in
c
ings for “K 2”
or
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clutch is renewed.
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6 - Dual clutch
t.
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❑ Removing ⇒ page 39 ht. rig
rig ht
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❑ Installing ⇒ page 56 co Vo
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7 - Retaining ring
moving.
8 - Hub
9 - Retaining ring
❑ Renewing
10 - Large engaging lever for
“K 1”
❑ With engagement bearing
❑ Always renew if dual clutch is renewed.
11 - Upper section of bushing
❑ For small engaging lever “K 2”
❑ Is removed and installed together with lower section of bushing
12 - Small engaging lever for “K 2”
❑ Is removed and installed together with upper and lower section of bushing
13 - Bolts
❑ Always renew after removing.
❑ 8 Nm + 90°
14 - Lower section of bushing
❑ is removed and installed together with upper part of guide sleeve
15 - Sealing ring
❑ For inner input shaft
16 - Sealing ring
❑ For outer input shaft

2.2 Removing dual clutch, gearboxes made

as of 06.2011
♦ hooks - 3438-
AG. Volkswagen AG d
agen oes
olksw not
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un
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rrectness o
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mer
atio
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n
c
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or
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Co
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♦ Tapered roller bearing puller
olks
wag-eT10373A- es n
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ab
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t to the co
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f inform
mer
atio
om
cardiagn.com
c
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or
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Cop py
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♦ 1 x sealing cap - 0AM 325 120 A- and 1 x sealing cap - 02M
co Vo
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cted
409 120- , as an alternative to engine bung set - VAS 6122-
agen
Prote AG.
Requirement:
• Gearbox removed and secured to engine and gearbox jack
⇒ page 287 .
• Mechatronic unit for dual clutch gearbox - J743- built into
gearbox.
– Pull off both breather caps -arrows- and close using clean
plugs from engine bung set - VAS 6122- to achieve an oil-tight
seal.
WARNING

Oil that escapes from the hydraulic fluid section of the mecha‐
tronic unit cannot be replenished, nor can the oil level be
checked. If there is any oil leakage, renew mechatronic unit.

– Turn gearbox on engine and gearbox jack upwards together

with clutch.
Note
The clutch is pulled off upwards. The mechatronic unit remains

on the gearbox.
– Remove retaining ring of hub -arrow-.
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
– Remove hub with hook - 3438- and a screwdriver.
es, in part or in w
t to the co
Note
rrectness of i
If parts of clutch are renewed, the position of engagement bear‐
l purpos
ings “K 1” and “K 2” must be set later. It is therefore advisable to

determine dimension “B” for the measurements now
⇒ page 43 .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Remove retaining ring -arrow- for clutch

p
cum
for
.
en
ng
t.
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op
If retaining ring cannot be removed:
C py
t. rig
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pyri by
Vo
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Note
Prote AG.
♦ If the retaining ring cannot be removed it is because the clutch

has »clamped« the retaining ring at the bottom.
♦ In this case, depress the clutch slightly as described in the
following. The retaining ring is thus relieved. Never strike the
clutch or shaft with a hammer!

– If necessary, balance out gaps using -T10356/5- , for example.
Note
Caution

• Push down clutch using only very light force.
– To press down, turn spindle against thrust piece - T10376- .
cardiagn.com
WARNING
It is not permissible to reuse the retaining ring.
Note
Do not dispose of the retaining ring, if later the dimension “B” must
be determined for adjusting the clutch engagement.
AG. Volkswagen AG d
agen oes
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Continuation once retaining by V ring has been removed:
ol
gu
ara
ed
is nte
– Insert puller - T10373A-
hor
into clutch and bore out clutch. eo
aut ra
ss c
ce
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un
pt
an
d
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ab
ility
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– Remove clutch together with puller - T10373A- .

rrectness o
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mer
atio
om
n
c
i
or
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pr
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fo
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ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove »large« engagement lever together with »small« en‐

gagement bearings.
Note
The upper section of bushing cannot be removed or installed

alone. It is always removed or installed together with lower section
of bushing and »small« engagement lever.
lkswage es n
o ot g
byV ua
d ran
ir se tee
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ss
– Undo and remove bolts and remove »small« engagement lev‐
ce
e
nl
pt
du
er together with upper and lower section of bushing.
an
itte
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ab
ility
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es, in part or in w
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rrectness of i
l purpos
If no parts are renewed, the ball-head pin -2- remains installed.
nf
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orm
m
atio
WARNING
om
n in
or c
thi
The hinge mounting -1- cannot be removed.
te
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t.
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Note
t. C rig
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by
If dimension “B” has already been determined, it is now possible cted agen
Prote AG.
to proceed with step “2” of the measurement ⇒ page 48
2.3 Adjusting position of engagement bear‐

ings for clutches “K 1” and “K 2”, gear‐
boxes made as of 06.2011
WARNING

also be renewed:
♦ Ball-head pin for engaging lever “K 2”.
“K 1 and K 2” must always be readjusted.
Note
♦ There is no need to adjust anything if all the components men‐

tioned have only been removed and reinstalled.
♦ The retaining ring must be renewed in each case.
Brief description
♦ Position of engagement bearings is comparable with clutch
play of a manual gearbox. In the 7-speed dual clutch gearbox
0AM there are tolerances in the engagement system of the
gearbox and in the gearbox itself. Within the dual clutch there
are tolerances as well. These tolerances must be taken into
account separately during adjustment.
♦ The following procedure first describes how to measure all
necessary dimensions on the gearbox so that the appropriate
shim can be selected. In addition are the tolerances in the
clutch that the manufacturer has already calculated. Toleran‐
ces on gearbox and tolerances in clutch determine thickness
of shim.
cardiagn.com
♦ Adhere to the sequence of work steps.
Overview of clutch actuation:
1 - Shim for “K 1” n AG. Volkswagen AG do

lkswage es n
2 - Large engaging lever for “K d byV
o ot g
ua
1” o
ir se
ran
tee
th or
❑ With engagement bear‐ au ac
ss
ing
ce
le
un
pt
an
d
itte
clutch is renewed.
y li
rm
ab
pe
ility
3 - Hinge mounting
ot
wit
, is n
❑ For large engaging lever
h re
“K 1”
hole
spec
❑ Cannot be renewed.
es, in part or in w
t to the co
4 - Small engagement bear‐
ings for “K 2”
rrectness of i
clutch is renewed.
l purpos
5 - Shim for “K 2”
nform
ercia
6 - Upper section of bushing

m

a
com
ti
er “K 2”
on in
r
te o
❑ Is removed and installed

thi
s
iva
together with lower sec‐

do
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tion of bushing
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fo
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t.
7 - Small engaging lever for “K
yi Co
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2”
C py
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❑ Is removed and installed
p by
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together with upper and Prote
cted AG.
agen
lower section of bushing
clutch is renewed.
8 - Ball pin
er “K 2”

AG. Vo7-speed
lkswagen Adual
G do clutch gearbox 0AM - Edition 12.2016
agen es n
ksw
Vol ot g
❑ Always renew if dual clutch ed is renewed.
by ua
ran
ris tee
ho
9 - Bolts au
t or
ac
ss
ce
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nl
pt
du
❑ 8 Nm + 90°
an
itte
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erm
ab
10 - Lower section of bushing
ility
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wit
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h re
❑ is removed and installed together with upper part of guide sleeve
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Gauge block - T10466-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
cardiagn.com
t
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t.
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Cop py
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rig ht
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Prote AG.
♦ Ruler - T40100-
Requirement:
• The gearbox flange must be level to assure good contact with
the ruler.
• Mechatronic unit for dual clutch gearbox - J743- must be in‐
stalled.
Caution

• Retainer for engaging lever and entire mechanism of en‐
gagement bearing must be dry and free of oil or grease.
– Remove installed ball pin using pliers.
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
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rm
ab
– Push in »new« ball pin by hand, if necessary using a plastic
pe
ility
hammer and drift to tap it in. ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
To avoid damage to ball pin, only tap the drift lightly with the ham‐
mer.
rrectness of i
cardiagn.com
l purpos
nform
mercia
a
com
t
– Install old retaining ring of outer input shaft.
ion in
r
te o
thi
s
iva
do
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fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Step 1: determine dimension “B” for clutch “K 1” and “K 2”

– Place ruler - T40100- upwards across end of shaft onto gear‐

box flange.
Caution

AG. Volkswagen AG d
agen
♦ The ruler - T40100-Voshould remain in this positionotfor the
es n o
lksw
gu
following measurements.
se
d by
Do not turn over, do not remove.
ara
n ri tee
utho or
a ac
ss
ce
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un
pt
an
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ab
ility
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- T40100- and position depth gauge rod on outer input shaft.
wit
is n
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ole,
spec
t to the co
rrectne
cardiagn.com
ss o
cial p
f inform
mer
atio
– Position depth gauge rod on retaining ring, as show in dia‐
om
n
gram.
c
i
or
n thi
te
– In this position, determine dimension “B1” to retaining ring.

sd
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pr
cum
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fo

en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– In the opposite position, determine dimension “B2” to retaining

ring.
Note
Do not measure on retaining ring joint. The .retaining ring could

Volkswagen AG
be pushed away and falsify the reading.
swa
gen AG does
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• Example: dimension “B ris ” = 2.58 mm
ho 2
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– Calculate mean value
ss from dimension “B1” and “B2”. c
ce
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un
pt
Formula: (B1 + B2)/2
an
d
itte
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rm
ab
Example:
pe
ility
ot
wit
• 2.62 + 2.582 = 2.60 mm
, is n
h re
hole
• Result: Dimension “B” = 2.60 mm
spec
es, in part or in w
t to the co
Note
cardiagn.com
rrectness of i
If the dual clutch is still in place after this measurement, it must
now be removed ⇒ page 41 .
l purpos
nform
ercia
– Remove and dispose of outer input shaft.

m
a
com
WARNING tion in
r
te o
thi
s
iva
It is not permissible to reuse the retaining ring.

do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

clutch “K 1”

– Insert large engaging lever.
Caution

– Check that engaging lever is seated correctly.
– Place end gauge - T10466- on large engagement bearing. Flat

side faces upwards.
cardiagn.com
box flange. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
d by ua
ran
e
Cautionris tee
utho or
a ac
ss
ce
e
nl
pt
du

an
itte
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erm
ab
ility
ot p
wit
, is n
h re

hole
spec
es, in part or in w

t to the co
in diagram.
– In this position, determine dimension “A 1a” to end gauge -
rrectness of i
T10466- .
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
co lksw
by
cted agen
Prote AG.

gauge - T10466- .
– Calculate mean value from dimension “A 1a” and “A 1gben”.AG. Volkswagen AG d
a oes
ksw not
Vol
Formula: (A1a + A1b)/2 ed by gu
ara
ris nte
ho eo
Example: au
t ra
c
ss
• 4.93 + 4.912 = 4.92 mm
ce
le
un
pt
an
d
itte
• Result: Dimension “A 1” = 4.92 mm
y li
erm
ab
Step 3: calculate height tolerance of engagement bearing for
ility
ot p
clutch “K 1”
wit
is n
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ole,
spec
Note
t to the co
On the basis of dimension “A 1” and dimension “B”, the height
tolerance of the clutch engagement bearing “K 1” is now calcula‐
rrectne
ted according to the following calculus.
cardiagn.com
ss
Dimension “A 1”
o
cial p
f in
form
mer
= Actual height tolerance of clutch engagement bearing “K
atio
m
1”
o
n
c
i
or
n thi
e
Example:
t
sd
iva
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pr
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• 4.92 mm – 2.60 mm = 2.32 mm
um
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• Result: Height tolerance of clutch engagement bearing “K 1”
Co
Cop py
= 2.32 mm
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Step 4: determine clutch tolerance of clutch “K 1”
agen
Prote AG.

• Example: Read off clutch tolerance value on clutch
“K 1 = +0.2”, as shown in illustration.
Step 5: Determine thickness of shim “SK 1”
Note
On the basis of the clutch tolerance “K 1”, the thickness of shim

“SK1” is now calculated according to the following method.
Height tolerance of engagement bearing “K 1”

Example:
• 2.32 mm + 0.20 mm = 2.52 mm

AG. Volkswagen G d
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oes gearbox 0AM - Edition 12.2016
olk no t gu
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– ise with the help of the part
Select required shim from thehtable
r nte
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number -magnifying glass- sand
au have it ready for installation. ra
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Calculated thick‐ Available shims Part number of shim
nl
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ness of shim Thickness in mm
itte
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erm
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1.21 … 1.60 1.50 0AM 141 383
wit
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1.61 … 1.80 1.70 0AM 141 383 A
hole
spec
1.81 … 2.00 1.90 0AM 141 383 B
es, in part or in w
t to the co
2.01 … 2.20 2.10 0AM 141 383 C
2.21 … 2.40 2.30 0AM 141 383 D
rrectness of i
2.41 … 2.60 2.50 0AM 141 383 E
2.61 … 2.80 2.70 0AM 141 383 F
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2.81 … 3.00 2.90 0AM 141 383 G
nform
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3.01 … 3.20 3.10 0AM 141 383 H

3.21 … 3.40 3.30 0AM 141 383 J
m
at
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ion
3.41 … 3.80 3.50 0AM 141 383 K
c
in t
or
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ate
Example:
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• Chosen shim thickness = 2.50 mm = part number DAM 141 C py
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WARNING
To avoid damage to clutch, only fit this shim later.
– Remove end gauge - T10466- and large engagement lever

again.

clutch “K 2”
Observe the following when installing a new engaging lever »K2«:
The new engaging lever »K2« with upper and lower section of
cardiagn.com
guide sleeve will be delivered in transport position -illustration-
and must be set to installation position prior to installation.
Setting engaging lever »K2« to installation position:
lkswage es n
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– Hold upper section of guide sleeve with one hand. With the
l purpos
other hand turn the lower section of guide sleeve in direction

of arrow until the sleeve moves freely.
nf
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atio
Note
om
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Apply high force to hold both sections, as this is necessary for

te
sd
a
turning the lower section of the guide sleeve.

iv
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Prote AG.

If the engaging lever is in installation position, the holes of the

lower section of guide sleeve are at right angles to the engaging
lever and the sleeve moves freely.
Continued for all:
– Install »small« engaging lever together with upper and lower
cardiagn.com
section of guide sleeve. Insert and tighten new bolts.
– Insert »small« engagement bearing.

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es, in part or in w
• Small engagement bearing only fits in one position due to 8

t to the co
grooves.
– By turning, check whether small engagement bearing has
rrectness of i
been installed correctly and that grooves are seated correctly.

l purpos
Caution
nform
ercia

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tion in
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te o
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2. Removing and installing dual clutch, gearboxes made from 06.2011 onwards
Prote
cted AG.
agen
– Place end gauge - T10466- on small engagement bearing. Flat

side faces upwards.

box flange.
Caution
cardiagn.com
– Set depth gauge to “0”. AG. Volkswagen AG d

agen oes
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– Position depth gauge rod on end gauge - T10466- d b, as show
y ara
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in diagram. thor eo
au ra
– In this position, determine dimension “A 2as” to end gauge -
s c
ce
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T10466- .
nl
pt
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spec
es, in part or in w
t to the co
rrectness of i
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gauge - T10466- .
– Calculate mean value from dimension “A 2a” and “A 2b”.
Formula: (A2a + A2b)/2
Example:
• 4.79 + 4.752 = 4.77 mm
• Result: dimension “A 2” = 4.77 mm
Step 7: calculate height tolerance of engagement bearing AGfor
. Volkswagen AG
agen does
clutch “K 2” Volksw not
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Note ss
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On the basis of dimension “A 2” and dimension “B”, the height
an
d
itte
tolerance of the clutch engagement bearing “K 2” is now calcula‐
y li
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ab
ted according to the following calculus.
pe
ility
ot
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wit
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Dimension “A 2”
hole
spec
es, in part or in w
t to the co
= Actual height tolerance of clutch engagement bearing “K
2”
rrectness of i
Example:
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• 4.77 mm – 2.60 mm = 2.17 mm

• Result: Height tolerance of clutch engagement bearing “K 2”
nform
ercia
= 2.17 mm
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a
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ti
Step 8: determine clutch tolerance of clutch “K 2”
on in
r
te o
thi
– Read clutch tolerance value from new clutch. s
iva
do
r
• Example: Read off clutch tolerance value on clutch “K 2 = –

rp
cum
fo
0.2”, as shown in diagram.

en
ng
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op
Step 9: determine thickness of shim “SK 2”
C py
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Note
Prote AG.
On the basis of the clutch tolerance “K 2”, the thickness of shim

“SK 2” is now calculated according to the following method.
Height tolerance of engagement bearing “K 2”

Example:
• 2.17 mm – 0.20 mm = 1.97 mm
Calculated thick‐ Available shims Part number of shim
ness of shim Thickness in mm
mm
0.31 … 0.90 0.80 WHT 005 518
0.91 … 1.10 1.00 WHT 005 518 A
1.11 … 1.30 1.20 WHT 005 518 B
1.31 … 1.50 1.40 WHT 005 518 C
1.51 … 1.70 1.60 WHT 005 518 D
1.71 … 1.90 1.80 WHT 005 518 E
1.91 … 2.10 2.00 WHT 005 518 F
2.11 … 2.30 2.20 WHT 005 518 G
2.31 … 2.50 2.40 WHT 005 518 H
2.51 … 2.70 2.60 WHT 005 518 J
AG. Volkswagen AG d
2.71 … 3.30 2.80 WHT
lksw 005 518 K
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Example: e ran
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ris tee
ho
ut or
• Result: calculated thickness ofss shim “SK 2”
a = 1.97 mm ac
ce
e
• Chosen shim thickness = 2.00 mm

nl
pt
du
an
itte
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ab
WARNING
ility
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wit
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To avoid damage to clutch, only fit this shim later.
h re
hole
spec
es, in part or in w
t to the co
Adjustment is now complete, and the »small« engagement lever
has been installed. The next step now is to install the clutch again.
– Install clutch ⇒ page 56 . rrectness of i
l purpos
2.4 Installing dual clutch, gearbox date from

06.2011
nf
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atio
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AG. Volkswagen AG d
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CC 2010 ➤ , Eos 2006orise ➤ , Golf 2004 ➤ , Golf 2009 ➤ , GolfanPlus tee 2005 ➤ ...
h
aut 7-speed dual clutch gearbox 0AM - Edition
or
ac 12.2016
ss
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♦ Tapered roller bearing puller - T10373A-

m
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tion in
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cardiagn.com
C py
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Prote AG.
Installing
WARNING

also be renewed:
♦ Ball-head pin for engaging lever “K 2”.
The hinge mounting cannot be removed.
“K 1 and K 2” must always be readjusted ⇒ page 43 .
Hinge mounting -1- and ball pin -2- have been installed.
Note
The upper section of bushing cannot be removed or installed

alone. It is always removed or installed together with lower section
of bushing and »small« engagement lever.
The following part of the work is only necessary if all the named AG. Volkswagen
parts are only removed and then installed again. lksw
agen AG do
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– Install »small« engagement lever together with
ss upper and low‐
ce
e
er section of bushing. Insert and tighten new bolts.
nl
pt
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ility
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Continuation for all:
wit
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hole
Caution
spec
es, in part or in w
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t to the co
• The positions of the engagement bearings must be set
rrectness of i
correctly.
Adjustment can only be carried out before the clutch is instal‐
l purpos
led.
nform
ercia
Do not continue with assembly until the setting is correct!

m
If no new parts have been installed, insert removed shims.
at
om
ion
c
For adjustment, only one shim per engagement bearing may
in t
or
his
e
be installed.
at
do
priv
c
• Clutch parts must be free of oil and grease.
um
for
en
ng
t.
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Cop py
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– Insert »large« engaging lever with measured shims for “K 1”
p by
co Vo
by lksw
and “K 2” and with small engagement bearing. Prote
cted AG.
agen
Note
♦ The large shim is inserted into the large engagement bearing,

with the hemispherical side of the shim facing downwards.
♦ The small shim goes under the small engagement bearing.
Therefore, insert shim first.

The shim and the small engagement bearing only fit in one posi‐
tion due to the 8 grooves.
– By turning, check that parts have been installed correctly and
that grooves are seated correctly.
– Check both engaging levers are seated correctly.
– Turn back spindle of puller -T10373- .
Caution

– Install clutch with puller - T10373A- in gearbox, as shown in

diagram.
cardiagn.com
AG. Volkswagen AG d
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– Position supportaubracket
th - T10323- parallel to gearbox flange or a
ss c
ce
e
nl
pt
du
– If necessary, balance out gaps using -T10356/5- from assem‐

an
itte
bly tool - T10356- , for example.

y li
erm
ab
ility

ot p
wit
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h re
hole
spec
Note
es, in part or in w
t to the co

rrectness of i
– Press on clutch as far as it will go.

l purpos
Note
nf
ercia
or
Place a hand on the clutch when pressing it on. A slight »rattling«

m
m
atio
will be felt. Rattling indicates that the clutch is being pressed onto
om
n in
its press seat. This also enables detection of the limit stop once
or c
the clutch has been seated correctly.

thi
te
sd
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rig ht
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Prote AG.
gen AG
. Volks0AM
wagen-AEdition
Gd 12.2016
wa oes
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– Take hold of inewed retaining
b ring with retaining ring pliers,
ara
nte as
rs
shown in thetho illustration. eo
au ra
c
• ss
Installation position: narrow surface of retaining ring on top.
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
– Inserting retaining ring -arrow-.
ss o
Note
cial p
f inform
mer
If the retaining ring cannot be inserted, the clutch has not been
atio
m
pressed in onto its limit stop.

o
n
c
i
or
n thi
e
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t
sd
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t.
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Cop py
t. rig
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Vo
co
– To move clutch to operating position hold spindle of puller -
by lksw
cted agen
Prote
T10373A- with one hand, and use the other hand to pull clutch
AG.
in direction of rotation -arrow- against retaining ring.
Note
♦ Pressing makes the clutch sit at the bottom against the limit
stop on the input shaft. This is not the optimum position.
♦ Clutch should only be pulled up far enough for it to contact
retaining ring.
Note
Only turn by hand. In this way, clutch slides against retaining ring.
Do not use any other tool.

– Insert hub.
• Hub has »large tooth« -arrow- and only fits in one position.
• »Large tooth« has a mark at engine end.
– Insert retaining ring -arrow- of hub.

• Joint of retaining ring must point towards »hub« of clutch.
lkswage es n
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ir se
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au ac
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un
pt
an
d
itte
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ab
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Turn clutch by hand. It should be possible to turn it without

difficulty.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
Note n AG. Volkswagen AG do

lkswage es n
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♦ If the clutch is difficult to turn ir seor if the clutch lining is being
d b ran
tee
rubbed hard, remove clutch uth again ⇒ page 39 .
o
or
a ac
ss
♦ Check installation position of shims -arrows-.
ce
e
nl
pt
du
♦ The shims must be properly seated and undamaged
an
itte
y li
⇒ page 56 .
erm
ab
ility
ot p
♦ A mathematical error could have been made. Check meas‐
wit
, is n
urements again ⇒ page 43
h re
hole
spec
♦ If no error has been made, the clutch may have been moved
es, in part or in w
out of position due to transport/assembly and a new clutch now
t to the co
has to be installed. The position of the engagement bearings
must then be readjusted ⇒ page 43 .
rrectness of i
– Remove two plugs and put breather caps -arrows-on.
l purpos
WARNING
nf
ercia
cardiagn.com
rm
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– Dispose of excess shims.
o
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– After installation of gearbox, perform Complete reset by
Co
Cop py
means of Guided functions ⇒ Vehicle diagnostic tester.
t. rig
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pyri by
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by
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Prote AG.

3 Removing and installing oil seals at

clutch end
There are 2 radial oil seals in gearbox atgeclutch
n AG. Vend.
olkswaBoth oil seals
gen AG
can be renewed without gearboxVbeing lkswa dismantled. If onlydoiloes
not
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seals are renewed, there is no ed bneed
y to adjust clutch. ara
n
ris tee
utho or
a ac
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un
pt
an
d
itte
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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cardiagn.com
nform
ercia

m
a
com
tion in
♦ Tube - VW 415 A-
r
te o
thi
s
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en
ng
t.
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Cop py
t. rig
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Prote AG.
♦ Seal puller - T10420-
3. Removing and installing oil seals at clutch end 63

♦ Extractor tool -T20143/2-
cardiagn.com
Requirement:
Dual clutch has been removed.
Up to gearbox manufacturing date 05.2011 ⇒ page 11
From gearbox manufacturing date 06.2011 onwards G. Volkswage
⇒ page 37 lksw
agen
A n AG d
oes
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edb ran
ris
Caution tho
tee
or
au ac
ss
If leaking, always check the dual clutch. Renew clutch if it is
ce
e
nl
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oily.
an
itte
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erm
ab
ility
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– Lever out outer oil seal.

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.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Drive in outer, »new« oil seal with a plastic mallet until flush
with clutch housing.
• Shoulder of pipe section -VW 415 A- points upwards -arrow-.
WARNING
Only drive in oil seal until flush, in order to avoid closing off oil
hole located behind it. Otherwise, bearing can no longer be
supplied with enough oil.
– Unscrew spindle of oil seal extractor - T10420- .
– Screw oil seal extractor - T10420- into »small«, inner oil seal.
Press puller when doing this.
Puller will become very tight as oil seal is turned. You can »feel«
when oil seal starts to turn in its seat as well.
AG. Volkswagen AG d
agen oes
olksw not
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ara
d
cardiagn.com
ise nte
or eo
h
aut ra
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nl
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itte
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ab
ility
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– Now screw in spindle.
wit
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– Pull out oil seal using spindle.
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
– Drive in new oil seal using thrust piece - T10421- (drive in until
or c
thrust piece contacts stop).

thi
te
sd
iva
o
r
Fitting depth of seal: 17.5 ± 0.2 mm.

rp
cu
o
m
f
en
ng
– Install dual clutch ⇒ page 30 .

t.
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Cop py
ht. rig
rig ht
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Note by c lksw
cted agen
Prote AG.
If there is a complaint about “leaking”, it might be worthwhile look‐

ing at the engine crankshaft now.
Install gearbox ⇒ page 276 .
3. Removing and installing oil seals at clutch end 65

34 – Controls, housing
1 Emergency release of selector lever
Do not remove knob ⇒ page 66 .
– Depress brake pedal or set handbrake.
In an emergency:
Vehicles to 02.2009
– Grip leather bellows and pull trim upwards.
– Press yellow plastic wedge from right to left.
cardiagn.com
Vehicles as of 03.2009
– Unclip selector lever cover and hold aside.
– Press yellow plastic wedge -arrow-. agen
AG. Volkswagen AG d
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Lever can now be moved from position »P«. ed byV gu
ara
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nl
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erm
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ility
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
66 Rep. gr.34 - Controls, housing

2 Removing and installing selector lev‐

er handle
Brief description
Depending on the model, different handles may be installed.
Handle is removed together with selector cover.
AG. Volkswagen AG d
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Removing: Volksw
oes
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– Shift selector lever to position “D”. orise nte
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th
u ra
Handle with push-button on side: ss a c
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nl
– First pull button far enough out of handle that a small gap is
pt
du
an
visible between handle and button. Button locks when re‐
itte
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leased.
ab
ility
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– Hold button in this position with a cable tie or wire to prevent
wit
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it from being pressed in.
h re
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spec
es, in part or in w
t to the co
cardiagn.com
rrectness of i
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Handle with front push-button:

Button does not need to be pulled out by hand. The push-button
nf
ercia
o
engages in installation position -arrow- when the handle is pulled
rm
m
atio
off.
om
n in
or c
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Vo
co lksw
by
cted agen
Prote AG.
Continuation for all handles:

– Unclip cover.
– Pull connector off selector cover.
– Push sleeve upwards to release knob.
2. Removing and installing selector lever handle 67

Polo 2010 only

One clamp is installed instead of sleeve in the Polo.
– Cut open clip beneath boot -arrow- using side cutters.
Continuation for all handles:
– Pull handle off selector lever without pressing button.
Note
Do not press button again after removal as it will no longer be

possible to install the handle.
Installing
– Install in reverse order of removal, observing the following:
• Selector lever is in position “D”.
Handle with push-button on side:
cardiagn.com
• Button in handle is pulled out and secured against being
pressed in.
Handle with front push-button: olkswage es n
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byV ua
• Push-button is in installation position -arrow-. ir se
d ran
tee
tho
or
If the button was pressed by mistake, the installation position
au can ac
ss
be restored.
ce
e
nl
pt
du
– Move push-button to installation position ⇒ page 69 . an

itte
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erm
ab
ility
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Note
New handle is supplied with installation guard. Do not remove

guard until just before installing. To remove, pull it out.
Continuation for all handles

– Push handle fully onto selector lever and lock.
– Push sleeve downwards to lock.
Polo 2010 only
– Push on handle with new clip onto stop.
– Secure clip with hose clip pliers - V.A.G 1275- .
– Push-button after installation.
Note
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leased.
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With this kind of handle, the push-button cannot be pulled out.
AG.
There are 2 ways of moving the push-button into the installation

position, »with« and »without« installation guard. Both of them are
described here.

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– Carefully unclip handle trim -A- upwards.

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♦ Only press the lever into the groove and no further.
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spec
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es, in part or in w
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er the small lever engages in the pull rod when the button is
pressed.
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3 Selector mechanism in vehicles up to

02.2009
WARNING
Before working on vehicle with engine running, move selector

lever into position “P” and apply handbrake. lkswage es n
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Selector mechanism from 03.2009 onwardsau
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3.1 Overview of selector mechanism up to 02.2009
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spec
emergency release, on‐
es, in part or in w
t to the co
ly the cover needs to be
unclipped ⇒ page 66 .
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❑ Before removing knob,
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pull lock button out past
its pressure point. Se‐
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❑ Brief instructions for re‐

moving and installing:
– Remove centre console
– Remove Bowden cable

from gearbox
⇒ page 73 .
– If necessary, disconnect
or remove parts of ⇒ ex‐
haust system; Rep. gr.
26 .
– Remove heat shield be‐

neath vehicle.
– Adjust selector lever cable after installing ⇒ page 85 .

3 - Bolt with spring
❑ 3 Nm.
4 - Pin
❑ Do not grease

5 - Securing clip
6 - Nut
❑ Qty. 4
❑ 9 Nm.
7 - Selector housing
❑ With seal
8 - Selector lever cable
❑ Cable must not be greased
❑ Removing and installing ⇒ page 73
❑ Checking and adjusting ⇒ page 85
9 - Lock washer
10 - Hexagon flange nut
❑ Qty. 4
❑ M6 - 8 Nm.
cardiagn.com
❑ M8 - 20 Nm.
Torque setting , selector lever to selector shaft ⇒ page 289 .
3.2 Removing and installing selector lever

cable up to 02.2009
Note
Following installation, cable must be checked for ease of move‐

ment and be adjusted.
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3. Selector mechanism in vehicles up to 02.2009 73

– Remove securing clip.

– Securing clips for selector lever cable must always be re‐
newed.
– Remove cable from ball head. AG. Volkswagen AG d
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– Remove securing clip of cable support bracket. Always renew
securing clip.

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-Selector housing- is pushed forwards slightly on cable.

To remove cable, securing tab must be pushed forwards -1-.

– At same time, push -pin- up with a screwdriver -2-.
– Insert -screwdriver- from underneath whilst pushing securing
cardiagn.com
tab forwards.
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Clarification:
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– Remove selector lever cable.

Remove selector housing from cable.
Installing
Do not grease cable.
– Route selector lever cable without stress. Do not secure with
securing clips yet. Do not clip in ball head.

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

stallation.
If the sheet metal is bent downwards, it may cause noises. The
cable will »vibrate« against the sheet metal.
– Observe sheet metal. Press it back up in the tunnel during
installation.
Loosen adjustment screw -arrow-.

– Put selector housing onto cable.
cardiagn.com
– Insert selector lever cable into selector
agenmechanism. AG do
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– Insert cable into bearing and insert pin from above, down‐
wards through eye.
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When freedom of movement of cable has been checked

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⇒ page 85 , insert securing clip.

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– Attach cable with new securing clip on cable support bracket

of selector mechanism.

AG. Volkswagen AG d
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– Install selector housing, heat shield and exhaust system. cted agen
Prote AG.
– Check selector lever cable ⇒ page 85 .

lkswage es n
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CC 2010 ➤ , Eos 2006 ➤ , Golf hor2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤nt...
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7-speed dual clutch gearboxs a0AM
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pt
du
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4 Selector mechanism from 03.2009
itte
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onwards
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, is n
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WARNING
spec
es, in part or in w
t to the co
Before working on vehicle with engine running, move selector
lever into position “P” and apply handbrake.
rrectness of i
Selector mechanism in vehicles up to 02.2009 ⇒ page 72
l purpos
4.1 Overview of selector mechanism in vehicles from 03.2009 onwards
nf
ercia
orm
m
atio
1 - Selector cover with knob
om
n in
c
❑ Do not remove handle

or
thi
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without reason. For

t
sd
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emergency release, on‐
o
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rp
cu
ly the cover needs to be
o
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f
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unclipped ⇒ page 66 .
t.
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py
❑ Before removing knob,
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pull lock button out past p by
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cure locking button with
AG.
a cable tie or appropri‐

ate wire against being
pressed in. This will pre‐
vent lock button from
being accidentally
pressed into the knob.
⇒ page 67
2 - Selector lever and selector
mechanism with selector lever
cable
❑ With selector lever lock
solenoid - N110-
❑ Cable must not be
greased
⇒ page 81
❑ Checking and adjusting
⇒ page 85
3 - Bolt
❑ 8 Nm.
4 - Hexagon flange nut
❑ Qty. 4
❑ M6 - 8 Nm.
❑ M8 - 20 Nm.
5 - Selector housing
6 - Securing clip

4.2 Removing and installing selector mech‐

anism
⇒ “4.2.1 Removing and installing selector mechanism with selec‐
tor housing”, page 81
⇒ “4.2.2 Removing and installing selector mechanism without se‐
lector housing”, page 83
4.2.1 Removing and installing selector mech‐

anism with selector housing
Brief description
Selector mechanism and selector lever cable are not allowed to
be separated from one another. Both are removed together with
the selector housing.
In the interior, the centre console must be removed.
. Volkswagen AG
gen AG does
The heat shield beneath the vehicle must be removed.
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The selector mechanism with selector leveroriscable
e can be re‐ nte
moved and installed separately without removing
auth and installing eo
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the selector housing ⇒ page 83 . ss c
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Following installation of selector mechanism, selector lever cable
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must be checked for ease of movement and be adjusted.
hole
spec
es, in part or in w
Removing
t to the co
– Remove selector lever handle ⇒ page 67 .
rrectness of i
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
l purpos
sole .
– Separate electrical connector from selector mechanism to ve‐
nform
ercia
hicle wiring harness.

m
a
– Remove air filter housing:
com
tion in
r
♦ Petrol engine ⇒ Rep. gr. 24 ; Air filter; Removing and installing

te o
thi
air filter housing .

s
iva
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♦ Diesel engine ⇒ Rep. gr. 23 ; Air filter; Removing and installing

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Use pliers to remove the securing clip on the cable support brack‐
agen
Prote AG.
et. Do not use a sharp-edged lever. The selector lever cable could
otherwise be damaged.
Securing clips for selector lever cable must always be renewed.
– Remove cable from ball head.
– Remove heat shield for centre tunnel beneath selector mech‐
anism ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body cover; Assembly overview - underbody cover .
Note
To remove selector mechanism, a 2nd mechanic is required un‐

der the vehicle.
4. Selector mechanism from 03.2009 onwards 81

– Remove nuts -arrows- inside vehicle.

– If fitted, remove bracket -A-.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards.
Installing
Install in reverse order of removal.
Note
♦ Do not bend or kink gear selector cable.

♦ Do not grease selector lever cable.
♦ Specified torques ⇒ page 80 .
– Install heat shield beneath selector mechanism ⇒ General

body repairs, exterior; Rep. gr. 66 ; Underbody cladding; As‐
sembly overview - underbody cladding .
– Install centre console ⇒ General body repairs, interior; Rep.
cardiagn.com
sole .
– Install selector lever handle ⇒ page 67 .
– Adjust selector lever cable ⇒ page 85 .
– Check selector mechanism ⇒ page 85 .
– Install air filter housing:
AG. Volkswagen AG d
agen oes
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Rep. gr.34 - Controls, housing
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4.2.2 Removing agen

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Brief description
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Selector
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mechanism and selector lever cable are not allowed to
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be separated from one another. Both are removed together.
pt
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In the interior, the centre console must be removed.
erm
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A cord must be attached to the Bowden cable before it is removed.
wit
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The cord is needed to guide the Bowden cable between the tunnel
h re
and the heat shield.
hole
spec
es, in part or in w
The selector mechanism with selector lever cable can also be
t to the co
removed and installed with the selector housing ⇒ page 81 .
Removing
rrectness of i
– Remove selector lever handle ⇒ page 67 .
l purpos
– Remove centre console ⇒ General body repairs, interior; Rep.

nf
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sole .
orm
m
– Separate electrical connector from selector mechanism to ve‐
atio
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m
hicle wiring harness.

o
n in
or c
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– Remove air filter housing.

t
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– Remove securing clip.
et. Do not use a sharp-edged lever. The selector lever cable could
otherwise be damaged.
Securing clips for selector lever cable must always be renewed.
– Then a long cord must be attached to the end of the Bowden
cable. The cord is needed to guide the Bowden cable between
the tunnel and heat shield during installation.
– Remove 4 bolts.
4. Selector mechanism from 03.2009 onwards 83

– Carefully pull selector mechanism with Bowden cable out of

the centre tunnel. Ensure that the cord remains accessible
from the engine compartment after being pulled by the Bow‐
den cable.
– Remove cord from Bowden cable.
Installing
Install in reverse order of removal, observing the following:
A second mechanic is needed to guide Bowden cable from pas‐
senger compartment into engine compartment.
Note
♦ Do not bend or kink gear selector cable.

♦ Do not grease selector lever cable.
♦ Specified torques ⇒ page 80 .
– Attach Bowden cable to cord which was drawn into the pas‐
senger compartment during removal.
cardiagn.com
– Carefully guide selector mechanism with Bowden cable
through opening in centre tunnel.
– Have the second mechanic pull cord with Bowden cable
through tunnel from engine compartment until Bowden cable
can be attached to support bracket.
– Remove cord from Bowden cable. lkswage es n
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– Secure selector mechanism to selector
uth housing using 4 bolts.
o
or
a ac
ss
– Install centre console ⇒ General body repairs, interior; Rep.
ce
le

un
pt
an
d
sole .
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ab
– Install selector lever handle ⇒ page 67 .

pe
ility
ot
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– Check selector mechanism ⇒ page 85 .

es, in part or in w
t to the co
– Install air filter housing:

rrectness of i

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5 Checking selector mechanism

The engine must not be able to start in the selector lever positions
“R”, “D”, “S” or the Tiptronic position.
On right-hand drive vehicles, the engine may only start in selector
lever positions “P” and “N” when the button in the gear knob is not
pressed.
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.
5.1 Selector lever in “P” position and ignition

switched on
• Brake pedal is not depressed:
Selector lever is locked and cannot be shifted out of “P” position
cardiagn.com
with the lock button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to actual selector lever position.
5.2 Selector lever in “N” position and ignition

switched on agen
AG. Volkswagen AG d
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• Brake pedal is not depressed: ed by ua
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Selector lever is locked and cannot be ashifted
utho out of “N” position or
ac
with the lock button pressed. Solenoidss for selector lever lock
blocks selector lever.
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pt
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• Brake pedal is depressed:

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Solenoid for selector lever lock releases selector lever. It is pos‐

ility
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sible to shift into a driving gear.

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5.3 Selector lever in position “Tiptronic”

spec
es, in part or in w
t to the co
– Shift selector lever into Tiptronic gate.

Symbols must change from “P R N D S” to “7 6 5 4 3 2 1”.
rrectness of i
5.4 Ignition and light switched on

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The respective symbol in the shift mechanism cover lights up.

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5.5 Selector lever position indicator

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5.6 Checking and adjusting selector lever

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Selector lever cable must be removed from gearbox so that its op Vo
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does not rub against anything.
5. Checking selector mechanism 85

The selector lever must be moved and then the cable must be
reattached to the gearbox.
Then the selector lever cable must be adjusted.
Do not grease cable!
Always adjust selector lever cable, when:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled. . Volkswage n AG n AG d
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♦ The cable itself or the selector
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– Move selector lever to position »P«.

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– Remove cable from lever on gearbox.

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– Reinstall cable with »loosened« adjustment screw.
AG.
If securing clip was removed, always install a »new« securing clip.

– Finally adjust selector lever cable.
Adjusting
– Move selector lever in vehicle to “P” position.

Adjuster screw -arrow- must be »loosened«.

– Shift lever on gearbox to position “P”.
The gearbox lever must be pressed »completely to right side of

vehicle« in the direction of selector lever cable support bracket.
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– Install Bowden cable with loosened adjusting screw -arrow-
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and new securing clip.
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WARNING
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The parking lock must be engaged.

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– To do this, turn both front wheels simultaneously »under the

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car« in the same direction until the parking lock can be heard
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– Gently push knob of selector lever forwards and backwards
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In this way the inner cable of the Bowden cable finds it optimal
position.
5. Checking selector mechanism 87

– Tighten adjusting screw -arrow- to 13 Nm.

This completes the adjustment.
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6 Safety note on mechatronic unit for dual clutch gearbox - J743-
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DANGER!
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Do not work on the accumulator. The accumulator is under

pressure and is not allowed to be opened.
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6. Safety note on mechatronic unit for dual clutch gearbox J743 89

7 Overview - mechatronic unit n AG. Volkswagen AG do

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3 - Mechatronic unit for dual
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♦ Observe the following when in‐
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stalling a new mechatronic unit:
agen
Prote AG.
♦ After unpacking a new mecha‐

tronic unit, do not discard the
packaging or the red cap on the
breather pipe. These will be nee‐
ded for returning the old mecha‐
tronic unit.
♦ A »new« mechatronic unit is cor‐
rectly filled with oil. Do not drain
or top up oil.
– When working on mechatronic unit, please remove cap

-arrow- and seal breather with a suitable plug so that no oil can
escape.
WARNING

The fill level can only be set correctly by changing the hydraulic
fluid. It is not possible to check the fill level.

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AG. Volkswagen AG d
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clutch gearbox 0AM - Edition 12.2016
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If a mechatronic unit which was removed is to be re-installed, the

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seal -shown in green- must be renewed before the unit is installed.

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7. Overview - mechatronic unit 91

8 Removing mechatronic unit for dual

clutch gearbox - J743- ; gearbox is
installed
♦ Assembly lever - T10407-
♦ Diesel extractor - VAS 5226-
cardiagn.com
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In order to remove the mechatronic unit, sufficient space must be

h re
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available in front of the gearbox. Depending on the vehicle, parts

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must be removed which do not have anything to do directly with

t to the co
the gearbox. For example, the air filter housing, if present, charge
air lines or coolant lines. In Polo 2010, for example, radiator fan
control unit - J293- with retainer.
rrectne
Any retainers fitted to the bolts in the cover of the mechatronic

unit must be removed.
ss o
Tester moves all gear actuators »into neutral position«.

cial p
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In this position, insert assembly lever - T10407- between clutch

mer
lever and gearbox housing. This makes it possible to remove load

atio
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from plungers of mechatronic unit so that they may be removed

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Mechatronic unit can be removed and inserted. When installing,

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make sure clutch plungers are correctly seated in cup of engaging

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Therefore, please follow description below step by step.
t. rig
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Note
♦ The clutch is self-adjusting. Shocks can have an effect on this

adjusting device. Even if the mechatronic unit has been re‐
moved, the »sudden removal« of the assembly lever - T10407-
from under the engaging levers can have a negative effect on
the adjusting mechanism.
♦ In order to remove the mechatronic unit, sufficient space must
be available in front of the gearbox. In some vehicles, parts
must be removed which do not have anything to do directly
with the gearbox. Remove any charge air lines or coolant lines
that may be present.
♦ Any retainers fitted to the bolts in the cover of the mechatronic
unit are also removed.
♦ After unpacking a new mechatronic unit, do not discard the
packaging or the red cap on the breather pipe. These will be
needed for returning the old mechatronic unit.
♦ A »new« mechatronic unit is correctly filled with oil. Do not
drain or top up oil.
cardiagn.com
♦ If a mechatronic unit is sent back, always observe the corre‐
sponding requirements.
Removing: AG. Volkswagen AG d

agen oes
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– Raise vehicle. All 4 supports of lifting by platform
Vol
must be at same not
gu
ara
height. rise
d
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– Move selector lever to position
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»P«. ra
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– Remove noise insulation ⇒ Rep. gr. 50 ; Assembly overview

un
pt
- noise insulation . an
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– Drain gear oil, then reinstall drain plug ⇒ page 289 .
pe
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– Connect vehicle diagnosis, testing and information system -

VAS 5051- .
rrectness of i
– Select Guided Fault Finding .

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– Under “7-speed dual clutch gearbox”, select Moving gear

actuator into -neutral- position .
nform
ercia
– Switch off ignition.

m
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tion in
– Raise vehicle on lift.

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– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing

do
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and installing air filter .

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8. Removing mechatronic unit for dual clutch gearbox J743 ; gearbox is installed 93
7-speed dual clutch gearboxen0AM
AG. Vo-lkEdition
swagen A12.2016
G
ag does
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Vol g
– Remove battery and -battery
ed
by tray- ⇒ Rep. gr. 27 ; Battery;uaran
Removing and installing
horis battery . tee
ut or
ac
– s a Electrical system;
Remove starter s⇒ Rep. gr. 27 ; Removing
ce
le
and installing starter .
un
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– Release mechatronic unit connector by pulling and pull off
connector.
ss
– Drain gear oil, then reinstall drain plug ⇒ page 289 .
o
cial p
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mer
atio
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n
c
i
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– Pull cap off breather and close using a suitable plug to achieve by c lksw
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an oil-tight seal.
Prote AG.
WARNING

– 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.
The next step is »difficult«:

Now press both engaging levers of dual clutch »away« from
plungers of mechatronic unit. Otherwise, levers will jam
AG. V olksmecha‐
wagen AG
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tronic unit at plungers and prevent mechatronic
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– Please read through this description
au
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This should help you to perform
ss the following steps »correct‐ c
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ly«.
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Both levers must now be carefully pressed away from the plung‐
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– First take a look at -reddish-brown- engaging lever in this pic‐
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AG. Volkswagen AG d
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CC 2010 ➤ , Eos orise2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , aGolf nte Plus
eo
2005 ➤ ...
h
7-speed dual
s a clutch gearbox 0AM - Edition 12.2016
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cardiagn.com
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– Insert assembly lever - T10407- to the right.

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– Far enough until groove lines up with housing rib.

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No further.
– Assembly lever - T10407- should make contact with gearbox
housing with its entire »rear face«.
Caution
– Apply a bit of force to tip of lever when turning.

This stops lever from slipping out when turning.
Turn assembly lever - T10407- anticlockwise. This presses the

engaging levers away from the plungers.

cardiagn.com
AG. Volkswagen AG d
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Do not take out assembly lever - T10407- . It must remain inserted

between clutch lever and gearbox housing for the entire process.
rrectness of i
– If necessary, press assembly lever - T10407- against gearbox

using a screwdriver.
l purpos
nform
mercia
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ion
c
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for
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AG. Volkswagen AG d
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Prote AG.
Note
The assembly lever - T10407- must remain inserted between

clutch lever and gearbox housing after removing the mechatron‐
ics. Removing the lever could have a negative effect on the clutch
adjustment.
– Unscrew bolts of mechatronic unit for dual clutch gearbox -

J743- »in diagonal sequence«.
»There are 4 long and 3 short bolts.«
Do not remove more than 7 bolts!
– Therefore, look carefully to check which bolts you are un‐
screwing. Do not unscrew any cover bolts.

7-speed
olksw
dual clutch gearbox 0AM - Edition 12.2016
AG. V agen AG
agen does
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The gearbox is shown here again from db
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The mechatronic unit must be
ss a removed. The cover does not have c
to be removed.
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pt
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Therefore, do not remove more than 7 bolts!
itte
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– Remove mechatronic unit.
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– Make sure no oil runs out of breather.
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WARNING
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or c
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If mechatronic unit »jams« and cannot be removed:

t
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au ac
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nform
mercia
Sometimes, the mechatronic unit cannot be removed. In this

at
om
io
case, the gear actuator is »caught« at the »top left« of the gearbox
n
c
in t
r
housing.
o
his
ate
do
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– First reposition mechatronic unit on gearbox housing and se‐

p
cum
or
cure it with one bolt.

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– Move mechatronic unit into »removal position« by hand Cop py
⇒ page 104 .
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Note
The remaining oil must be extracted from the gearbox before the
mechatronic unit is fitted.

– All the oil remaining in the gearbox must be removed using

diesel extractor - VAS 5226- .
Installing mechatronic unit ⇒ page 106 .
cardiagn.com
AG. Volkswagen AG d
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103
AG.
8. Removing mechatronic unit for dual clutch gearbox J743 ; gearbox is installed
9 Moving mechatronic unit for dual clutch gearbox - J743- into »removal
position« 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-.
AG. Volkswagen AG d
agen oes
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mer
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The »sticking« gear actuator -arrow- can be pressed by hand into

its »removal position«. To do this, push a selector fork behind the
parking lock cover.
Procedure:
– First reposition mechatronic unit on gearbox housing and se‐
cure it with one bolt.
– Move selector lever to position “P”.

– Remove securing clip -arrow-.

– Securing clips for selector lever cable must always be re‐
newed.

– Use your hand to press lever to stop in direction of cable sup‐
port bracket.
cardiagn.com
AG. Volkswagen AG d
agen oes
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– Remove lever of selector shaft. rised ara
nte
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– Unbolt cover. aut ra
ss c
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WARNING
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The mechatronic unit will not be »stuck« after the next step.
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secure mechatronic unit on gearbox with one bolt to prevent it
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from falling down.
spec
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t to the co
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– Working through opening, push selector fork to side.
l purpos
(Press to left in direction of travel.)

This presses back »sticking« gear actuator and mechatronic unit
nform
ercia
can be removed.
m
at
om
– Add gear oil after completing work on mechatronic unit

ion
c
⇒ page 289 .
in t
or
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9. Moving mechatronic unit for dual clutch gearbox J743 into »removal position« by hand 105
10 Installing mechatronic unit for dual

clutch gearbox - J743-
♦ Guide bolt - T10406-
♦ Diesel extractor - VAS 5226-
cardiagn.com
AG. Volkswagen AG d
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Requirement:
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The assembly lever - T10407- is inserted between clutch lever

, is n
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and gearbox housing.

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Note
♦ Observe the following when installing a new mechatronic unit:

rrectness of i
♦ After unpacking a new mechatronic unit, do not discard the

l purpos
packaging or the red cap on the breather pipe. These will be

needed for returning the old mechatronic unit.
nform
ercia
♦ A »new« mechatronic unit is correctly filled with oil. Do not

m
drain or top up oil.

at
om
ion
c
♦ If a mechatronic unit is sent back, always observe the corre‐

in t
or
sponding requirements.
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ate
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WARNING
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Before fitting the mechatronic unit, ensure that there is no more p by
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oil in the gearbox.
lksw
cted agen
Prote AG.

– Remove all remaining oil from the gearbox now using diesel
extractor - VAS 5226- if this has not already been done.
Installing
cardiagn.com
– All selector forks are positioned in »neutral« position.
Note
Make sure that all selector forksolkare

en AG. V
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gen AG in -N-, »in the middle«, and therefore that the gearbox is in neutral.
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10. Installing mechatronic unit for dual clutch gearbox J743 107
AG. Volkswagen AG d
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nform
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tion in
– Therefore, check each of 4 selector forks by hand.

r
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Every selector fork has 3 positions: »gear selected - neutral - gear

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selected«.
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– Move each fork once into each position in succession. Then
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disengage all gears and return selector forks to »middle posi‐
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Note
»Neutral, neutral, neutral«, or gearbox will not function!
Turn gear slightly for assistance. This makes it »easier« to shift

the forks.
– Clean sealing surface on gearbox, where mechatronic unit will
make contact later on.
Oil residues on sealing surface will later result in a misdiagnosis
of »leaking«.

– Screw in guide pin - T10406- until finger-tight.
Make sure that all 4 gear actuators project by 25 millimetres -a-.
wage
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co lksw
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Caution
When levering the plungers out of the mechatronic unit, make

sure that you do not brace yourself on the sensors.
New mechatronic unit:

– Clean sealing surface of mechatronic unit.
• The seal around mechatronic unit for dual clutch gearbox -
J743- must be fully and properly inserted in the groove.
Removed mechatronic unit which is to be re-installed:
– Remove old seal from mechatronic unit, and clean groove for
seal (-highlighted in green-) before installing a new seal.
Note
The seal fits only in one position.
cardiagn.com
– Fit new seal all-round into groove in mechatronic unit. The nub
on the seal -lower arrow- must be seated in the recess on the
mechatronic unit -upper arrow-.
Continuation for all: AG. Volkswagen AG d
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– Pay attention to sender. Clip ed must not be damaged.
b ara
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– Put on mechatronic unit.
aut ra
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– When gripping and putting on, make sure selector forks are
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not inadvertently pressed out of their position.

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– Also observe engaging levers and plungers on mechatronic

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unit.
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– Screw in 7 new bolts and tighten until finger-tight.

spec
es, in part or in w
– Remove guide pins - T10406- again.

t to the co
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– Make sure that plungers meet up correctly in cups of engaging

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levers.
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– Pull out plungers by hand until they are seated in cups. . Cop py
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Plungers can be moved into position with a hook bent from a piece py by
co Vo
of welding wire.
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– 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.
cardiagn.com
– Install gearbox input speed sender 3 - G641- .
– Pay attention to sender. Clip must not be damaged.
• Sender lug must be fully and firmly in contact with gearbox
housing. If sender is »loose« because the clip is broken, renew
mechatronic unit. swa
gen AG
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– Remove plug and put on breather cap.

wit
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WARNING
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rrectne
– Reconnect mechatronic unit connector.

ss o
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– Mount all retainers and brackets on front of gearbox.
AG. Volkswagen AG d
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Now add gear oil ⇒ page 289 .
rrectness of i
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– Fit coolant hose or air lines if necessary.
co lksw
by
cted agen
Prote AG.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
installing starter .
– Install battery and air filter.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and connecting battery .
– If necessary, top up coolant ⇒ Engine; Rep. gr. 19 ; Draining
and filling coolant .
– Install noise insulation⇒ Rep. gr. 50 ; Assembly overview -
noise insulation .
– Connect ⇒ Vehicle diagnostic tester.

– Initiate basic adjustment ⇒ page 10 .

11 View on selector forks; mechatronic unit is removed
N - Idling/gearbox neutral po‐

sition »in the middle«
R - Reverse gear
❑ If reverse gear is engag‐
ed, extended plunger of
mechatronic unit catch‐
es behind gearbox
housing.
– Therefore, move me‐
chatronic unit into re‐
moval position by hand
⇒ page 104 .
1 - gear
AG. Volkswagen AG d
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2 - gear Volksw not
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3 - gear horis nte
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11. View on selector forks; mechatronic unit is removed 113

12 Renewing clutch actuator

♦ Used oil collector and extractor - V.A.G 1782-
♦ Cleaning solution, part number: D 009 401 04 ⇒ Electronic

Parts Catalogue (ETKA)
AG. Volkswagen AG d
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Caution byV
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♦ To achieve the desired results when performing repairs, it
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is important to work with the greatest possible care and
an
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cleanliness, and to use proper tools which are in perfect
y li
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condition.
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♦ The clutch actuator is magnetic. To ensure the highest
wit
, is n
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level of cleanliness, do not remove new clutch actuators
hole
from their packaging until immediately before installing
spec
them.
es, in part or in w
t to the co
♦ Install the clutch actuators as soon as they have been re‐
moved from their packaging. Do not put them down any‐
where beforehand.
rrectness of i
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Procedure
nform
ercia
– Removing mechatronic unit ⇒ page 92

m
– Remove oil filler plug -arrow-.

com
tion in
r
Renew bolt after each removal.

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. Volk7-speed
swagen AGdual clutch gearbox 0AM - Edition 12.2016
wa gen AG d oes
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– If still fitted, remove cap from ed bleeder
b hole -arrow-. ara
nte
ris
tho eo
au ra
c
WARNING ss
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nl
pt
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erm
ab
ility
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wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
When turning the mechatronic unit, the oil will flow out of both the
oil drilling and the bleeder hole. Make sure to hold both openings
rrectness of i
over the tray of the used oil collection and extraction unit - V.A.G
1782- .
l purpos
– Turn over mechatronic unit, and drain oil completely.
nf
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atio
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Note
o
n in
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Do not fill hydraulic fluid until the following steps have been com‐
t
sd
iva
pleted.
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– Once the oil is drained, place the mechatronic unit on a clean, t. C rig
gh ht
flat surface such as a worktop. Oil filler hole points upwards yri
p by
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-arrow-.
c by lksw
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Prote AG.
Note
The area around the clutch actuator must always be clean and
dry. Any contamination may cause leaks at a later point.
– Clean area -1- around clutch actuators using cleaning solution

D 009 401 04 or a bottle -2- with washing-up liquid. Remove
any stubborn dirt with a brush. Then, use a lint-free cloth to
thoroughly clean area -1- again.
– Turn mechatronic unit and place it down so that clutch actua‐
tors face upwards.
12. Renewing clutch actuator 115

– Use a screwdriver -2- to lever bellows -1- off mechatronic unit.
Note
Clean guide bush thoroughly before any work step, since any kind
of contamination may cause leaks at a later point.
– Fit guide bush -2- with the large opening facing upwards onto
mechatronic unit, as shown in illustration, and hold it with one
hand. Use other hand to pull out clutch actuator -1- as far as
stop.
cardiagn.com
– Carefully remove guide bush. Do not pull out clutch actuator
-1- any further when doing this.
Proceed in the same way with the other clutch actuator.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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nl
pt
du
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erm
ab
ility
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wit
, is n
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– Place mechatronic unit down in such a way again that oil filler
hole
hole -arrow- faces upwards.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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n in
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thi
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Cop py
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pyri by
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by c lksw
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Prote AG.

– Clean area around seal -2- using cleaning solution D 009 401
04 or a bottle -1- with washing-up liquid. Then, let the washing-
up liquid drip off, and dry it off with a lint-free cloth as neces‐
sary.
– Place mechatronic unit on side in such a way that clutch ac‐

tuators face upwards.
Note
Extreme care and a high level of cleanliness are required for any
work. Therefore, always make sure that no dirt gets into the open‐
ing when pulling out the clutch actuator.
cardiagn.com
– Pull both clutch actuators out of mechatronic unit.
Installing n AG. Volkswagen AG do
lkswage es n
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Caution o
ir se tee
th or
au ac
ss
Risk of damaging mechatronic unit.
ce
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nl
pt
du
♦ To achieve the desired results when performing repairs, it

an
itte
y li
is important to work with the greatest possible care and
erm
cleanliness, and to use proper tools which are in perfect ab

ility
ot p
condition. wit
, is n
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♦ The clutch actuator is magnetic. To ensure the highest
hole
spec
level of cleanliness, do not remove new clutch actuators

es, in part or in w
from their packaging until immediately before installing

t to the co
them.
♦ Install the clutch actuators as soon as they have been re‐
rrectness of i
moved from their packaging. Do not put them down any‐

where beforehand.
l purpos
nform
ercia
Note
m
at
om
ion
c
in t
r
Clean guide bush thoroughly before any work step, since any kind
o
his
te
of contamination may cause leaks at a later point.

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

– Lightly coat sealing lip -arrow- of seal -2- with oil, and slide it
to stop into guide bush -1-.
– Carefully fit clutch actuator -1- with guide bush -2- onto open‐
ing in mechatronic unit. Hold guide bush with one hand and
use other hand to slide clutch actuator 30 mm into mechatronic
unit.
– Carefully remove guide bush. Do not pull out clutch actuator
again when doing this.
– Carefully push clutch actuator further into mechatronic unit
until boot rests against opening.
cardiagn.com
– Use 4 fingers to engage catch -2- of bellows -1- firmly in me‐
chatronic unit.
. Volkswagen AG
gen AG d
– Install the other clutch
Vol
ksactuator
wa in the same way.
oes
not
by gu
ara
ed nte
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itte
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hole
spec
es, in part or in w
– Remove old seal from mechatronic unit, and clean groove for
t to the co
seal (-highlighted in green-) before installing a new seal.

rrectness of i
Note
l purpos
The seal fits only in one position.

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

– Fit new seal all-round into groove in mechatronic unit. The nub
on the seal -lower arrow- must be seated in the recess on the
mechatronic unit -upper arrow-.
– Replenish oil level in mechatronic unit
⇒ “15.2 Draining and filling hydraulic fluid for mechatronic
unit”, page 291 .
– Installing mechatronic unit ⇒ page 106 .
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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aut ra
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nl
pt
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Prote AG.

13 Removing and installing gearbox
13.1 Notes on different vehicles, different

gearboxes
Support engine and gearbox in the Touran.
Contour of headlights has been changed several times in the
Touran. This means there are different contact surfaces for sup‐
port bracket - 10 - 222 A- on wing.
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
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pt
an
d
♦ To 11.06: small headlights -arrow 1-.

itte
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erm
ab
♦ From 11.06 to 05.10: large headlights with curvature

ility
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-arrow 2-.
wit
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♦ From 05.10: large headlights without curvature -arrow 3-

ole,
spec
Adapters have been adjusted accordingly. It is essential to take

t to the co
this into account.

rrectness o
cial p
f inform
– Small headlights -arrow 1-: adapter - 10 - 222 A /22- .

mer
atio
om
n
c
i
or
n thi
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sd
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Cop py
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Prote AG.

– Large headlights with curvature -arrows 2-: adapter - 10 - 222

A /26- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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– Large headlights without
aut curvature -arrow 3-: adapter - 10 - ra
c
222 A /30- . ss
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un
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an
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t to the co
rrectne
Gearbox with different output shafts.
ss o
A - Stub shafts »up to November 2008«
cial p
f inform
mer
B - Flange shafts »from November 2008«

atio
m
Vehicles with stub shafts on gearbox

o
n
c
i
or
n thi
To remove gearboxes with stub shafts, it is necessary to remove

te
sd
va
stub shafts. Only shafts with straight joints can be put back onto
i
o
pr
cum
the output shafts safely. Therefore, these shafts must be re‐

r
fo
en
ng
moved.
t.
yi Co
Cop py
Vehicles with flange shafts on gearbox
t. rig
gh ht
pyri by
Vo
o
For gearboxes with flange shafts, the drive shafts must be unbol‐ by c lksw
cted agen
ted from the gearbox. This way, the gearbox can be removed. In
Prote AG.
individual cases, it is necessary to remove left-hand drive shaft

completely and right-hand flange shaft from gearbox. This pro‐
duces enough clearance for removing gearbox.
Secure drive shafts to suspension strut using securing straps -

T10038- .
13. Removing and installing gearbox 121

13.2 Removing gearbox, Golf 2009 ► and Golf Plus 2009 ►, 1.2 l - 63 and 77 kW
petrol engine
Special tools and workshop

equipment required
♦ Support - 10 - 222 A-
♦ Adjustment plate - 3282/59-
♦ adapters - 10 - 222 A /8-
♦ Gearbox support - 3282-
AG. Volkswagen AG d
♦ Insert tool, 18 mm - ksw
agen oes
not
l
T10179- by Vo gu
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♦ Hexagon bit, long reach - uthor eo
T10061- ss a ra
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♦ Holder - T10346- nl
pt
du
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es, in part or in w
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orm
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n in
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♦ Golf Plus only wing compensation plate - T10311-
yV
olks ot g
ua
b
ed ran
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♦ Not illustrated: Engine and gearbox jack - V.A.G 1383 A-
rrectness of i
Brief description
l purpos
The gearbox is removed downwards separately, without engine.

»From above«
nf
ercia
orm
The battery, air filter and starter are removed.
m
atio
om
n in
c
»From below«
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or
thi
te
sd
a
Remove noise insulation beneath engine, lower cover in front left

iv
o
r
wheel housing and pendulum support.

rp
cu
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f
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t.
Removing:
yi Co
Cop py
t. rig
At a later stage, the support bracket - 10-222 A- and adapters - gh ht
yri by
10 - 222 A /8- is fitted onto the longitudinal members.
op Vo
by c lksw
cted agen
Prote AG.
• To prevent damage to edges of wings, cover lower areas of
both adapters - 10 - 222 A /8- with duct tape -arrow- ⇒ Elec‐
tronic parts catalogue (ETKA, chemical substances) .
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Follow the instructions for different vehicles ⇒ page 120 .
– Remove battery and -battery tray- ⇒ Rep. gr. 27 ; Battery;

Removing and installing battery .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
In cars with stop/start system, disconnect electrical connections
above gearbox.

– Remove selector lever cable from ball head, remove securing

clip.
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.
Remove cable with great care from cable support bracket on
gearbox. Do not bend.

connector.
– Remove all upper connecting bolts between engine and gear‐
box.
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- noise insulation .
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– If present, remove heat shield above right drive shaft. Tight‐

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– Unscrew left transverse link from suspension strut.
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– 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 securing straps - T10038- are therefore very
good for this.

Secure both drive shafts to suspension struts using tensioning

straps - T10038- .
– Remove right flange shaft of gearbox using socket - T10107

A- .
Bolt has a 6 mm hexagon socket. Bolt can also be removed and
installed with socket - V.A.G 1669- .
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– Screw 2 bolts into flange and counter hold flange shaft with a
lever in order to remove and install flange shaft.
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– Disconnect front exhaust pipe from catalytic converter so that

lower engine/gearbox connecting bolts -arrows- can be re‐
moved ⇒ Rep. gr. 26 ; Removing and installing parts of
exhaust system .
– Remove engine cover panel from cylinder head.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222A- , remove these now.
Golf Plus
– Use wing supports - T10311- on both sides.
The supports prevent the weight of the engine from damaging the
wings.
– Bolt bracket - T10346- to rear mounting hole for battery tray.
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port bracket - 10 - 222 A- so that bracket can be removed.

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– Press gearbox off engine, »observing selector lever cable«
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spec
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t to the co
13.3 Removing gearbox, Golf 2009 ►, 1.8 l -
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118 kW petrol engine
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equipment required
♦ Support - 10 - 222 A-
♦ adapters - 10 - 222 A /8-
♦ Insert tool, 18 mm -
T10179-
♦ Hexagon bit, long reach -
T10061-
♦ Holder - T10346-
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The gearbox is removed downwardsisseparately,ed b without engine. ara
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clip.
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gearbox. Do not bend cable.

connector.
– Remove upper connecting bolts between engine and gearbox.

cardiagn.com
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– Remove front left part of wheel housing liner ⇒ Rep. gr. 66 ;
Assembly overview - front wheel housing liner .
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– Remove pendulum support.

– Disconnect left coupling rod from anti-roll bar ⇒ Rep. gr. 40 ;
Assembly overview - subframe, anti-roll bar, suspension links .
cardiagn.com
– Only unscrew left transverse link from suspension strut. Do not
touch right transverse link.
Both centre bolts of shafts remain installed.
– Unbolt both drive shafts from gearbox and carefully lay to side.
⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and
installing drive shafts . wage
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A- .
– Remove flange shaft with compression spring.
– Close opening in drive shaft using a suitable plug.
– To install flange shaft, if necessary press against gearbox with
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– Move engine and gearbox jack - V.A.G 1383 A- under gearbox

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AG.
13.4 Removing gearbox, Polo 2010 ►, 1.2 l -

63 and 77 kW petrol engine
Brief description
»From above«
Remove battery and starter.
»From below«
Remove noise insulation beneath engine, front left wheel housing
liner and subframe with pendulum support. Secure drive shafts
so that they do not disrupt removal. However, leave them on the
suspension struts. The gearbox is removed downwards sepa‐
rately, without engine.
Subframe must be secured.
Removing:
height.


– Remove air line to air filter housing ⇒ Rep. gr. 24 ; Removing
– Remove battery carrier.
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clip.
might fall off.
gearbox. Do not bend it.
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.
– Now remove all upper connecting bolts between engine and
gearbox.

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

used instead of an 18 mm socket.

connector.
– Remove left front part of wheel housing liner ⇒ Rep. gr. 66 ;
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– If fitted, remove radiator fan control unit - J293- with retainer

wit
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h re
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– If fitted, remove power steering hydraulic unit from longitudinal

es, in part or in w
member and secure with wire.

t to the co
– Remove subframe with pendulum support and secure ⇒ Rep.

gr. 40 .
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– Unbolt both drive shafts from gearbox.

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– Then lower engine and gearbox slightly using spindle of sup‐

port bracket - 10 - 222 A- until lower bolts of bracket can be
removed.
3282/59- .

chatronic unit.
cardiagn.com
and lower gearbox.
13.5 Removing gearbox, Polo 2010 ►, 1.4 l o-lk63

swa
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T10107 A-
♦ Shackle - 10 - 222 A /12-
♦ Tensioning straps -
T10038- , qty. 3
♦ Engine and gearbox jack -
V.A.G 1383 A-
AG. Volkswagen AG d
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Brief description
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»From above« by c lksw
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Remove battery and starter.
»From below«
Removing:
height.


– Remove air line to air filter housing ⇒ Rep. gr. 24 ; Removing
AG. Volkswagen AG d
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AG. Volkswagen AG d
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clip.
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gearbox.



connector.
cardiagn.com
AG. Volkswagen AG d
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– Remove all retainers and brackets fromssfront of gearbox.
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A- .
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13.6 Removing gearbox, Polo 2010 ►, 1.4 l -

103 kW petrol engine
♦ Support - 10 - 222 A-

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♦ Not illustrated:
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♦ Engine and gearbox jack - V.A.G 1383 A-
Brief description
The gearbox is removed downwards separately.
»From above«
The battery, air filter and starter are removed. The engine and
gearbox must be supported before the left subframe mounting is
removed.
»From below«

The -subframe- is removed together with -pendulum support- and

-both suspension links-. The -steering rack- remains installed in
the vehicle.
Both drive shafts are disconnected from gearbox and left installed
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.
Removing:
height.
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Lever selector lever cable -1- off gearbox selector lever.

– Remove bolts -2-, raise and tie selector lever cable together
with support bracket.
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ble socket from shock absorber set - T10001- .
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♦ Do not under any circumstances touch the contacts in the
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– Disconnect electrical connector -1- for mechatronic unit for

dual clutch gearbox - J743- . To do this, pull locking element
upwards -arrow-.
– Unscrew nuts -2- and -3- and remove wiring retainer from
gearbox.
– Tie up wiring in area of gearbox cover.
– Remove front left wheel housing liner ⇒ Rep. gr. 66 ; Assem‐
bly overview - front wheel housing liner .
– Remove subframe without steering rack ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐
ling subframe without steering rack .
– Open spacer -arrow- and lay lines to one side.
cardiagn.com
– Disconnect both drive shafts from gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft: Removing and in‐
stalling drive shafts .
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– Secure drive shaft to suspension strut with tensioning strap -
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T10038- .
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es, in part or in w
t to the co
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2 bolts vertical, 1 bolt horizontal on top of gearbox -arrows-.
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Note
Be careful of all lines when lowering gearbox.
Transporting gearbox and securing to engine block

⇒ page 287 .
13.7 Removing gearbox, Polo 2010 ►, 1.6 l - 66 kW diesel engine


equipment required
♦ Support - 10 - 222 A-
T10035-
T10061-
♦ Insert tool, 18 mm - AG. Volkswagen AG d
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T10107 A-
♦ Shackle - 10 - 222 A /12-
♦ Tensioning straps -
T10038- , qty. 3
♦ adapters - 10 - 222 A /18-
V.A.G 1383 A-
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Brief description
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clip.
might fall off.
– Remove charge air line to access upper connecting bolts of
gearbox ⇒ Rep. gr. 21 .
gearbox.


connector.
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– Remove all retainers and brackets from front
ss a of gearbox. ra
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– If fitted, remove radiator fan control unit - J293- with retainer un
pt
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gr. 40 .
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es, in part or in w
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– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
nform
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straps - T10038- .
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Specified torque: 30 Nm t. C rig
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– In some vehicles, there is still another small cover plate on

intermediate plate. It is above right drive flange. Remove this
plate.

AG. Volkswagen AG d
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chatronic unit.
and lower gearbox.
13.8 Removing gearbox, Polo 2010 ►, 1.4 l - 132 kW petrol engine


equipment required
♦ Support - 10 - 222 A-
T10035-
T10061-
T10179-
cardiagn.com
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T10107 A-
♦ Shackle - 10 - 222 A /12-
♦ tensioning straps - T10038-
V.A.G 1383 A-
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Remove complete air filter housing and starter.

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engine.
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Removing:
height.

– Step on the brake pedal while a 2nd mechanic loosens the left
nut from drive shaft -arrow-.
Note
After loosening centre nut, do not lower vehicle to ground again.

– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Removing and
installing battery .
– Remove air filter housing ⇒ Rep. gr. e24 ; Removing
n AG and
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– Remove starter ⇒ Electrical ise system; Rep. gr. 27 ; Removing
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clip.
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– Remove all upper connecting bolts between engine and gear‐
l purpos
box. nform
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connector.
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– Remove left drive shaft ⇒ Running gear,edaxles,
by steering; Rep. ara
cardiagn.com
gr. 40 ; Removing and installing drive
thorisshafts . nte
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au ra
– Unbolt right drive shaft from gearbox.
ss c
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nl
pt
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Right drive shaft is fixed onto suspension strut with tensioning
ility
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gr. 40 .
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A- .
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nform
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m
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i
on
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port eyes for support bracket - 10-222 A- , remove these now.
or
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– Unscrew main fuse box. First unscrew bolts -1-, then lift up
printed circuit board and unscrew bolt -2-.
– Box can then be placed to side in order to gain access to bolts
-3-.



removed.
3282/59- .
cardiagn.com
chatronic unit.
AG. Volkswagen AG d
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an
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and lower gearbox.

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13.9 Removing gearbox with flange shafts;

hole
spec
Touran 1.4 l - 103, 110 and 125 kW pet‐

es, in part or in w
t to the co
rol engine (and 110 kW Eco-Fuel)

rrectness of i
l purpos
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com
tion in
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t.
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Cop py
t. rig
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equipment required
♦ Support - 10 - 222 A-
T10035-
T10061-
T10179-
♦ Not illustrated:
V.A.G 1383 A-
cardiagn.com
AG. Volkswagen AG d
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Up to October 2008, gearboxes were installed with stub shafts.

rrectness of i
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stallation. In gearboxes with flange shafts, drive shafts remain in
l purpos
vehicle.
Brief description
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»From above«
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liner and pendulum support. The subframe remains in the vehicle.
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Removing:
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height.
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– Remove engine cover panel.



clip.
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gearbox.
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ab
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– Unbolt front left vehicle level sender - G78- from suspension
rrectness of i
link.
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– Unbolt left suspension link from suspension strut.
op Vo
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work.
good for this.

straps - T10038- .


A- .
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– Remove connecting bolt

3282/59- .

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and lower gearbox.
13.10 Removing gearbox, Touran 1.6 l - 77 kW TDI engine
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»From above«
»From below«
Remove noise insulation beneath engine, cover in front left wheel
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height.
– Step on the brake pedal while a second mechanic loosens the
left drive shaft bolt -arrow-.
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A /10- and adapter - 10 - 222 A /16- by about 5 rotations each.
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Up to October 2008, gearboxes were installed with stub shafts.
In these gearboxes, both drive shafts are removed for secure in‐
stallation. In gearboxes with flange shafts, drive shafts remain in
vehicle.
Brief description
»From above«
»From below«
housing, drive shafts and pendulum support. The subframe re‐
mains in the vehicle.
Removing:
height.

Only in vehicles with stub shafts
Note
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drive shaft bolts -arrow-.
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with certainty.

– Remove connecting bolts at top.

3282/59- .

chatronic unit.
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and lower gearbox.
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13.12 Removing gearbox, Passat 2006 ► 1.4 l - 110 kW Eco-Fuel engine
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Brief description
»From above«
»From below«
Both drive shafts must also be removed. The shafts can be prop‐
erly inserted during installation only if they are guided »straight«
onto the ends of the gearbox shafts. Partially installed shafts can‐
not be inserted straight.
Removing:
height.


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3282/59- .


chatronic unit.
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13.13 Removing gearbox, Passat 1.4 l - 90 and 110 kW petrol engine

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Brief description
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clip.
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connector.
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straps - T10038- .

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Brief description
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gr. 40 ; Removing and installing drive shafts . olkswage es n
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3282/59- .


chatronic unit.
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13.16 Removing gearbox, Golf Plus 2009 ►, 1.6 l - 75 kW petrol engine

equipment required
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connector.
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Brief description
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link.
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13.23 Removing gearbox, Golf 2004 and Golf Plus 2005 1.9 l - 77 kW TDI engine

equipment required
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wheel housing, left drive shaft and pendulum support.

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13.25 Removing gearbox, Passat CC 2009►, CC 2010►, 1.8 l - 90 and 118 kW

petrol engine

equipment required
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– Unbolt right drive shaft from gearbox⇒ Rep. gr. 40 ; Removing

strap - T10038- .

– Remove pendulum support. First remove bolt -1-, followed by

bolts -2- and -3- ⇒ Rep. gr. 40 . AG. Volkswagen n AG do
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– Close opening in drive shaft using a suitable plug. Prote AG.


port eyes for support bracket - 10-222 A- , remove these now.


Adapters - 10 - 222 A /1- can also be used instead of racks - 10
- 222 A /8- .
Caution
The support bracket must not be placed on the wings, other‐

wise these might be damaged.

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– Remove all connecting tho bolts except one which is in an easily or
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– Remove last engine/gearbox connecting bolt.

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and lower gearbox.
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13.26 Removing gearbox, Golf Cabriolet 2012 ►, 1.4 l - 90 or 118 kW petrol engine
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en AG. Vgearbox 0AM
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♦ Support - 10 - 222 A- ss
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Brief description
»From above«
»From below«
Removing:
height.
Note

– Depress the brake pedal and loosen left bolt of drive shaft
-arrow- (2nd mechanic).

Removing and installing battery . n AG. Volkswagen AG do
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– Remove starter ⇒ Electrical system; Rep.
ed
by gr. 27 ; Removing
V
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and installing starter . ho
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– Remove upper engine/gearbox connecting bolts. olkswage es n
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– Remove left drive shaft completely ⇒ Rep. gr. 40 ; Removing
nform
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– Unbolt right drive shaft from gearbox ⇒ Rep. gr. 40 ; Remov‐
on in
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ing and installing drive shafts .
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– Unbolt right transverse link from axle link ⇒ Rep. gr. 40 ; rig ht
py by
Subframe, anti-roll bar, transverse link .
co Vo
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strap - T10038- .

– Remove pendulum support. First, unscrew bolt -1-, followed

by bolts -2- and -3- ⇒ Rep. gr. 40 .

A- .
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– To install flange shaft, if necessary press against gearbox with h re

ole,

spec
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– Unclip line to Lambda probe.

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– Remove connecting hose between charge air cooler and

inform
charge air pipe.

mer
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– Unbolt bottom of charge air pipe from engine and swing for‐
o
n
c
wards ⇒ Rep. gr. 21 ; Removing and installing parts of charge

i
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– Unbolt exhaust system bracket from subframe ⇒ Rep. gr.ed 26 ;
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exhaust system .
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– Remove all connecting bolts except one which is in an easily
accessible place between engine and gearbox.
3282/59- .

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– Remove last engine/gearbox connecting bolt. an
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and lower gearbox.

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13.27 Installing gearbox

– Please read these important work steps before installing gear‐
rrectness of i
box.
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– In some cases, there are brackets on the front of the removed

gearbox. Attach these brackets to the »new« gearbox.
nform
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Gearbox with stub shafts -A- tho
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Gearbox with flange shafts -B-
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– In gearboxes with stub shafts, stub shaft must be reinstalled
an
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on »new« gearbox in some cases. For this procedure, refer to
rm
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⇒ page 389 .
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h re
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– Remove right-hand flange shaft of gearbox in order to install
es, in part or in w
gearbox.
t to the co
Gearbox with flange shafts, torque setting ⇒ page 392
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– Renew needle bearing -arrow- in crankshaft ⇒ Rep. gr. 13y V; olks ot g
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Crankshaft; Renewing needle bearing in crankshaft . ised b ran
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If the needle bearing in the crankshaft is damaged, the gears
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ility
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– Clean input shaft splines and splines of torsional damper, re‐
spec
es, in part or in w
move corrosion and lubricate splines with only a very thin
t to the co
coating of grease ⇒ Electronic Parts Catalogue (ETKA) . Re‐
move excess grease.
– Check for proper seating of both dowel sleeves between en‐
rrectness of i
gine and gearbox.
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– Check for proper seating of intermediate plate.

Pay attention to selector lever cable when raising gearbox. Guide
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cable as soon as possible into cable support bracket.
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Bowden cable must not be greased.

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It must be possible to guide the engine and gearbox together by
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– Re-adjust gearbox support until engine and gearbox »are
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– If necessary, turn crankshaft slightly.
– After fitting starter motor, check that both breather caps are in
place!
– Securing clip for selector lever cable must be renewed.

might fall off.

– If cable support bracket -1- has been removed, bolt it to gear‐

box -arrows-.
– Ensure that selector lever cable is properly routed during in‐

stallation.
If the sheet metal has been bent downwards when the gearbox
was removed, it may cause noises. The cable will »vibrate«
against the sheet metal.
– Observe sheet metal. Press it back up in the tunnel during
installation.
cardiagn.com
– Always adjust selector lever cable ⇒ page 85 .
– Initiate basic adjustment ⇒ page 10 .
Torque settings for gearbox installation ⇒ page 279 .
13.28 Torque settings »Gearbox to engine«

and notes on assembly mounting
AG. Volkswagen AG d
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The »next chapters« list the torque settings for gearboxolinstalla‐ oes
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tion. db
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There is also information about the »left« assembly
ut
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Threaded connections that are not directly assigned to the gear‐
ce
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box can be found in the associated assembly groups.

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es, in part or in w
ning gear; Rep. gr. 40 .

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Left assembly mounting

– Renew all bolts of left assembly mounting.
rrectness of i
– First screw in all bolts by hand.

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– First bolt bracket onto gearbox with bolts -1-. Specified torque:
40 Nm + +90°
– Then bolt gearbox bracket to left assembly mounting.
Polo:
Bolts -A- for gearbox bracket. Specified torque: 40 Nm + +90°
Disregard bolts -B, C-.
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Bolts -2- to gearbox bracket. Specified torque: 60 Nm + +90°

n in
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Continuation for all:

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Bolts -2- for securing cable support bracket to gearbox. Specified

torque: 8 Nm.
Starter to gearbox ⇒ Rep. gr. 27 ; Removing and installing start‐
er .
Pendulum support to subframe and gearbox ⇒ Rep. gr. 40 ; As‐
sembly overview - subframe, anti-roll bar, suspension links .
♦ 1.4 l - 63 kW engine ⇒ page 282
♦ 1.4 l - 103 kW engine ⇒ page 283
♦ 1.9 l - 77 kW diesel engine and 1.6 l - 66 kW diesel engine
⇒ page 286
♦ 1.6 l - 77 kW diesel engine ⇒ page 285
♦ 1.6 l - 66 kW diesel engine
♦ 1.2 l and 1.4 l and 1.6 l engine ⇒ page 284
♦ 1.8 - 118 kW engine ⇒ page 281
13.28.1 1.8 - 118 kW engine
cardiagn.com
M12 - 80 Nm.
❑ If 18 mm insert -
T10179- is used: 65 Nm.
M10 - 40 Nm.
- Arrows point towards dowel wage
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c
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7-speed dual clutch gearboxA0AM
G. Volk-sw
Edition
agen A 12.2016 n G do
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13.28.2 1.4 l - 63 kW petrol engine ris
ed
by ua
ran
tee
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M12 - 80 Nm.
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With stop/start

CC 2010
AG. Volkswa➤
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AG do2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
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M12 - 80
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13.28.3 1.4 l - 103 kW petrol engine

Gearbox to engine:
Item Bolt Nm
1, 3 M12x55 80
2 1) M12x170 80
4, 8 M12x65 80
5, 6, 7 M10x55 40
A Dowel sleeves for centring
• 1) Also secures starter

13.28.4 1.2 l and 1.4 l and 1.6 l engine
M12 - 80 Nm.
T10179- is used: 65 Nm.
M10 - 40 Nm.
sleeves
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te o
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13.28.5 1.6 l - 77 kW diesel engine
M12 - 80 Nm.
T10179- is used: 65 Nm. AG. Volkswagen AG d
agen oes
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M10 - 40 Nm. by
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13.28.6 1.9 l - 77 kW diesel engine and 1.6 l - 66 kW diesel engine
M12 - 80 Nm.
T10179- is used: 65 Nm.
M10 - 40 Nm.
sleeves
AG. Volkswagen AG d
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14 Transporting gearbox and securing

to assembly stand
Transporting gearbox.
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– Pull off both breather caps -arrows- and close using suitable
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plugs to achieve an oil-tight seal.
rrectness of i
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Secure gearbox on gearbox support - VW 353- .

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14. Transporting gearbox and securing to assembly stand 287

Lift gearbox into assembly stand.

The gearbox is lifted »into assembly stand« together with gearbox
support - VW 353- .
AG. Volkswagen AG d
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15 Gear oil
15.1 Renewing gear oil

AG. Volkswagen AG d
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♦ Adapter for oil filling - VAS 6262 A-
es, in part or in w
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♦ Extension - VAS 6262/7-

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The gearbox is filled for life. Therefore, there is no need to check

the oil level of this gearbox.
This explains why there is no oil level check.
If the gearbox has started leaking, check where the oil is coming
from.
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
15. Gear oil 289

– Then drain remaining oil.

– Repair leak.
– Then install the drain plug again.
The new oil is poured in through the breather hole.

If the gearbox has been installed, the air filter and/or battery must
be removed in order to fill the gearbox with oil, ndepending
AG. Volkswagon the
en AG do
model and engine. olk swage es n
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Removing and installing air filter housing
ris
ed ⇒ Rep. gr. 24 . nte
tho eo
– Remove battery and -battery
ss
au tray- ⇒ Rep. gr. 27 ; Battery; ra
c
ce
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– Pull cap off breather hole.
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– Fit oil filling adapter - VAS 6262 A- with adapter - VAS 6262/4-
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♦ Only the gearbox fluid for the 7-speed dual clutch gearbox
0AM, which is available through the replacement parts sys‐
tem, may be used ⇒ Electronic Parts Catalogue (ETKA) .
♦ Shake oil bottles before filling.
♦ Breather pipe of adapter for oil filling - VAS 6262 A- may need
to be shortened.

– In order to ensure that the breather pipe of the adapter for oil
filling - VAS 6262 A- does not contact the bottom of some oil
bottles, the pipe must be shortened to the length -a-.
Dimension -a- = 182 mm
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
– Mark dimension -a- on the breather pipe and shorten pipe with
pipe cutter - VAS 6056/2- .
cardiagn.com
– Bolt extension - VAS 6262/7- onto bottle. Then screw on,
adapter for oil filling - VAS 6262 A- .
– Fill 1.7 l of oil. AG. Volkswagen AG d
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The oil is available as a replacement
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not
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After filling, remove soil
s filling adapter - VAS 6262 A- . Clean area
a ra
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around breather hole with a cloth and fit the breather cap.
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15.2 Draining and filling hydraulic fluid for

mechatronic unit
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15. Gear oil 291

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♦ Funnel, commercially horis
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The hydraulic fluidsfor the mechatronic unit is filled for the entire
s c
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lifetime of the unit. It is not possible to check the oil level.

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spec
♦ Use only the hydraulic fluid which is available as a re‐
es, in part or in w
placement part for the mechatronic unit ⇒ Electronic parts
t to the co
catalogue (ETKA) .
♦ Other oils will lead to malfunctions or failure of the me‐
rrectness of i
chatronic unit.
l purpos
♦ It is not possible to check the fill level of the hydraulic fluid

section of the mechatronic unit for dual clutch gearbox -
J743- . During installation work the breather of the dual
nform
ercia
clutch gearbox mechatronic unit - J743- must be sealed

so that no oil can escape. If any oil escapes from the hy‐
m
a
com
ti
draulic fluid section of the mechatronic unit for dual clutch

on in
gearbox - J743- , it is not possible to check the fill level!

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♦ The fill level can only be set correctly by changing the hy‐
do
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draulic fluid. It is not possible to check the fill level.

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Conditions
♦ Mechatronic unit is removed ⇒ page 92

Draining hydraulic fluid

– Remove oil filler plug -arrow-.
Renew oil filler plug after each removal.
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– If still fitted, remove cap from bleeder hole -arrow-.
s o
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WARNING
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When turning the mechatronic unit, the oil will flow out of both the
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oil drilling and the bleeder hole. Make sure to hold both openings
AG.
over the tray of the used oil collection and extraction unit - V.A.G
1782- .
– Turn over mechatronic unit, and drain oil completely.

Filling with hydraulic fluid:
Note
Do not fill new oil until all repair work on the mechatronic unit has
been completed.
– After the oil has been drained completely, turn mechatronic

unit back. The oil filler hole faces upwards.
15. Gear oil 293

– Fit a clean commercially available funnel into oil filler hole.

Shake the oil bottle before opening it.
– Pour in 0.9 l of hydraulic fluid.
– Install new oil filler plug.
Specified torque: 5 Nm + 90°
Caution
AG. Volkswagen AG d
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Risk of damaging mechatronic unit. d by
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♦ The fill level can only be set correctlyaubyt changing the hy‐
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ss the fill level. c
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♦ If the fill level is too low or too high, the operation of the
pt
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– Seal bleeder hole of mechatronic unit using a clean plug from
h re
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engine bung set - VAS 6122- . This will prevent any oil from
spec
flowing unintentionally out of the hole.
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t to the co
– Installing mechatronic unit ⇒ page 106
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35 – Gears, shafts
1 Notes on gearbox disassembly
Gearbox spare parts are allocated to gearbox code.
For every installation on shafts, always check »lower« bearing. It
is easy for bearing cages to become bent and damaged by
»bumping«.
Bearing races are not allowed to be swapped over. They are
paired with the bearing.
Always renew the bearings on a shaft together.
– Install with care, without using force.
cardiagn.com
AG. Volkswagen AG d
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Always use guide pins - 3411- to install differential. Take
aut care not ra
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1.1 Overview: gearbox disassembly
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1. Notes on gearbox disassembly 295

A - Outer input shaft

I - Inner input shaft
1 - Output shaft 1
2 - Output shaft 2
3 - Output shaft 3
cardiagn.com
AG. Volkswagen AG d
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296 Rep. gr.35 - Gears, shafts

2 Dismantling gearbox
– Secure gearbox to stand ⇒ page 287 .
Conditions
• Clutch is removed
• Mechatronic unit is removed
• Gear oil is drained
– Engage parking lock.
cardiagn.com
– Remove cable support bracket.
AG. Volkswagen AG d
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– Remove parking lock ⇒ page 387 .

wit
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– Remove dual clutch ⇒ page 13 .

hole
spec
es, in part or in w
t to the co
rrectness of i
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2. Dismantling gearbox 297

– If not already removed: remove both engaging levers.

– Remove mechatronic unit ⇒ page 92 .
– Remove flange shafts or stub shafts ⇒ page 389 .
– Remove connecting bolts of housing halves at clutch end.
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– Fit support bridge - T10323- and rotate spindle against Volinner
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input shaft until finger tight. ise
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This supports shaft. Gearbox housing is pulledsoffau later. In this or
ac
way, the force required is not applied to the gearbox
s in an uncon‐
ce
le
trolled manner.
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– Turn gearbox, remove remaining connecting bolts of housing

rrectne
halves.
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– Penetrate cover of “inner input shaft” and lever out.

Drive screwdriver »centrally« and at a very »acute« angle into
cover. Only far enough so you can lever out cover.
– Remove retaining ring.

– Remove dowel sleeves of mechatronic unit.
AG. Volkswagen AG d
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– From above, mount another puller. ility
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Screw on -A- square pin - T10427/1- and -B- angled rod - T10427-
h re
until finger-tight.
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Spindle should press against input shaft.

t to the co
– Whilst pulling off, you can apply »targeted« hammer blows to

reinforce pulling force.
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– Use a hardwood block as protection.

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This will make it easier to release glue between both housing

halves.
nf
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– Pull off gearbox housing and place it to one side.

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Gearbox housing can be clamped in 1 vice for further assembly cop Vo
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AG. Volkswagen G d
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7-speed dualolclutch - Edition
oes 12.2016
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– Remove magnet
ho
ris
and clean it. eo
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ss c
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– Move selector fork for 1st and 3rd gear upwards into 1st gear.
l purpos
– Slightly raise output shaft 1, tip it a little -arrow- and remove

selector fork.
nform
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– Move selector fork for 2nd and 4th gear upwards into 4th gear.
Prote AG.
– Again, raise output shaft 1 slightly, tilt it and remove selector

fork.
– Remove output shaft 1.

– Shift down both remaining selector forks.
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– Raise output shafts 2 and 3 out of the lower bearings.
wit
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– Place both shafts »in direction of« selector forks onto clutch
r
te o
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housing.
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Prote AG.
– Screw one guide pin - 3411- into differential.

– Remove differential. Output shaft 2 can be raised slightly for
this purpose.

– Remove output shafts 2 and 3.
– Selector forks rotate »inwards«.

– Remove selector forks.
AG. Volkswagen AG d
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– Remove inner input shaft.
wit
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– There is a roller bearing between inner and outer input shaft.
hole
spec
Please also remove this.
es, in part or in w
t to the co
• This bearing is not allowed to be broken.
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– Unscrew 3 bolts.
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Prote AG.
– Turn over clutch housing together with »last«, outer input
shaft.

– Lever out outer oil seal.
– Outer input shaft can be pressed out now. AG. Volkswagen AG d

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– Hold shaft firmly with one hand. This prevents by it from falling
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Note
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»Pressed out« shaft will fall down.
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– Bearing of outer input shaft must always be renewed
nform
ercia
⇒ page 323 . New retaining ring -arrow- must also be pressed

m
in.
at
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ion
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Pressing out shaft caused force to be applied through balls of

in t
or
bearing. his
ate
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– Clean surfaces of both housings with silicone remover -

um
for
LSE020100A3- .
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Disassembly of gearbox is completed. t. C rig
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Further »links«:
o Vo
by c lksw
cted agen
Prote AG.
Assembling gearbox ⇒ page 304 .
Dismantling and assembling gearbox housing ⇒ page 315
Dismantling and assembling clutch housing ⇒ page 319
Dismantling and assembling outer input shaft ⇒ page 323
Dismantling and assembling inner input shaft ⇒ page 325 .
Dismantling and assembling output shaft 1 ⇒ page 328 .

3 Assembling gearbox
Clean sealing surfaces on both gearbox halves.
– First install outer input shaft.
• External input shaft must be prepared for this in advance. 1
new bearing with correct retaining ring must already be at‐
tached ⇒ page 323 .
– Heat clutch housing in area of outer input shaft to approx. 100 °
C using a hot air blower.
• If housing has been heated correctly then outer input shaft can
be inserted by hand up to stop. This is done without force.
If bearing jams then clutch housing is »still too cold«.
Do not re-press!
– Remove shaft again, heat clutch housing correctly.
cardiagn.com
– After cooling down: tighten 3 bolts.
Specified torque: 8 Nm 90 °
– Turn clutch housing around.
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– Drive in outer, »new« oil seal with a plastic mallet until flush
hole
spec
with clutch housing.

es, in part or in w
t to the co
WARNING
rrectness of i
Only drive in oil seal until flush, in order to avoid closing off oil
hole located behind it. Otherwise, bearing can no longer be
l purpos
supplied with enough oil.

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– Turn clutch housing back around.

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– Insert inner input shaft with roller bearing.

Bearing is not allowed to be broken. Oil bearing.
– Shift all locking collars of output shafts 2 and 3 »downwards«.
– Insert selector fork for 6th gear and reverse gear.
cardiagn.com
– Fork cannot be turned in its position unless it is »all the way
down«.
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– Insert selector fork for 5th and 7th gears.
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This selector fork can be inserted very easily if you raise the other
h re
ole,
selector fork a little.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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3. Assembling gearbox 305

For the following steps:

olkswagen AG
en AG. V
Tapered roller bearings are destroyed
olks
wag very quickly if the
doecage
s no is
bent due to being inserted
ed
forcefully
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– Insert output shaft 2.
cardiagn.com
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com
t
– Watch out for both locking collars. Mouth »top« and mouth
ion in
»bottom« -arrow- must be inserted correctly.
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– Output shaft 2 is placed on clutch housing, not in bearing race.

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– Insert output shaft 3.

– Watch out for mouth of selector fork and locking collar.
This shaft is also »placed« on clutch housing.
– Install differential.
– Make sure that you do not strike bearing against clutch hous‐
ing.
– Carefully insert output shafts into bearings.
– Raise inner input shaft slightly. This allows output shaft 2 to
find its installation position.
– Take out guide pin - 3411- .

– On output shaft 1, shift »upper« locking collar upwards.
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– Insert output shaft 1 »at an angle from above«.
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Shaft should remain at an angle.
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This is because selector forks must still be installed before shaft
es, in part or in w
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is set in installation position.
rrectness of i
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ion
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– First insert selector fork for 2nd and 4th gears into collar then
in t
or
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swivel it to its guide.
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Prote AG.
– Insert selector fork for 1st - 3rd gears onto collar then swivel it
to its guide.

– Raise inner input shaft slightly. In this way, you can move out‐
put shaft 1 into its installation position.
– After insertion, position all selector forks in neutral.
– Make sure all selector forks and pinion shafts are correctly
seated.
1- Turn shafts.
2- Look at selector forks.
3- Turn gears on shafts a little back and forth. Also on differ‐
ential.
4- Grip inner and outer input shaft from below. Turn shafts
once.
• It must be possible to turn all parts back and forth without
catching.
AG. Volkswagen AG d
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– Insert magnet. d byV
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– Insert dowel sleeves.

rrectness of i
It is essential to leave gearbox in this position.

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– Mount support bridge - T10323- from below. co Vo
by lksw
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– Turn spindle against inner input shaft until finger-tight.

Shaft should only be supported. It is only allowed to be pushed

up until gear for 7th gear on inner input shaft -A- touches syn‐
chromeshed gear for 3rd gear on output shaft 1 -B-.
It is adequate for spindle to touch shaft.
This prevents inadmissible force being applied to gearbox later
on when gearbox housinggen AG
. is
Voput
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AG do should be absorbed
by support bridge
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– Drip ooil
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– Prepare
ss
a gearbox housing to be put on. c
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nl
• Make sure that gearbox housing is completely assembled.
pt
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• Flange surface is cleaned.
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• Oil guide is installed.
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hole
– Apply a bead of assembly adhesive - AMV 174 003 02- onto
spec
flange of clutch housing.
es, in part or in w
t to the co
• »Thickness of adhesive bead«: maximum 1 millimetre.
Adhesive is applied with hand-cartridge gun - V.A.G 1628- .
rrectness of i
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– Adhesive bead should seal oil space. Therefore, do not spray
l purpos
around holes.
– Put on gearbox housing. nf
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atio
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Note
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Do not grip cleaned flange surfaces when putting on gearbox

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– Place large inner diameter of tube - VW 416 B- onto inner ring.

– A second mechanic should hold gearbox housing in position
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– Apply targeted blows with a plastic hammer to drive inner input
shaft into its bearing.
– Make sure seating on guide bushes is correct.

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– Remove support bridge - T10323- from below.
– Screw new connecting bolts against gearbox housing. Do not

tighten them yet.
– A second mechanic turns gearbox whilst housing halves are
being tightened.

– To do this: engage 1st gear. agen

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– Knock cover of “inner input shaft” in until flush.
– Install connecting bolts of housing halves at clutch end.

Torque setting
Steel bolts: 20 Nm + 45°
Aluminium bolts: 10 Nm + 90°

– Install drain plug.
– Install oil seals of input shafts ⇒ page 63 .

If large oil seal has already been renewed, you do not need to
renew it again.
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– Install parking lock.
– Install new bolts.
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– Installing mechatronic unit ⇒ page 106 .

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– Install flange shafts or stub shafts, installing new sealing rings

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– Install dual clutch ⇒ page 30 .

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– Install lever and cover.
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– Put both breather caps -arrows- back on.

– Take gearbox off assembly stand.
Assembly of gearbox is completed.
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❑ Driving in ⇒ page 318
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⇒ page 366 .
in ⇒ page 317
❑ Pressing in
⇒ page 317 .
❑ Determining thickness ⇒ page 366 .
❑ Pressing in ⇒ page 316 .
11 - Bearing for the inner input shaft
❑ Remove to press out retaining ring
❑ Press in »new« bearing ⇒ page 316
12 - Retaining ring
❑ Always renew
4. Dismantling and assembling gearbox housing 315

Pressing in bearing for inner input shaft

– Press in bearing to stop.
– Install »new« retaining ring.
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– Press in bearing race to stop.

Prepare bearing races of output shafts 2 and 3 for pressing in

– First insert 1 shim into housing.
– Then position »correct« bearing race and drive bearing race
in using targeted, light taps until it can no longer drop out.
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-A- Output shaft bearing race 2
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-B- Output shaft bearing race 3

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Bearing is driven out using a suitable drift.

– Before driving out, place ring of thrust pieces for drive pinion
bearing - VW 470- under bearing.
– To prevent gearbox housing from rocking, also insert wedge -
T10357- under housing.
4. Dismantling and assembling gearbox housing 317

Drive in bearing race of differential

A second mechanic is required for driving in.
– Place thrust piece - T10380- on edge of workbench. Position
gearbox housing with area of bearing point on thrust piece,
and hold housing firmly like that.
– Second mechanic inserts oil ring and shim. Second mechanic
drives in bearing as far as stop.
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5 Dismantling and assembling clutch housing
1 - Clutch housing
❑ Remove outer input
shaft ⇒ page 297
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❑ Pressing in
⇒ page 321 .
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⇒ page 353 .
❑ Preparing for pressing in ⇒ page 321
❑ Pressing in ⇒ page 322 .
❑ Determining thickness ⇒ page 353 .
❑ Preparing for pressing in ⇒ page 320
❑ Pressing in output shaft 2 ⇒ page 320
12 - Outer input shaft
❑ Dismantling and assembling ⇒ page 323
13 - Centring sleeve
❑ Qty. 2
5. Dismantling and assembling clutch housing 319

Preparing output shaft bearing race 2 for pressing in

– First place thrust piece - T 10428- onto press bed.
– Insert shim and oil deflector.
– Then carefully drive bearing race in with a drift until it no longer
drops out.
Pressing in output shaft bearing race 2

– Place clutch housing »the wrong way around« on thrust piece
- T10428- .
Use installing sleeve - VW 455- so that pressure will be applied
to clutch housing in a controlled manner.
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Pulling out output shaft bearing race 1

Preparing output shaft bearing race 1 for pressing in

– First place tube - VW 415 A- under bearing seat.
This illustration show view »from below«. This means press pres‐
sure is not applied to clutch housing in an uncontrolled manner,
but is absorbed by tube.
5. Dismantling and assembling clutch housing 321

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Note
It may be that oil deflectors get in the way when internal puller is
being put on. Carefully knock down guide plates with 1 hammer.
Plates deformed in this way must be renewed during installation.

6 Dismantling and assembling outer in‐

put shaft
Overview
1- Outer input shaft
2- Retaining plate with bolts: lettering faces the gears - smooth
side towards the bearing
3- Bearing: pressing off ⇒ page 323 ; pressing on
⇒ page 323
4- Determining thickness of retaining ring ⇒ page 323
Outer input shaft - pressing off bearing

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– Select ring that is just small enough to still be installed.
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6. Dismantling and assembling outer input shaft 323

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7 Dismantling and assembling inner input

shaft
Overview: inner input shaft
1- Inner input shaft
2- Gear wheel for 5th gear: endoes
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4- Gear wheel for 3rd gear: pressing off ⇒ page 326 ; pressing
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7- Needle cage
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8- Needle cage; »large« needles
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9- Roller cage
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Pressing off gear wheel for 7th gear

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Pressing on gear wheel for 7th gear

– Carefully press on to stop.
7. 325
Pressing off gear wheel for 3rd gear
Pressing on gear wheel for 3rd gear

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– Align tube - 2040- on thrust plate - VW 401- so that shaft can

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Drive sensor ring onto »cooled« gear wheel for 5th gear
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7. 327
8 Dismantling and assembling output shaft 1 - overview
1 - Output shaft 1
2 - Needle bearing
3 - Synchromeshed gear for
2nd gear
4 - Synchro-ring
5 - Outer ring
6 - Synchro-ring
7 - Locking collar and synchro-
hub for 2nd and 4th gears
❑ Dismantling and assem‐
bling ⇒ page 338
8 - Synchro-ring
9 - Outer ring
cardiagn.com
10 - Synchro-ring
11 - Needle bearing
12 - Sleeve for needle bearing
4th gear
14 - Washer
Note
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20 - Synchro-ring
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21 - Locking collar and synchro-hub for 1st and 3rd gears

❑ Dismantling and assembling ⇒ page 338
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22 - Synchro-ring
23 - Outer ring
24 - Synchro-ring
25 - Needle bearing
27 - Synchromeshed gear for 1st gear
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❑ 60 Nm, 90° further.
31 - Bearing race
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• Bearing races are not allowed to be swapped over. They are paired with the bearing.
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32 - Bearing race
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• Bearing races are not allowed to be swapped over. They are paired with the bearing.
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❑ Pressing off ⇒ page 332

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shaft together.
8.1 Dismantling output shaft 1 partially

Output shaft 1 only needs to be dismantled partially in order to
adjust gearbox.
Dismantle output shaft completely if gearbox is to be cleaned or
if parts of shaft are to be renewed ⇒ page 331 .
8. Dismantling and assembling output shaft 1 - overview 329

– Insert protective jaw covers in vice, and clamp output shaft in

vice.
– Loosen bolt with socket, multi-point bit - T10061- , and remove
it.
Special wrench - T10035- can also be used.
Always renew the bolt after removing.
Note
To prevent the shaft from falling, position suitable items under the
press. It is also possible to hold shaft by hand.
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– Press synchromeshed gear for 1st gear
ised with bearing off output ara
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– Press synchromeshed gear for 3rd gear with locking collar and
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Assembling output shaft 1 ⇒ page 333 .

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8.2 Dismantling output shaft 1 completely

vice.
it.
Note
– Press synchromeshed gear for 1st gear with bearing off output
shaft.
– Remove needle bearing.
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8.3 Assembling output shaft 1
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In this procedure, you will see how output shaft 1 is assembled.
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• If bearing is pressed on, thrust plate - VW 447 i- must also be
Prote AG.
used for each pressing operation.

• Pressing off bearing: ⇒ page 332
• Pressing on bearing: ⇒ page 333
– Place needle bearing onto output shaft.

– Make sure that cage is not broken.
– Wet bearing with oil.

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chro-ring to locate its installation position before ring is clam‐
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ped by synchro-hub.
♦ Once the ring has found its seat, only continue pressing until
an increased force is felt. Then stop pressing immediately.
Synchromeshed gear for 2nd gear must have axial play. Gear
has reached its installation position as soon as force during
pressing rises. Continuing to press will force synchro-hub
against needle bearing and damage it.
After pressing, gear wheel must turn »freely« when shaft is in

horizontal position.
– Press on sleeve for needle bearing of synchromeshed gear for

4th gear.
Installation direction: lettering points »downwards«.
Note
Here also stop pressing immediately when you notice a rise in

force during pressing. Do not re-press!

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– Fit needle bearing. oris eo
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– Put on synchromeshed gear for 4th gear.

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Cop py
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– Press on washer.
Note
♦ Here also stop pressing immediately when you notice a rise in

♦ After pressing, gear wheel must turn »freely« when shaft is in
♦ Output shaft is assembled as far as this shim for purpose of
adjusting shaft.
WARNING
Do not assemble the output shaft further until the gearbox has
been adjusted ⇒ page 352 .


3rd gear.
Note

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– Fit needle bearing. d byV gu
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– Press on locking collar and synchro-hub.
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chro-ring to locate its installation position before ring is clam‐ cted agen
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ped by synchro-hub.
Synchromeshed gear for 3rd gear must have axial play. Gear



1st gear.
Note

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Gear wheel and rings can be placed on shaft together.
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– Press on bearing.
Note


– Tighten new bolt.

Special wrench - T10035- can also be used for tightening.
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8.4 Dismantling and assembling locking col‐ ol not
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Before dismantling, mark the installation position and orientation
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Dismantling and assembling 2nd and 4th gear locking collar and
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Lettered side of synchro-hub faces groove in locking collar.
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1 - Output shaft 2
2 - Needle thrust bearing
3 - Needle bearing
4 - Reverse gear wheel
5 - Washer
hub for 6th gear
bling ⇒ page 346
7 - Synchro-ring
8 - Needle bearing
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7th gear
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15 - Synchro-ring
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16 - Locking collar and syn‐

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17 - Synchro-ring
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21 - Bearings
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Note

shaft together.
22 - Bolt
❑ 60 Nm, 90° further.

23 - Bearing race
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❑ Removing and installingss⇒ page 319
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25 - Bearings
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❑ Pressing off ⇒ page 341
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– Press synchromeshed gear for 5th gear with bearing off output
shaft.
– Remove needle bearing.

– Press out output shaft completely.
Note
Press off bearing of output shaft 2.
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– First destroy cage of bearing.
Note
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341
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9. Dismantling and assembling output shaft 2 - overview
Press on bearing of output shaft 2.

– Assemble output shaft 2 ⇒ page 342 .
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Dismantling and assembling locking collar ⇒ page 346 .

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for 6th gear. C py
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– Wet bearing and friction surfaces with oil.
copy Vo
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– Press on washer for synchromeshed gear for 6th gear.

If this washer has lettering then position this side of shim »down‐
wards«.
Note
♦ Here also stop pressing immediately when you notice a rise in

♦ Output shaft is assembled as far as this shim for purpose of
adjusting shaft.
WARNING
Do not assemble the output shaft further until the gearbox has
been adjusted ⇒ page 352 .


7th gear.
Note

– Put on needle bearing, synchromeshed gear for 7th gear and

synchro-ring.
– Wet bearing and friction surface with oil.
– Put on locking collar with synchro-hub. Make sure circumfer‐
ential edge of sleeve is pointing »upwards«, and collar of
locking collar »downwards«.
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Rep. gr.35 - Gears, shafts cted agen
Prote AG.

5th gear.
Note

– Fit synchro-ring, needle bearing and gear wheel for 5th gear.
AG. Volkswagen AG d
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– Insert and tighten new bolt.

Special wrench - T10035- can also be used for tightening.

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9.3 Dismantling and assembling locking col‐
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Locking collar and synchro-hub for synchromeshed gear for 6th
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Locking collar and synchro-hub for synchromeshed gear for 7th

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1 - Output shaft 3
2 - Needle bearing
3 - Reverse gear synchro‐
meshed gear
4 - Synchro-ring
hub for reverse gear
bling ⇒ page 351
6 - Retaining ring
7 - Stop ring
8 - Parking lock gear
❑ Smooth side points to‐
wards shaft end, gen AG
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11 - Bearing race
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⇒ page 319
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13 - Bearings
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10.1 Dismantling output shaft 3
Note

– Press off parking lock gear together with bearing.
– Remove retaining ring.
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– Press out shaft.
Note

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Press on bearing of output shaft 3.
– Assemble output shaft 3 ⇒ page 349 .
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AG.
work on press.
• If bearing is pressed on, thrust plate - VW 447 H- must also be
used for each pressing operation.
• Pressing off bearing: ⇒ page 348
– Fit needle bearing.

– Wet bearing slightly with oil.

– Put on reverse gear synchromeshed gear, synchro-ring and

locking collar.
– Wet friction surface with oil.
– Press on synchro-hub and locking collar.
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AG. Volkswagen AG d
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Bear two things in mind when pressing:
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♦ Raise gear wheel and turn it at same
s time. This allows syn‐
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– Insert retaining ring.
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– Insert -stop ring-.

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– Put on parking lock gear and bearing.
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– Press on both together.
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ar
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10.3 Dismantling and assembling locking col‐
ss
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lar and synchro-hub of output shaft 3
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Dismantling and assembling locking collar and synchro-hub of
output shaft 3
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11 Notes on gearbox adjustment

Adjustment work is divided into 2 »sections«:
A - This involves finding shims

that are inserted into clutch
housing.
❑ This is the start of the
work. Objective is to
align output shafts 1 to 3
in clutch housing »in
one imaginary plane«.
This »imaginary plane« AG. Volkswagen AG d
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is defined by face end of Volksw
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outer input shaft. For d by ara
this procedure, refer to rise nte
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On gearboxes as of production
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date 06/2011 a shim is inserted
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underneath the bearing race of
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ility
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shown in the illustration. If fit‐
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B - During assembly of gear‐
box, »thickness« of these
shims determines force with
which shafts are »clamped«
rrectness of i
between both halves. These
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shims are inserted in gearbox

housing.
❑ For this procedure, refer
nf
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o
to ⇒ page 366
rm
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• Only once correct shims

o
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c
-A- have been calculated

or
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for clutch housing, or if

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there is no need for meas‐
o
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• Therefore, do not calculate yri
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shims -B- until shims -A- cop Vo
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are OK.
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Prote AG.
• Work with intact tools, make sure the workplace is clean.

• Avoid temperature differences between gearbox and adjusting
tool.
• Flange surfaces of both housing halves should be smooth and
neither »indented nor damaged«.
• Do not put on measuring table unless there are guide bushes
in housing.
• Do not swap over bearing races of same size, always renew
bearings on a shaft jointly.
• Follow this procedure step by step. Temperature differences,
such as between »summer and winter«, affect all measuring
tools that are used.
• Numbers given in the calculations below are in millimetres.
»Your measuring tools« and »dimensions on your gearbox«
will differ from the values stated here. Numerical values such

as these are always identified with this supplement:

-example-.
• Notes made during measurements should be legible and easy
to follow. Oily pieces of paper are not appropriate for this.
11.1 Calculating shims for clutch housing

♦ Measuring tool - T10425-
AG. Volkswagen AG d
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hole
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♦ Dial gauge - VAS 6079-
es, in part or in w
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♦ Universal dial gauge holder - VW 387- cu

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♦ Not shown: Depth gauge, digital 200 mm with measuring hook

- VAS 6619-
Brief description
This »section« explains how to calculate thickness of shims in
clutch housing. 3 shims are installed in total. There is 1 shim under
each output shaft. Differential does not have a shim here.
11. Notes on gearbox adjustment 353

AG. Volkswagen AG d
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n
c
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t.
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Cop py
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Prote AG.
This is the start of the work. Objective is to align output shafts 1

to 3 in clutch housing »in one imaginary plane«. This »imaginary
plane« is defined by face end of outer input shaft.
Oil deflectors are inserted under output shafts 2 and 3, which are
not shown here. For information about installation of shims, oil
deflectors and bearing races, refer to ⇒ page 319 .
Note
♦ Do not install any oil deflectors or shims when calculating which shims to use. Only install bearing races of
shafts.
♦ On gearboxes as of production date 06/2011 a shim is inserted underneath the bearing race of the differ‐
ential. The shim is not shown in the illustration. If fitted, it must be installed together with the bearing race.

Requirement:
• The sealing surface of the clutch housing must be clean,
smooth and neither »indented nor damaged«.
• Outer input shaft is installed ⇒ page 319 .
• Bearing races of all shafts and bearing race of differential are
installed ⇒ page 319 .
• No oil deflector and no shim is installed.
Note
For adjustment only: do not install any shims. Do not install any
oil deflectors.
– Place partially dismantled output shaft 1 and output shaft 2 into

bearing race.
To find out how »far« shafts are allowed to be assembled, refer
to ⇒ page 329 for output shaft 1, and ⇒ page 342 for output shaft
2.
cardiagn.com
AG. Volkswagen AG d
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– Make sure that dowel sleeves are inserted in clutch housing.
wit
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Assemble measuring tool - T10425- for work on clutch housing.

AG. Volkswagen AG d
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un
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– Place measuring tool - T10425- on dowel sleeves.
an
d
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– Place drift - T10425/3- on output shaft 1.

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Note
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All gears have burrs on their teeth. These burrs »disrupt« meas‐
r
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urement. This is intended to show -where- gear wheels are meas‐

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ured in following measurements.

n
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Measuring surfaces start at »roots« of teeth.

They extend as far as »first shoulder«. Shown here in “light” col‐
our in illustration.
Teeth themselves can be used for measurement. It is important
to make sure that depth gauge does not locate on burrs.
Start with output shaft 1.

– Fit depth gauge - VAS 6619- on outer input shaft. Shown here
in »green«. Set depth gauge to »zero«.
– Use depth gauge - VAS 6619- to measure on 4th gear wheel
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of output shaft 1. Shown here in »blue«.
G. Volkswage nA n AG d
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– Make a note of this value.
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– Call this value “A1aho”.ris nte
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AG. Volkswagen AG d
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CC 2010 ➤ , Eos 2006 rised
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7-speed dual clutch
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– Three measurements are taken. Call the other values “A1b”
nl
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and “A1c”.
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– Mark input shaft before turning it further.
ot p
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– Turn input shaft by 120° further in -direction of arrow-, and
h re
hole
repeat measurement. Then turn through another 120° and
spec
measure again.
es, in part or in w
t to the co
Note
rrectness of i
Gears of shafts have helical gearing. It is possible for shafts to be
l purpos
raised out of their bearing when they are turned.
nf
ercia
– To make sure that shafts remain in their bearing, tap drift -
orm
T10425/3- firmly with one hand whilst turning. Do not forget
m
atio
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headpiece - T10425/5- .
o
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Calculate the average from the 3 values “A1a”, “A1b” and “A1c”.
thi
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Formula: (A1a + A1b + A1c)/3 = A1

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Gear wheel for 4th gear has axial play on shaft. Measure the play
Co
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as follows:
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– Bolt universal dial gauge bracket - VW 387- to sealing surface

of clutch housing.
– Place measuring pin of dial gauge - VAS 6079- on gear wheel
for 4th gear.
– Set dial gauge to »0« with preload.
– Raise gear wheel for 4th gear as far as stop and note result of
measurement.
– Call this value “B1”.
– Calculation: “A1” minus “B1” = calculated shim thickness.
Calculated shim thickness Shim to be installed (in milli‐
metres)
of to
0.625 0.674 0.65
0.675 0.724 0.70
0.725 0.774 0.75
0775 0.824 0.80
0.825 0.874 0.85
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0.875 0.924 0.90 Volksw
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0.925 0.974 0.95 rise
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1.075 1.124 1.10

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1.125 1.174 1.15
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1.175 1.224 1.20
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1.225 1.274 1.25
ole,
spec
1.275 1.324 1.30
t to the co
1.325 1.374 1.35
1.375 1.424 1.40
rrectne
1.425 1.474 1.45
1.475 1.524 1.50
ss o
1.525 1.574 1.55
cial p
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1.575 1.624 1.60
mer
1.625 1.674 1.65 atio

om
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1.675 1.724 1.70

i
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– From the supplied shims, measure and select the one that is
t.
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Later on, only insert this 1 shim. Not 2.
Keep this shim carefully, do not mix it up with any other shims.
Continue with output shaft 2.

– Place drift - T10425/3- on output shaft 2.

Turn mark on outer input shaft »into alignment« with output shaft
2.
Note


headpiece - T10425/5- . en AG. V
olkswagen AG
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– Fit depth gauge - VAS 6619- on outer input shaft. Shown here
ot
cardiagn.com
wit
in »green«. Set depth gauge to »zero«.
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Use depth gauge - VAS 6619- to measure on 6th gear wheel
co Vo
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of output shaft 2. Shown here in »red«.
agen
Prote AG.
– Make a note of this value.

– Call this value “A2a”.

– Three measurements are taken. Call the other values “A2b”

and “A2c”.
Use »existing« mark for orientation.
– Turn input shaft by 120° further in -direction of arrow-, and
repeat measurement. Then turn through another 120° and agen
AG. Volkswagen AG d
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Note au ac
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headpiece - T10425/5- .
spec
Calculate the average from the 3 values “A2a”, “A2b” and “A2c”.
t to the co
Formula: (A2a + A2b + A2c)/3 = A2
rrectne
Gear wheel for 6th gear has axial play on shaft. Measure the play
cardiagn.com
as follows:
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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fo
en
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

en AG. V
olkswagen AG
ag does
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Vol gu
– Bolt universal dial gauge bracket - VW ed 387- to sealing surface
by ara
nte
of clutch housing. thoris eo
au ra
– Place measuring pin of dial gauge
ss - VAS 6079- on gear wheel c
ce
le
for 6th gear.
un
pt
an
d
itte
– Set dial gauge to »0« with preload.
y li
rm
ab
pe
ility
– Raise gear wheel for 6th gear as far as stop and note result of
ot
wit
measurement.
, is n
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hole
– Call this value “B2”.
spec
es, in part or in w
– Calculation: “A2” minus “B2” = calculated shim thickness.
t to the co
Calculated shim thickness Shim to be installed (in milli‐
metres)
rrectness of i
of to
l purpos
0.625 0.674 0.65

0.675 0.724 0.70
nform
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0.725 0.774 0.75

m
a
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0775 0.824 0.80
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0.825 0.874 0.85
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0.875 0.924 0.90
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en
0.925 0.974
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0.95
n
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0.975 1.024 1.00
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1.025 1.074 1.05
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1.075 1.124 Prote 1.10
AG.
1.125 1.174 1.15

1.175 1.224 1.20
1.225 1.274 1.25
1.275 1.324 1.30
1.325 1.374 1.35
1.375 1.424 1.40
1.425 1.474 1.45
1.475 1.524 1.50
1.525 1.574 1.55
1.575 1.624 1.60
1.625 1.674 1.65
1.675 1.724 1.70
1.725 1.774 1.75
1.775 1.824 1.80
1.825 1.874 1.85
1.875 1.924 1.90

required.
WARNING
Keep this shim carefully, do not mix it up with any other shims.
– Remove output shafts 1 and 2 and assemble them.
♦ Output shaft 1 ⇒ page 333
♦ Output shaft 2 ⇒ page 342
♦ Then adjust output shaft 3
– First measure thickness of synchromeshed gear for reverse

gear.
Note
cardiagn.com
It is important to make sure that the measurement is not per‐
formed on the burr of the teeth.
– Make a note of this value and call it “B3”.
lkswage es n
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Adjust output shaft 3.

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Output shaft 3 is set correctly when dimension -K- = 19.9 milli‐

y li
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metres.
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– Place output shaft 3 into bearing.

is n
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– Take bearing race that is to be installed and place onto shaft.

– Place mandrel - T10425/3- onto shaft.
AG. Volkswagen AG d
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– Zero depth gauge - VAS 6594- on synchromeshed gear for
rm
ab
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pe
reverse gear.
ility
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Note
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es, in part or in w
t to the co
It is important to make sure that the measurement is not per‐
formed on the burr of the teeth.
rrectness of i
l purpos
nform
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– Measure distance from housing flange surface. opy
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– Make a note of this value and call it “A3”.
by
cted agen
Prote AG.
– To determine the required shim, subtract the »thickness« of

synchromeshed gear for reverse gear “B3” from the value
“A3”. Call this value “C”.
Formula: “A3” minus “B3” = “C”

As a reminder: Output shaft 3 is set correctly when dimension

-K- = 19.9 millimetres.
– Therefore, now calculate a shim to arrive at -K- = 19.9 milli‐
metres.
Based on dimension -K- and dimension “C”, the shim thickness
is calculated as indicated
wage
below.
n AG. Volkswagen AG
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Formula:ed19.9
by millimetres minus value for “C”
gu
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shimhthickness.
or
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ac
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Calculated
s shim thickness Shim to be installed (in milli‐
ce
e
metres)
nl
pt
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an
itte
of to
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ility
0.775 0.824 0.80
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0.825 0.874 0.85
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hole
0.875 0.924 0.90
spec
es, in part or in w
0.925 0.974 0.95
t to the co
0.975 1.024 1.00
1.025 1.074 1.05
rrectness of i
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1.075 1.124 1.10
l purpos
1.125 1.174 1.15

1.175 1.224 1.20 nf
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or
1.225 1.274 1.25
m
m
atio
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1.275 1.324 1.30

o
n in
or c
1.325 1.374 1.35

thi
te
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1.375 1.424 1.40

o
r
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o
1.425 1.474 1.45

f
en
ng
t.
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op
1.475 1.524 1.50
C py
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1.525 1.574 1.55
pyri by
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Prote AG.
required.
WARNING
1- Keep this measured shim carefully, do not mix it up with any

other shims.
2- Place measuring tool - T10425- to one side.
3- Install measured shims for output shafts, bearing races and
oil deflectors ⇒ page 319 .
4- Assembling output shaft 1 ⇒ page 333 .
5- Assembling output shaft 2 ⇒ page 342 .
6- Insert all output shafts in clutch housing.
7- Put measuring tool - T10425- back onto clutch housing.
– Calculating shims for gearbox housing ⇒ page 366 .

7-speed dual clutch gearbox 0AM. V-olEdition
gen AG
12.2016
kswagen AGd
wa oes
olks not
byV gu
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12 Calculating shims for gearbox hous‐
ris nte
tho eo
au ra
ing ss c
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♦ Measuring tool - T10425-
pe
ility
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es, in part or in w
t to the co
rrectness of i
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♦ Not shown: Depth gauge, digital 300 mm - VAS 6594-
n in
r
te o
thi
Brief description
cardiagn.com
s
iva
do
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c
This »section« explains how to calculate thickness of shims in
um
fo
en
gearbox housing. 4 shims are installed in total. There is 1 shim
ng
t.
yi Co
on each output shaft. Differential has 1 shim as well here. t. Cop py
rig
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AG. Volkswagen AG d
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First calculate how »high« shafts stand in clutch housing.

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Then measure how »deep« gearbox housing is.

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Subtract both »heights« from one another.

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The correct shim can then be calculated in each case.
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For information about installation of shims and bearing races after
»calculation«, refer to ⇒ page 315 .
Comply with following work instructions:
– Measure height of your drift - T10425/3- .
12. Calculating shims for gearbox housing 367

– Zero depth gauge - VAS 6594- on shoulder for bearing races.
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– Measure height of drift.
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Make a note of your mandrel height. Its height is needed in sub‐

sequent calculations. Identify height of mandrel as D=? mm.
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Example: 230.03 mm
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Each drift has a different height. Therefore always measure drift

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Start with output shaft 1. t. C rig
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– Put on bearing race, drift and headpiece.

– Turn outer input shaft. Firmly press down drift with one hand
whilst turning.
This locates output shaft 1 correctly in its bearing seat.
– Remove headpiece - T10425/5- from drift again and place it
to one side.

– Zero depth gauge - VAS 6594- on measuring tool - T10425- .

– Measure distance (height) from surface of measuring tool -
T10425- to flange surface of clutch housing.
Always measure close to the respective bearing position.
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– Measure distance (height) from drift to measuring tool -

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“a1” + “b1” minus height of drift “D” = height of output shaft 1 Prote AG.
Example:
264.97 mm + 163.85 mm - 230.03 mm = 198.79 mm
– Note calculated result for “height of output shaft 1”.
Example: “height of output shaft 1” = 198.79 mm
You will require this value later.

– Put on bearing race which is to be installed, drift and head‐

piece.
whilst turning.
This locates output shaft 2 correctly in its bearing seat.
– Remove headpiece - T10425/5- from drift again and place it
to one side.
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– Measure distance (height) from surface of measuring AGtool
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– Call this value “a2”.

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– Note reading.
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“a2” = 264.93 mm
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T10425- .
– Note reading.
Example:
“b2” = 138.99 mm
Calculation:
“a2” + “b2” minus height of drift “D” = height of output shaft 2
Example:
264.93 mm + 138.99 mm - 230.03 mm = 173.89 mm
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– Put on bearing race which is to be installed, drift and head‐
piece.
whilst turning.
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This locates output shaft 3 correctly in its bearing seat. agen oes
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– Call this value “a3”.
– Note reading.
Example:
“a3” = 264.92 mm
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“b3” = 85.59 mm
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“a3” + “b3” minus height of drift “D” = height of output shaft 3

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264.92 mm + 85.59 mm - 230.03 mm = 120.48 mm

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1- Place measuring tool - T10425- to one side. t. Cop py
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2- Remove output shafts 1, 2 and 3 p by
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3- Install differential. Prote AG.
4- Put measuring tool - T10425- back onto clutch housing.

5- Place drift - T10425/3- with adapter - T10425/4- onto meas‐
uring tool - T10425- .

– Zero depth gauge - VAS 6594- on shoulder for bearing race.

Make sure which is shoulder for bearing race.
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– Measure height of drift - T10425/3- with adapter - T10425/4- .
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Note length (height) of drift with adapter. Its height is needed in
subsequent calculations. Name length (height) of drift E=? mm.
Example: E = 256.00 mm
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Note
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Each drift responds to ambient temperature. Therefore measure
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mandrel prior to each gearbox repair. When measuring, make
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Always use guide pins - 3411- to install and remove differential. ht. Cop py
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– Put on bearing race, adapter, drift and headpiece.

– Turn differential. Firmly press down drift with one hand whilst
turning.
The differential will then seat correctly in its bearing seat.

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– Note reading.
– Call this value “a4a”.
Measure at 2 more points to keep inaccuracies as low as possible.
Call these values “a4b” and “a4c”.
– Calculate average of these 3 measuring
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• “a4” = (264.96 mm + 264.98 mm + 264.94 mm)/ 3 = 264.96 mm
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• Result: Dimension “a4” = 264.96 mm

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T10425- .
– Note reading.
Example:
“b4” = 6.21 mm
Calculation:
“a4” + “b4” minus height of drift “E” = height of differential
Example:
264.96 mm + 6.21 mm - 256.00 mm = 15.17 mm
– Note calculated result for “heightgeof
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– Secure gearbox housing in a vice using support bridge -
T10323- .
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– Insert dowel sleeves in gearbox housing.

– Set measuring tool on gearbox housing.
– Place measuring tool - T10425- on dowel sleeves.
Start again with measurements for output shaft 1:
Bearing preload for this output shaft 1 is: 0.25 mm.
– Zero depth gauge - VAS 6594- on flange surface.
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Note
When zeroing, press against leg of depth gauge -arrow-.
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– Measure at seat of bearing race in gearbox housing.

– Note calculated result for “depth of output shaft 1”.
Example: “depth for output shaft 1” = 199.89 mm
Now value for “height of output shaft 1” is required.
– Complete following calculus: “depth for output shaft 1” minus
“height of output shaft 1” plus bearing preload 0.25 mm = cal‐
culated shim thickness
199.89 mm minus 198.79 mm + 0.25 mm = 1.35 mm
– Note calculated result for “shim thickness”.
Example: “calculated shim thickness” = 1.35 mm
Calculated shim thickness in Shim to be installed (in milli‐
gearbox housing for output shaft metres)
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1.775 1.824 1.80
1.825 1.874 1.85

– From the shims that have been supplied, measure shim that
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WARNING
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1.575 1.624 1.60
1.625 1.674 1.65
1.675 1.724 1.70
1.725 1.774 1.75
1.775 1.824 1.80
1.825 1.874 1.85

required.
WARNING
Continue with measurements for output shaft 3:
Bearing preload for this output shaft 3 is: 0.15 mm. AG. Volkswagen AG d
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1.075 1.124 1.10
1.125 1.174 1.15
1.175 1.224 1.20
1.225 1.274 1.25
1.275 1.324 1.30
1.325 1.374 1.35
1.375 1.424 1.40
1.425 1.474 1.45
1.475 1.524 1.50
1.525 1.574 1.55
1.575 1.624 1.60
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required.
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Later on, only insert this 1 shim. Not 2. aut ra
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Continue with measurements for differential:
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Bearing preload for differential is: 0.20 mm.
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Remove measuring tool - T10425- .
Calculate depth of differential:
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To measure depth of differential as accurately as possible, meas‐
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results.
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– Place two rulers - T40100- on flange surface.
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– Measure 3 times around bearing seat -arrows-.

Measure carefully.
– Make a note of average of these 3 measurements.
Example: 16.28 mm + 16.27 mm + 16.29 mm3 = 16.28 mm
Example: first measurement result = 16.28 mm
Second measurement is taken:

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Measure carefully.
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Example: second measurement result = 16.25 mm

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– Zero depth gauge - VAS 6594- on flange surface. cop Vo
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Measure carefully.
Example: third measurement result = 16.23 mm
Calculate average of all 3 measured values.
– Correct mathematical rounding: = 16.25 mm
– Note calculated result for “depth of output shaft”.
Example: “depth for differential” = 16.25 mm
Now value for “height of differential” is required.
– Calculate as follows: “depth for differential” minus “height of
differential” plus bearing preload 0.20 mm = calculated shim
thickness
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1.375 1.424 1.40

required.
WARNING
– Installing shims and bearing races of gearbox housing

⇒ page 315 .
– Assembling gearbox ⇒ page 304 .
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13 Parking lock
⇒ “13.1 Removing and installing cover for parking lock”,
page 386
⇒ “13.2 Removing and installing parking lock”, page 387
13.1 Removing and installing cover for park‐

ing lock
♦ Removal lever - 80 - 200-
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Removing
• Gearbox is installed.
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13.2 Removing and installing parking lock

♦ Hexagon bit, long reach - 3410-
Removing
• Gearbox is installed.
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13. Parking lock 387

– Remove bolts -2- and pull parking lock -1- off dowel sleeves
-arrows-.
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39 – Final drive - front differential

1 Oil seals
Gearbox with stub shafts -A-.
Right ⇒ page 389
Left ⇒ page 390
Gearbox with flange shafts -B-.
Right ⇒ page 392
Left ⇒ page 394
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– Insert stub shaft.
– Tighten new countersunk bolt for stub shaft to 30 Nm.
– Reinstall drive shaft ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
– Renew gear oil ⇒ page 289 .
– Install noise insulation and tighten, specified torques ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Overview - noise
insulation .
1.2 Renewing oil seal for left stub shaft

Right side ⇒ page 389 .
390 Rep. gr.39 - Final drive - front differential

♦ Press tool - 3305-

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1. Oil seals 391

– Pull out stub shaft oil seal with multi-purpose tool -VW 771-
and puller hooks -VW 771/37-.
Seal can also be removed using extractor tool - T20143- .
– Half-fill space between sealing lip and dust lip with sealing
grease .
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shaft using drift sleeve - 40 - 20- . Do not use a hammer.
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Rep. gr. 50 ; Assembly overview - noise insulation .
– Remove drive shaft deflector cap from engine -arrows-, if fit‐

ted.
Unbolt drive shaft from gearbox.
– Raise drive shaft as high as possible and secure. Take care
not to damage paint on drive shaft in the process.
1. Oil seals 393

– Remove right flange shaft of gearbox.

– Pull out flange shaft.
– Pry seal out using assembly lever.
– Half-fill space between sealing lip and dust lip of new seal with
sealing grease .
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1. Oil seals 395


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thread.
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drive shafts .

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shafts .
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1. Oil seals 397

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Service

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg K0058895220

5.5 Working with tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.6 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

13.7 Removing gearbox, Polo 2010 ►, 1.6 l - 66 kW diesel engine . . . . . . . . . . . . . . . . . . . . . . 152

110 kW Eco-Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

13.18 Removing gearbox, Golf 2009 ►, 1.6 l - 75 kW petrol engine . . . . . . . . . . . . . . . . . . . . . . 218

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

13 Parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386

13.2 Removing and installing parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

1.2 Renewing oil seal for left stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

KHN - Gearbox code letters n AG. Volkswagen AG do

0026 - Serial number

2 Overview - power transmission

2 Rep. gr.00 - Technical data

3 Code, engine allocation

3.1 Polo 2010 ►

Allocation: gearbox codes for diesel engines

Allocation: gearbox codes for petrol engines

NQA, NTP, NTX, PMH, PVU, QQT, PKM, PMH, PVU,

PKU, PKM, PMH, QGV QGV, QQT

Allocation: gearbox codes for diesel engines

LQN, MLE, MPL, KHM, LKF, LKL,

NAV, NQE, NTT, LPH, LSR, MGJ

PKQ, PML, PVX,

1.6 l - 77 kW TDI 1.9 l - 77 kW TDI

3.3 Golf 2004 ►

Allocation: gearbox codes for diesel engines

3. Code, engine allocation 3

quired for a repair.

FSI 110 kW 118 kW 118 kW

3.5 Passat 2006 ►

KHN, LPJ, LSS, MLC,

3.6 Golf 2009 ►

Allocation: gearbox codes for petrol engines

Allocation: gearbox codes for diesel engines

3.7 Golf Plus 2009 ►

4 Rep. gr.00 - Technical data

Allocation: gearbox codes for petrol engines

Allocation: gearbox codes for diesel engines

1.6 l - 77 kW TDI 1.9 l - 77 kW TDI

3.9 Scirocco 2009 ►

NAZ, NQA, NQJ,

NTP, NTX, PKM,

PKU, PMH, PMQ,

1.4 l - 90 kW FSI 1.4 l - 118 kW TSI

3. Code, engine allocation 5

Lubricant Gear oil for dual clutch gearbox 0AM

Capacities Hydraulic fluid section in mechatronic unit for

Risk of damage to gearbox.

6 Rep. gr.00 - Technical data

5 General repair instructions

5. General repair instructions 7

– Cover the hole with a cloth before installation work.

8 Rep. gr.00 - Technical data

In some vehicles, a cover is fitted over the engaging levers.

cause irreparable damage to the bearings during operation of the

Do not mix »additives« in oil.

Oil which has been drained out cannot be added again.

Be careful when working with oil. Dispose of drained oil ac‐