Caja de Cambios Touareg PDF

Service
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Touareg 2003 ➤
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6-speed manual gearbox 08D
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Edition 08.2017
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data swage
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30 - Clutch d b ua
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34 - Controls, housing auth or
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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 © 2017 Volkswagen AG, Wolfsburg K0058961820

Touareg 2003 ➤
6-speed manual gearbox 08D - Edition 08.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Removing, installing and adjusting clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Removing and installing clutch pedal switch F194 (interlock switch) . . . . . . . . . . . . . . . . . . 13
1.5 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.6 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.8 Assembly overview - hydraulics (RHD) . . . . .lk.sw. a.g.e.n A . . . . . . . . . . .A.G.d.oe. s.n. . . . . . . . . . . . . . 19
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1.9 Removing and installing master cylinder ed .by.V. . . . . . . . . . . . . . . . . . . . . . . .t g. u.ar.a . . . . . . . . . 21
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1.10 Bleeding clutch mechanism . . . . . .th.or.i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e.o . . . . . . 22
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2 Repairing clutch release mechanism ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . 24
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2.1 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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4 Check and, if necessary, reset adjuster ring of self-adjusting pressure plate of new clutches
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 I - Removing and installing gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1.3 II - Repairing gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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1.4 III - Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . 40

1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.6 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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2.1 Removing and installing gearbox, vehicles with 5-cylinder diesel engines . . . . . . . . . . . . 52
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2.2 Removing and installing gearbox, vehicles with 6-cylinder diesel engines . . . . . . . . . . . . 59
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2.3 Removing and installing gearbox, vehicles with 6-cylinder petrol engine . . . . . . . . . . . . . . 66
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2.4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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3 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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4 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Assembly overview - components on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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4.2 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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4.3 Renewing locking pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5 Renewing seals and sealing covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.1 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.3 Renewing seals for rotary gear and gate selector shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.4 Renewing layshaft cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6 Selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
Touareg 2003 ➤
6.1 Removing and installing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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ii Contents
Touareg 2003 ➤
00 – Technical data
1 Gearbox identification
(VRL010813; Edition 08.2017)
The 6-speed 08D manual gearbox is installed in conjunction with
the 6-cylinder injection engine as well as the 5 and 6-cylinder TDI
engines in the Touareg 2003 ▸.
⇒ “1.1 Location on gearbox”, page 1 .
⇒ “1.2 Identification code, assembly allocation, capacities”, page
1.
1.1 Location on gearbox

Location on gearbox at either -arrow 1- or -arrow 2-
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Code letters and date of manual gearbox manufacture -arrow-
Example FEA 10 04 03
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Additional data depend on manufacture.
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1.2 Identification code, assembly allocation, capacities
Manual gearbox 6-speed, 08D
Codes FDZ FEA GXB
Manufactured from 07.02 10.02 11.04
02.07 10.08 10.08
to
Allocation Model Touareg 2003 ► Touareg 2003 ► Touareg 2003 ►
Engine 3.2 l - 162 kW 2.5 l - 128 kW 3.0 l - 165 kW
3.2 l - 177 kW turbo diesel turbo diesel
3.6 l - 206 kW
Capacity of manual gearbox 1.8 l
1. Gearbox identification 1
Touareg 2003 ➤
Glean following data from ⇒ Electronic parts catalogue (ETKA) :

♦ Gear oil
♦ Clutch allocation
♦ Allocation of transfer box according to gearbox identification
code
♦ Allocation of front and rear final drives according to engine
code
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Touareg 2003 ➤
2 Overview - power transmission

Designation:
1 - 6-speed manual gearbox

08D
2 - Transfer box
3 - Rear propshaft
4 - Rear final drive
5 - Front propshaft
6 - Front final drive
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2. Overview - power transmission 3

Touareg 2003 ➤
3 Calculating overall gear ratio “i”

Example:
6th gear Constant Final drive
mesh gears
Drive gear ZG1 = 49 ZK1 = 31 ZA1 = 10
Driven gear ZG2 = 31 ZK2 = 41 ZG2 = 37
i = ZG2 : ZG1 1)
iG = Gear ratio = ZG2 : ZG1= 31 : 49 = 0.633
iK = Constant mesh gears ratio = ZK2 : ZK1 = 41 : 31 = 1.323
iA = final drive ratio = ZG2 : ZG1 = 37 : 10 = 3.700
itotal = Overall ratio = total ratio = iG x iK x iA = 0.633 x 1.323 x
3.700 = 3.099
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
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4 Rep. gr.00 - Technical data

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To ensure flawless and successful gearbox repairs, the greatest
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care and cleanliness as well as the use of good and proper tools
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are essential. Of course, the basic rules for safety also apply dur‐
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ing repair work.
A number of general notes on the individual repair procedures,
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which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
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♦ The removal and installation of components on the outside of

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♦ When installing the manual gearbox, ensure that the dowel
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♦ When installing mounting brackets or waxed components,
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clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue “ETKA” .
♦ When exchanging a manual gearbox, fill with gear oil to lower
edge of filler hole ⇒ page 78 .
♦ Capacities and specifications ⇒ page 1 .
Gaskets and seals
After removing gaskets and seals, always inspect contact surfa‐
ces of housing and shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing radial oil seals, half-fill space between sealing
lips with sealing grease -arrow-.
♦ For grease allocation, refer to ⇒ Electronic parts catalogue
(ETKA) .
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
Sealant
♦ For allocation of sealant , refer to ⇒ Electronic Parts Catalogue
(ETKA) .
♦ Thoroughly clean housing joint surfaces before applying seal‐
ant .
♦ Apply sealant uniformly and not too thickly.
♦ Breather holes must remain free of sealant .
4. Repair instructions 5
Touareg 2003 ➤
Locking devices
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6 Rep. gr.00 - Technical data

Touareg 2003 ➤
♦ Renew retaining rings.

♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot must be in line
with direction of force.
Nuts and bolts
♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Renew self-locking bolts and nuts after each removal. AG. Volkswagen AG d
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♦ Use a thread chaser to clear residual locking fluid from all
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threaded holes into which self-locking bolts are to be screwed.
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Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
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When reconnecting battery, refer to ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
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♦ When removing gearbox, remove clutch slave cylinder without

disconnecting pipes.
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♦ If the clutch slave cylinder is removed with the hydraulic line

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♦ Ensure that the pressure plate does not cant: loosen and tight‐
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♦ If the clutch pedal does not return to its initial position after cted agen
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having been depressed, the clutch mechanism must be bled.
The clutch mechanism should be bled at the same intervals
as the brake system.
Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ In order to reduce the smell of a burned clutch, the clutch
housing as well as the stopping face of the flywheel must be
thoroughly cleaned with a cloth.
4. Repair instructions 7
Touareg 2003 ➤
30 – Clutch
1 Repairing clutch mechanism
⇒ “1.1 Overview”, page 8
⇒ “1.2 Assembly overview - pedal cluster”, page 10
⇒ “1.3 Removing, installing and adjusting clutch pedal switch F36
”, page 12
⇒ “1.4 Removing and installing clutch pedal switch F194 (interlock
switch)”, page 13
⇒ “1.5 Removing and installing over-centre spring”, page 14
⇒ “1.6 Removing and installing clutch pedal”, page 15
⇒ “1.7 Assembly overview - hydraulics (LHD)”, page 16
⇒ “1.8 Assembly overview - hydraulics (RHD)”, page 19
⇒ “1.9 Removing and installing master cylinder”, page 21
⇒ “1.10 Bleeding clutch mechanism”, page 22
1.1 Overview
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♦ Note radio code for vehicles with coded radio.
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Disconnect battery ⇒ Electrical system;
s Rep. gr. 27 ; Disconnecting and reconnecting battery .
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♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting
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♦ Grease all bearing points and contact surfaces.
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

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8 Rep. gr.30 - Clutch

Touareg 2003 ➤
I - Assembly overview - pedal

cluster ⇒ page 10
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 16
II - Assembly overview - hy‐
draulics (RHD) ⇒ page 19
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es, in part or in w
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1. Repairing clutch mechanism 9

Touareg 2003 ➤
AG. Volkswagen n AG do
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1.2 Assembly overview - pedal cluster
V
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th or
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ss
1 - Seal
ce
le
un
pt
❑ Self-adhesive
an
d
itte
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❑ Renew after removing
erm
ab
ility
bearing block
ot p
wit
is n
❑ Bond to mounting
h re
ole,
bracket for pedal clus‐
spec
ter.
t to the co
2 - Self-locking hexagon nut,
20 Nm
❑ Renew
rrectne
3 - Pedal cluster mounting
s
bracket
s o
cial p
f
❑ To renew:
inform
mer
♦ Removing and installing
atio
brake servo ⇒ Rep. gr. 47 ;
om
n
Removing and installing
c
i
or
n
brake servo
thi
te
sd
iva
o
r
♦ Removing and installing

p
cum
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fo
dash panel ⇒ Rep. gr. 70 ;
en
ng
t.
yi
Removing and installing
Co
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dash panel t. C rig
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♦ Bolt mounting bracket to
co Vo
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cted
mounting plate with 23 Nm
agen
Prote AG.
torque
4 - Bearing mounting
❑ Bears brake pedal and
mounting bracket for
clutch pedal.
5 - Self-locking hexagon nut,
20 Nm
❑ Renew
6 - Bolt
❑ For clutch pedal mounting bracket
7 - Seal
❑ Renew after removing bearing block
❑ Bond to mounting bracket for pedal cluster
8 - Bolt
❑ 10 Nm
❑ for master cylinder on bulkhead
9 - Master cylinder
❑ Removing and installing ⇒ page 21
10 - Support
❑ Renew only with master cylinder removed
❑ Detaching ⇒ page 19
❑ Pressing on ⇒ page 19
12 - Clutch pedal

Touareg 2003 ➤
13 - Cap
❑ For clutch pedal
14 - Retaining clip
❑ Always renew
15 - Over-centre spring
❑ Dismantling and assembling ⇒ page 11
Volkswa
16 - Bearing bush agen
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❑ Bears over-centre spring in mounting
ed bracket
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for clutch pedal. gu
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17 - Buffer stop au
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❑ Clip into mounting bracket fors clutch pedal.
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nl
pt
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18 - Securing clip
an
itte
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❑ Insert in pivot pin ⇒ Item 19 (page 11) .
erm
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ility
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❑ Lock locating mechanism in mounting bracket for clutch pedal ⇒ page 15 .
wit
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❑ Always renew
h re
hole
spec
es, in part or in w
t to the co
❑ Bears clutch pedal in mounting bracket for clutch pedal.
❑ Must be locked in mounting bracket for clutch pedal by means of securing clip ⇒ Item 18 (page 11)
⇒ page 15 .
rrectness of i
20 - Securing clip
l purpos
❑ Always renew
21 - Clutch pedal mounting bracket
nform
mercia
22 - Clutch pedal switch - F36-
at
om
io
❑ Removing, installing and adjusting ⇒ page 12
n
c
in t
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23 - Clutch pedal switch - F194-

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❑ (Interlock switch)
um
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❑ Vehicle can be started only when clutch pedal is completely depressed.

n
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op py
❑ Removing, installing and adjusting ⇒ page 13
t. C rig
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Dismantling and assembling over-centre spring
1- Housing
2- Washer
3- Compression spring
4- Guide
5- Pin
Note
Note installation position of compression spring ⇒ page 11 .

Touareg 2003 ➤
1.3 Removing, installing and adjusting

clutch pedal switch - F36-
To make sure the clutch pedal switch is firmly seated, install it only
once.
1.3.1 Removing
– Remove lower cover on driver side ⇒ General body repairs,
interior; Rep. gr. 68 ; Removing andwinstalling
agen
AG. Vofootwell covers
lkswagen AG
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– Remove trim on driver side e⇒
d b General body repairs, interior;
y ara
nte
Rep. gr. 70 ; Removingthand
or
is installing dash panel .
eo
au ra
– Pull connector off clutch
ss pedal switch - F36- . c
ce
le
un
pt
– Turn clutch pedal switch - F36- -2- on housing 45° anti-clock‐
an
d
itte
wise and pull out of support.
y li
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1.3.2 Installing and adjusting new clutch pedal

m
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tion in
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Install in the reverse order of removal, observing the following.

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Distinguishing between clutch pedal switches

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Clutch pedal switch

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-A- = »without light-coloured • Pull plunger out fully prior to
ht. rig
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tip« on plunger head -arrow- installation.
py by
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-B- = »with light-coloured tip« • Plunger is not allowed to be
on plunger head -arrow- pulled out.
• Clutch pedal must be in rest position.

Clutch pedal switch »without light-coloured tip« on plunger head
-arrow- ⇒ figure above.

Touareg 2003 ➤
Note
♦ First, check the clutch pedal switch.

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♦ Stop -A- must be located in front of shoulder -B-. y Volksw not
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♦ The stop is then located directly behind the mounting ishook
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-C-. th
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If this is not the case, the plunger must not be pulled out.
an
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Otherwise, the clutch pedal switch will be destroyed.
erm
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ility
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The position of the stops -A- and -C- must be modified:
wit
is n
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– Push in plunger to stop -arrow 1-. ole,
spec
t to the co
– At the same time, turn upper part of clutch pedal switch to stop
in -direction of arrow 2-.
– Now, before installing clutch pedal switch , pull out plunger
rrectne
completely.
Continuation for all
ss o
cial p
f
– Now insert clutch pedal switch - F36- into assembly opening.
inform
mer
– To lock, turn clutch pedal switch - F36- on housing clockwise
atio
m
through 45°.
o
n
c
i
or
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– Push connector onto clutch pedal switch - F36- .
thi
te
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– Install trim on driver side ⇒ General body repairs, interior; Rep.
pr
cum
r
fo
gr. 70 ; Removing and installing dash panel .
en
ng
t.
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op
– Install lower cover on driver side ⇒ General body repairs, in‐ C py
t. rig
terior; Rep. gr. 68 ; Removing and installing footwell covers .
gh ht
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1.4 Removing and installing clutch pedal
AG.
switch - F194- (interlock switch)
1.4.1 Removing
To make sure the clutch pedal switch is firmly seated, install it only
once.
interior; Rep. gr. 68 ; Removing and installing footwell covers .
– Remove trim on driver side ⇒ General body repairs, interior;
Rep. gr. 70 ; Removing and installing dash panel .
– Pull connector off clutch pedal switch - F194- .
– Turn clutch pedal switch - F194- -1- on housing 45° anti-clock‐
wise and pull out of support.

Touareg 2003 ➤
1.4.2 Installing and adjusting new clutch pedal

switch agen
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Install in the reverse order of removal, observing the following. ed b y V gu
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The clutch pedal must always remain in rest position (do not aut de‐
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press) during the installation of the clutch pedal switch. ss c
ce
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nl
– Pull plunger completely out of clutch pedal switch - F194- .
pt
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– Now insert clutch pedal switch - F194- into assembly opening.
erm
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ility
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– To lock, turn clutch pedal switch - F194- on housing clockwise
wit
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through 45°.
h re
hole
spec
– Depress clutch pedal to stop.
es, in part or in w
t to the co
– Push connector onto clutch pedal switch - F194- .
rrectness of i
– Install lower cover on driver side ⇒ General body repairs, in‐
l purpos
nf
1.5 Removing and installing over-centre
ercia
orm
spring
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1.5.1 Removing
iv
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t.
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interior; Rep. gr. 68 ; Removing and installing footwell covers . Cop py
t. rig
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– Remove trim on driver side ⇒ General body repairs, interior; p by
co Vo
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cted agen
Prote AG.
– Remove securing clip -1- from pivot pin -2- of over-centre
spring.
– Remove pivot pin from clutch pedal -arrow-.
– Remove complete over-centre spring -3- from clutch pedal
mounting bracket.
1.5.2 Installing
The over-centre spring consists of several parts and must be as‐
sembled before installation ⇒ page 11 .

Touareg 2003 ➤
– Insert complete over-centre spring -3- in clutch pedal mount‐

ing bracket.
– Align pivot pin -2- with clutch pin using hexagon flats -arrow-
and push in to stop.
– It must be possible to push securing clip -1- into pivot pin.
1.6 Removing and installing clutch pedal
1.6.1 Removing
– Remove over-centre spring ⇒ page 14 .
– Separate clutch pedal from master cylinder ⇒ page 22 and
push operating rod towards engine compartment to stop.
– Remove securing clip -arrow- from pivot pin -A- in clutch pedal
mounting bracket.
– Push pivot pin -A- to left out of clutch pedal, pressing wiring
harness to side if necessary.
– Remove clutch pedal. agen
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1.6.2 Installing wit

is n
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ole,

spec
– When pivot pin with securing clip -1- is pushed into clutch ped‐
t to the co
al mounting bracket, locking mechanism must already be on

clip -arrow-
.
rrectness o
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mer
atio
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Prote AG.

Touareg 2003 ➤
– It must be possible to push retainer -arrow- into the fulcrum pin

-A-.
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– The retainer -A- must be fitted to the master cylinder operating
an
itte
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rod -B-.
erm
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ility
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– Press clutch pedal in -direction of arrow- until it engages. En‐
wit
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sure that it is properly locked.
h re
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– Install over-centre spring ⇒ page 14 .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
1.7 Assembly overview - hydraulics (LHD)

m
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ion
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t.
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Prote AG.

Touareg 2003 ➤
1 - Brake fluid reservoir

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❑ If damaged, renew ed
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❑ The sealsss must be loca‐ c
ted in supply hose
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3 - Supply hose
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4 - Bulkhead
ility
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5 - Support
h re
hole
❑ Renew only with master
spec
cylinder removed
es, in part or in w
t to the co
❑ Pressing on
⇒ page 19
rrectness of i
6 - Clutch pedal
l purpos
❑ Removing and installing

⇒ page 15
nf
ercia
orm
7 - Master cylinder
m
atio
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⇒ page 21
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8 - Clip
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❑ Pull out clip to stop to re‐
f
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move and install pipe/
Co
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9 - Seal / O-ring
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❑ Always renew
AG.
❑ Pull onto line connection

❑ Insert with brake fluid
❑ Seals, O-rings depend‐
ing on line connection
⇒ page 19
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
10 - Pipe/hose line
❑ Allocation ⇒ Electronic parts catalogue “ETKA” .
11 - Nut, 8 Nm
12 - Bracket
❑ Secured to bulkhead
13 - Seal / O-ring
❑ Always renew
❑ Seals, O-rings depending on line connection ⇒ page 19
14 - Pipe/hose line
15 - Seal / O-ring
❑ Always renew

Touareg 2003 ➤
16 - Bracket
17 - Clip
❑ Pull out completely
18 - Pressure pipe
19 - Seals, O-rings
❑ Always renew
20 - Bracket
❑ Holds pipe/hose line on coolant pipe
21 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line agen
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22 - Bleeder valve d by gu
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❑ Bleeding clutch mechanism ⇒ page 22 utho eo
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23 - Dust cap s
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pt
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24 - Bolt
an
itte
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erm
❑ For securing slave cylinder to gearbox
ab
ility
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❑ Specified torque ⇒ page 24
wit
, is n
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25 - Slave cylinder
hole
spec
es, in part or in w
t to the co
26 - Gearbox
27 - Seal / O-ring
rrectness of i
❑ Always renew
l purpos

nf
ercia

orm
m

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om
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c
28 - Bracket
or
thi
te
sd
❑ For pipe/hose assembly of slave cylinder

iva
o
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cu
❑ ⇒ page 56
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ng
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Cop py
❑ Clipped onto gearbox
t. rig
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29 - Hexagon nut, 8 Nm
c by lksw
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Prote AG.
❑
30 - Bracket
❑ Secured to bulkhead

Touareg 2003 ➤
Seals and O-rings for pipe and hose lines

Item Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• For line connection having circumferential groove -arrow 1-
and -arrow 3-, a seal or O-ring must be set there.
Lever off retainer -A- in direction of arrow.
AG. Volkswagen AG d
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Pressing master cylinder operating rod into retainer -A- in

wit
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-direction of arrow-
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
1.8 Assembly overview - hydraulics (RHD)

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

Touareg 2003 ➤
1 - Brake fluid reservoir

2 - Seal
❑ If damaged, renew to‐
gether with supply hose
❑ The seals must be loca‐
ted in supply hose
3 - Supply hose
4 - Bulkhead
5 - Support
❑ Renew only with master
cylinder removed
❑ Pressing on ⇒ page 19
6 - Clutch pedal
⇒ page 15
7 - Master cylinder
⇒ page 21
8 - Clip
❑ Pull out clip to stop to re‐ AG. Volkswagen AG d
agen oes
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move and install pipe/ byV
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9 - Seal / O-ring ss a ra
c
❑ Always renew
ce
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nl
pt
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an
itte
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erm
ab
ility
ot p
❑ Seals, O-rings depend‐
wit
, is n
ing on line connection
h re
hole
⇒ page 19
spec
es, in part or in w
t to the co
10 - Pipe/hose line
rrectness of i
11 - Bracket
l purpos
❑ Secured to bulkhead of plenum chamber

nf
ercia
or
12 - Bracket
m
m
atio
m
❑ Secured to bulkhead of plenum chamber

o
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or c

thi
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13 - Bracket
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rp
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❑ Clipped onto gearbox

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ng
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14 - Dust cap
. C rig
ht ht
rig by
py
15 - Bleeder valve
co Vo
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cted agen
Prote
❑ Bleeding clutch mechanism ⇒ page 22
AG.
16 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
17 - Bolt
❑ For securing slave cylinder to gearbox
❑ Specified torque ⇒ page 24

Touareg 2003 ➤
18 - Slave cylinder
19 - Gearbox
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1.9 Removing and installing master cylinder utho tee
or
a ac
ss
Special tools and workshop equipment required
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pt
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♦ Pliers - T10005-
itte
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es, in part or in w
t to the co
rrectness of i
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ercia
♦ Torque wrench - V.A.G 1331-

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ion
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ate
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en
ng
t.
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1.9.1 Removing
– Note radio code for vehicles with coded radio.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
Left-hand drive:
– Remove electronics box on left in plenum chamber ⇒ Electri‐
cal system; Rep. gr. 97 ; Removing and installing fuse holders,
relay carriers, electronics boxes and control units .
Right-hand drive:
– Remove cowl panel trim ⇒ General body repairs, exterior;
Rep. gr. 50 .
– In order to access supply hose and pipe/hose line on master
cylinder, it may be necessary to remove right bulkhead ⇒
General body repairs, exterior; Rep. gr. 50 .
Continued for all vehicles:
– Place lint-free cloth in plenum chamber below supply hose to
brake fluid reservoir.

Touareg 2003 ➤
6-speed manual gearbox 08D - GEdition
en A . Volkswa08.2017
gen AG
ag does
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– Pull supply hose -1- offsebrake
db fluid reservoir and seal. ara
nte
ri
ho eo
– Pull clip -2- for pipe/hose
aut line out of master cylinder to stop. ra
c
ss
– Pull pipe/hose line -3- out from master cylinder and seal hose.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Remove over-centre spring ⇒ page 14 .
es, in part or in w
t to the co
– Move clutch pedal to rest position.
rrectness of i
Release master cylinder operating rod from clutch pedal as fol‐
lows:
l purpos
– Pull clutch pedal gently into passenger compartment.
nform
ercia
– Press sides of retainer inwards -arrows- using pliers -

T10005- .
m
at
om
io
– Remove clutch pedal from mounting bracket for clutch pedal
n
c
in t
or
⇒ page 15 .
his
ate
do
riv
– Then remove master cylinder securing bolts from bulkhead.

p
cum
for
en
g
– Remove master cylinder.

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1.9.2 Installing
by lksw
cted agen
Prote AG.

– The retainer -A- must be fitted to the master cylinder operating
rod -B-.
– Install clutch pedal ⇒ page 15 .
– Pull piston rod out of master cylinder slightly and hold using
pliers, being careful not to damage it.
– At the same time, press clutch pedal in direction of arrow until
it engages. Ensure that it is properly locked.
– Install over-centre spring ⇒ page 14 .
– Install electronics box on left in plenum chamber ⇒ Electrical
system; Rep. gr. 97 ; Removing and installing fuse holders,
relay carriers, electronics boxes and control units .
– Bleed clutch mechanism after installing master cylinder
⇒ page 22 .
1.9.3 Specified torque

Master cylinder on bulkhead: ⇒ Item 8 (page 10)
1.10 Bleeding clutch mechanism


lkswage es n
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ho
ir se tee Touareg 2003 ➤
t or
au 6-speed manual ac gearbox 08D - Edition 08.2017
ss
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nl
♦ Brake filling and bleeding unit - VAS 5234-
pt
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itte
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Specifications for brake fluid ⇒ Brake systems; Rep. gr. 47 ;

Bleeding brake system .
m
at
om
ion
– Connect brake filling and bleeding equipment .
c
in t
or
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te
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if

a
do
riv
necessary.
p
cum
for
en
ng
– To do this, connect the bleeder hose to the collector bottle of

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the brake bleeding device. C py
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– Connect bleeder hose -A- to bleeder connection. cop Vo
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– Pressurise system to 2 bar.
AG.
– Open bleeder valve.

– Allow about 100 cm3 of brake fluid to flow out.
– Close bleeder valve.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open bleeder valve.
– Allow another 50 cm3 of brake fluid to flow out.
– Close bleeder valve.
– Depress clutch pedal several times after completion of bleed‐
ing process.

Touareg 2003 ➤
AG. Volkswagen AG d
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agen oes
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ris tee
2 Repairing clutch release
s
mechanism au
tho or
ac
s
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le
⇒ “2.1 Removing and installing slave cylinder”, page 25
un
pt
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d
itte
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erm
ab
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
♦ Locking fluid - D 197 300 A2-
i
or
n thi
te
sd
iva
o
pr
c
1 - Bolt, 25 Nm
um
r
fo
en
ng
t.
yi
2 - Slave cylinder
Co
Cop py
ht. rig
❑ Removing and installing rig ht
py by
⇒ page 25 co Vo
by lksw
cted agen
Prote AG.
3 - Plunger
❑ Grease plunger head
with MoS2 grease
4 - Input shaft seal
❑ Renew after removal
⇒ page 83
5 - Guide bush
❑ Removing ⇒ page 25
❑ Lubricate in area of re‐
lease bearing with
MoS2 grease.
❑ To renew input shaft
seal, remove guide
sleeve
6 - Clutch release lever
❑ Remove and install to‐
gether with release
bearing
⇒ Item 7 (page 24) .
❑ Lubricate surface con‐
tacting ball pin with
MoS2 grease
7 - Release bearing
❑ Do not wash out bear‐
ing; wipe only
❑ Renew noisy bearings
❑ Retainer lugs of release
bearing must engage in
release lever.

Touareg 2003 ➤
8 - Bolt, 10 Nm
❑ Qty. 4
❑ Install using locking fluid - D 197 300 A2-
9 - Retaining spring
AG. Volkswagen AG d
❑ Secure to clutch release lever
ksw
agen oes
n ol ot g
yV ua
10 - Ball-head pin, 18 isNm
ed
b ran
or tee
❑ Lubricate withau MoS2 grease.
th or
ac
ss
11 - Gearbox
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Removing and installing guide sleeve
ot p
wit
, is n
– Unscrew bolts -arrows-, and remove guide sleeve -A-.
h re
hole
spec
– Before installing, clean threads of securing bolts for guide
es, in part or in w
sleeve using a wire brush. Then insert bolts -arrows- with lock‐
t to the co
ing fluid - D 197 300 A2- and tighten to specified torque
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
2.1 Removing and installing slave cylinder

n in
or c
thi
te
sd
a

iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.1.1 Removing
– If noise insulation is installed beneath gearbox, remove insu‐
lation.
– Unclip pipe/hose line from retainer -2- on gearbox.
– Remove bolt -1- and pull out slave cylinder to the rear.
– Place drip tray underneath.
2. Repairing clutch release mechanism 25

Touareg 2003 ➤
lks clip -A- to stop using wage es n
– To remove pipe/hose assembly, lever Voout ot g
by ua
a screwdriver. Only then can you
ris
e pull out the pipe-hose line
d ran
tee
-C-. ut
ho or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.1.2 Installing
rrectness of i
l purpos
nform
ercia
Note
m
at
om
io
♦ Do not allow brake fluid to come into contact with the gearbox.
n
c
in t
If necessary, clean gearbox housing.
or
his
ate
do
riv
♦ Preload slave cylinder sufficiently so that the securing bolt can

p
cum
easily be inserted.
for
en
ng
t.
yi Co
op py
– Before inserting slave cylinder, examine boot -arrow A- for t. C rig
gh ht
damage and renew slave cylinder if necessary. yri
p by
co Vo
by lksw
cted
– Apply a thin coat of MoS2 grease to surface of plunger
agen
Prote AG.
-arrow B- which contacts clutch release lever.
Renew O-ring -B- for pipe/hose assembly.

– Insert pipe/hose line -C- into slave cylinder to stop.
– Press in clip -A- to stop.

Touareg 2003 ➤
– Guide slave cylinder into mounting hole of clutch housing with‐

out deviating significantly from line of operation of plunger.
Tighten bolt -1- to specified torque ⇒ Item 1 (page 24) .
. Volkswagen AG
a gen AG does
– Clip pipe/hose line into retainer -2-
Vol on gearbox.
ksw not
gu
y
db ara
– Bleed clutch mechanism ⇒oripage
se 22 . nte
eo
th
s au ra
c
s
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
Slave cylinder on gearbox: ⇒ Item 1 (page 24)
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Repairing clutch release mechanism 27

Touareg 2003 ➤
3 Repairing clutch
Special tools and workshop

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Counter-hold tool - 10-201-

♦ or counter-hold tool - 3067-
♦ Centring mandrel - 3434-
♦ Pin wrench - 3212-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by Touareg 2003
ara ➤
ise nte
r
ut 6-speed manual gearbox 08D - Edition 08.2017
h o eo
a ra
ss c
♦ Grease for splines
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Gearbox is removed.
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
essary.
rrectness of i
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
box (rattling of gears which are not engaged) could occur.
l purpos
♦ Renew clutch plates and pressure plates with damaged or loose rivets.
nform
ercia
♦ Select clutch plate and pressure plate according to ⇒ Electronic parts catalogue “ETKA” and engine code.
m
a
♦ For self-adjusting clutches (with SAC pressure plate), renew clutch and pressure plates only as a pair.
com
tion in
r
te o
thi
s
iva
do
1 - Two-part flywheel
r
rp
cum
fo
❑ Ensure that centring
en
ng
t.
yi
pins fit tightly
Co
Cop py
t. rig
❑ Contact surface for
gh ht
yri by
clutch lining must be
op Vo
by c lksw
cted
free of grooves, oil and
agen
Prote AG.
grease
⇒ Rep. gr. 13
2 - Clutch plate
❑ Allocation ⇒ Electronic
parts catalogue “ET‐
KA” .
❑ Fitting position: the lon‐
ger hub end of the clutch
plate -arrow- faces pres‐
sure plate
❑ Text
“Getriebeseite” (gear‐
box side), if present,
faces pressure plate or
gearbox
❑ Centring ⇒ page 30
❑ Lightly grease splines
Note
Clean input shaft splines and, on

used clutch plates, hub splines. Re‐
move corrosion and apply a very
thin coat of clutch plate spline
grease to splines of input shaft.
Then, move the clutch plate back
and forth on the drive shaft until the
hub moves easily on the shaft. Re‐
move excess grease.
3 - Thrust plate
❑ Removing plate ⇒ Item 5 (page 30) for preloading diaphragm spring ⇒ page 30
❑ Check ends of diaphragm spring ⇒ page 31
3. Repairing clutch 29
Touareg 2003 ➤
Note
. Volkswagen AG
gen AG
Pressure plates are
Vol
ksw protected
a does
not
against corrosion
ed
by and greased. gu
ara
Clean contact
ho
ris surface only; other‐ nte
eo
wise sthe
au service life of the clutch will
t ra
c
be considerably
s reduced.
ce
e
nl
pt
du
an
itte
4 - Bolt, 22 Nm
y li
erm
ab
❑ Loosen or tighten bolts in small steps and in diagonal sequence
ility
ot p
wit
, is n
5 - Plate
h re
hole
❑ For preloading diaphragm spring.
spec
es, in part or in w
❑ May be installed in new pressure plates.
t to the co
❑ Must always be removed following attachment to two-piece flywheel ⇒ page 30 .
rrectness of i
Centring clutch plate and removing and installing pressure plate
l purpos
– Loosen or tighten bolts diagonally in stages.
nform
ercia
– Reverse position of counterhold - 3067- when removing.

m
at
om
ion
c
Note in t
or
his
ate
do
riv
♦ Pressure plate contact surface and clutch plate lining must

p
cum
or
make full contact with flywheel.

f
en
ng
t.
yi Co
op
♦ Tighten securing bolts diagonally and evenly to prevent dam‐ C py
t. rig
age to pressure plate centring hole and flywheel centring pins.gh ht
pyri by
Vo
co lksw
by
♦ Renew pressure plate and clutch plate together only. Prote
cted AG.
agen
♦ If a plate for preloading the diaphragm spring is installed, it

must be removed after the pressure plate is bolted on
⇒ page 30 .
Removing plate for preloading diaphragm spring

– First bolt new pressure plate with clutch plate and centring
mandrel to two-piece flywheel ⇒ page 30 .
– Now rotate plate -A- anti-clockwise -direction of arrow- using,
for example, pin wrench - 3212- and remove plate.
– Then remove centring mandrel - 3434- .

Touareg 2003 ➤
Check ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring is per‐
mitted.
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
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.
3. Repairing clutch 31
Touareg 2003 ➤
4 Check and, if necessary, reset ad‐

juster ring of self-adjusting pressure
plate of new clutches only
♦ Press tool - VW 412-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
♦ Thrust plate - 3062- thor eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
• It applies only if a new pressure plate and clutch disc are in‐
l purpos
stalled.
nf
• If the previously used pressure plate and clutch disc are rein‐
ercia
o
stalled, the adjustment ring must not be reset.
rm
m
atio
m
If a new pressure plate and clutch disc are installed, check the
o
n in
c
position of the adjustment ring in the pressure plate.

or
thi
te
sd
iva
• The adjustment ring must be turned back to stop.

o
r
rp
cu
o
m
f
• The springs -arrow - are then compressed to the “block”.

en
ng
t.
yi Co
op py
Otherwise, the clutch pressure will be reduced, causing increased t. C rig
gh ht
wear to the clutch plate. yri
p by
co Vo
by lksw
cted
If the springs are not compressed to the “block”, turn back the
agen
Prote AG.
adjustment ring.
– Insert three M 6 x 35 bolts -A- offset 120° in securing holes of
pressure plate as shown in the diagram.

Touareg 2003 ➤
-B- = spacers, about 20 mm high, e.g. 10 mm socket for 1/4 inch

drive.
– Screw 3 nuts, -C- onto bolts -A-.
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
– Place pressure plate on workshop press so that just the 3 bolt
ab
ility
heads -arrows- make contact.
ot p
wit
is n
– Centre thrust pad - 3062- in middle of pressure plate.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Do not use excessive force for the following work or the adjuster
atio
m
ring forks may break off.

o
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.
4. Check and, if necessary, reset adjuster ring of self-adjusting pressure plate of new clutches only 33
Touareg 2003 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Apply two screwdrivers to pins on adjusting ring.

atio
om
– Press down on pressure plate with press until adjusting ring

c
i
or
can just be moved.

thi
te
sd
iva
– Using the two screwdrivers, turn back adjusting ring evenly in

pr
cum
r
fo
direction of arrows to stop.

en
ng
t.
yi Co
op
– Hold adjuster ring against stop and reduce pressure exerted C py
t. rig
by press so that adjuster ring is held in this position.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
34 – Controls, housing
1 Repairing selector mechanism
⇒ “1.1 Installation position of selector mechanism”, page 35
⇒ “1.2 I - Removing and installing gear knob and cover”,
page 37
⇒ “1.3 II - Repairing gear lever and selector housing”, page 39
⇒ “1.4 III - Assembly overview - removing and installing selector
cables”, page 40
⇒ “1.5 Removing and installing selector mechanism”, page 42
⇒ “1.6 Adjusting selector mechanism”, page 46
1.1 Installation position of selector mechanism

Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
A - Gear selector cable

B - Gate selector cable
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
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
Removing and installing selector mechanism ⇒ page 42 .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Repairing selector mechanism 35

Touareg 2003 ➤
Adjust selector mechanism ⇒ page 46 .
Note
♦ Before working on selector mechanism, disconnect batteries ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and connecting batteries .
♦ Do not kink selector cables.
I - Removing and installing

gear knob and cover
⇒ page 37
II - Repairing gear lever and
selector housing ⇒ page 39
III - Assembly overview - re‐
moving and installing selector
cables ⇒ page 40
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.
36 Rep. gr.34 - Controls, housing

Touareg 2003 ➤
♦ Hose clip pliers - V.A.G 1275-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Two-arm puller - VAS 251 001- , or e.g. two-arm puller - Kukko

20/10-
1.2 I - Removing and installing gear knob and cover

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
swage es n
1 - Gear knob byV
olk ot g
ua
ed ran
❑ Selector lever hor knob and
is tee
gaiter cannot
aut be sepa‐ or
ac
rated from one another.
ss
ce
le
un
pt
an
d
itte
gether with gaiter.
y li
rm
ab
pe
2 - Cover with frame
ility
ot
wit
, is n
❑ Selector lever knob and
h re
gaiter cannot be sepa‐
hole
spec
rated from one another.
es, in part or in w
t to the co
gether with gear knob.
3 - Clip
rrectness of i
❑ To secure gear knob on
l purpos
selector lever
❑ Secure to gear knob us‐
nform
ercia
ing hose clip pliers -

V.A.G 1275-
m
a
com
tio
4 - Noise insulation
n 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.

Touareg 2003 ➤
1.3 II - Repairing gear lever and selector housing

AG. Volkswagen AG d
agen oes
olksw not
V gu
Note ed by ara
nte
ris
ho eo
ut ra
♦ Lubricate bearing positions and sliding
ss a surfaces. c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
1 - Securing clip
wit
, is n
h re
hole
⇒ page 40
spec
es, in part or in w
t to the co
2 - Bush
3 - Compression spring
rrectness of i
4 - Bush
l purpos
❑ Installation position:
narrow shoulder faces
upwards
nf
ercia
or
5 - Bolt, 5 Nm
m
m
atio
m
6 - Cover
o
n in
or c
thi
e
7 - Dampers
t
sd
iva
o
r
rp
cu
8 - Bearing bush
o
m
f
en
ng
t.
yi
9 - Gear lever guide
Co
Cop py
t. rig
10 - Damping washer
gh ht
pyri by
Vo
o
by c lksw
11 - Seal cted agen
Prote AG.
❑ Between selector hous‐
ing and underbody
❑ Self-adhesive
❑ Bond to selector lever
housing
12 - Gear lever
13 - Dampers
14 - Selector housing
15 - Bearing bush
17 - Guide bush
18 - Compression spring
❑ Installing ⇒ page 40
19 - Gate selector lever
20 - Bolt, 5 Nm
21 - Floor panel
❑ Bend open tabs to remove
❑ With bonded seal
❑ Always renew
22 - Gate change cable
❑ On gate selector lever
❑ Fitting position ⇒ page 35

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
23 - Gear change cable olks
w not
byV gu
ara
❑ Press onto gear lever ris guide
ed nte
ho eo
❑ Fitting position ⇒
sa
upage 35
t ra
c
s
24 - Securing clip
ce
le
un
pt
an
d
itte
25 - Bolt, 20 Nm
y li
rm
ab
❑ Qty. 4
pe
ility
ot
wit
, is n
26 - Bearing bush
h re
hole
❑ Fits in one position only
spec
es, in part or in w
27 - Securing clip
t to the co
rrectness of i
Removing and installing securing clip
l purpos
– To remove or install securing clip, pull selector lever in direc‐

tion of arrow -A- and at same time push down spacer bush in
direction of arrow -B- to stop using screwdriver.
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
♦ Do not cant spacer bush when pushing down.
do
r
rp
cum
fo
♦ Slot in gear lever for securing clip must be visible.

en
ng
t.
yi Co
op
♦ Carefully release spring tension. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted
Installing compression spring
agen
Prote AG.
– Insert compression spring so that extension -A- lies on top of

pin -arrow-.
– Then pull extension -B- down so that it sits below pin -arrow-.
1.4 III - Assembly overview - removing and

installing selector cables
Note
♦ Lubricate bearing positions and sliding surfaces.

♦ Do not kink selector cables.

Touareg 2003 ➤
1 - Gear change cable

AG. Volkswagen AG d
⇒ page 42 ksw
agen oes
not
Vol
❑ Install on gearbox selec‐ d by gu
ara
tor lever rise nte
ho eo
⇒ Item 13 (page 41) . s aut ra
c
s
❑ Fitting position
ce
e
nl
pt
⇒ page 35
du
an
itte
y li
2 - Gate change cable
erm
ab
ility
ot p
wit
, is n
⇒ page 42
h re
hole
❑ Install on relay lever
spec
⇒ Item 14 (page 42) .
es, in part or in w
t to the co
⇒ page 35
rrectness of i
3 - Cable end-piece
❑ For gear selector cable
l purpos
❑ Press onto gear lever

guide
nform
ercia

m
at
4 - Cable end-piece
om
ion
c
in t
❑ For gate selector cable
or
his
ate
❑ Install on gate selector
do
priv
c
lever
um
for
⇒ Item 19 (page 39) .
en
ng
t.
yi Co
op
5 - Securing clip
C py
t. rig
gh ht
yri
❑ Always renew
p by
co Vo
by lksw
cted agen
6 - Selector housing
Prote AG.
7 - Securing clip
❑ Do not damage cables
when removing
8 - Securing clip
❑ Do not damage cables when removing
9 - Hexagon bolt, 23 Nm
❑ With captive washer
❑ For selector cable support bracket to gearbox
❑ Qty. 3
10 - Grommet
❑ Cable support bracket mounting on gearbox
11 - Spacer
12 - Cable support bracket
13 - Gearbox selector lever
❑ With damper weight
❑ Detach gear selector cable ⇒ page 42
❑ If the gearbox selector lever is to be renewed, then coat the splines of the selector shaft and the thread
of the hexagon nut ⇒ Item 15 (page 42) with the enclosed locking fluid.
❑ Install so that master spline aligns with selector shaft.
❑ Gearbox selector levers which have been installed with locking fluid must be pulled off using two-arm
puller - VAS 251 001- , or e. g. two-arm puller - Kukko 20/10- . See
⇒ “2 Removing and installing gearbox”, page 52 .
❑ Locking fluid can also be ordered from the ⇒ Electronic parts catalogue “ETKA” .

Touareg 2003 ➤
❑ After installing, adjust selector mechanism ⇒ page 46
14 - Deflector lever
❑ Detach selector lever cable ⇒ page 42 .
❑ Install so that master spline aligns with selector shaft.
❑ After installing, adjust selector mechanism ⇒ page 46
15 - Self-locking hexagon nut, 23 Nm
❑ Always renew
❑ Coat thread with locking fluid for selector lever shaft ⇒ Item 13 (page 41) before installing
16 - Securing clip
❑ Always renew
17 - Cover
Installation position of gearbox selector lever/relay lever

1 - Gearbox selector lever with damper weight agen
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spec
1.5 Removing and installing selector mech‐
t to the co
anism
rrectne
ss o
cial p
f inform
mer
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aut 6-speed manual gearbox ra 08D - Edition 08.2017
ss c
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nl
pt
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♦ Engine and gearbox jack - V.A.G 1383 A-
rm
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♦ Or engine and gearbox jack - VAS 6931-
1.5.1 Removing
– Pull cover for gear lever knob upwards off centre console.
– Pull cover over gear knob.
– Then destroy clip -A- using pliers -B-.
– Apply pliers horizontally to avoid damaging gear knob.
– Pull off gear knob with gaiter.
– Pull noise insulation out of centre console.
– Remove ashtray and remove shift mechanism cover from cen‐
tre console ⇒ General body repairs, interior; Rep. gr. 68 ;
Compartments, covers and trims; Removing and installing
centre console .

Touareg 2003 ➤
– Remove bolt -1- for selector housing to centre console.

– Now remove front securing bolts -2- for selector housing to
body.
– Remove bolts -1- for selector housing to strut -2- of centre

console.
– Then remove rear securing bolts -3- for selector housing to
body.
Vehicles with 5-cylinder diesel engine
– Pull connecting hose -A- between intake pipe and charge air
cooler off intake pipe ⇒ 5-cylinder diesel engine; Rep. gr. 21 ;
Charge air system with turbocharger . AG. Volkswagen A
agen G do
es n
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Continued for all vehicles by Vol ot g
ua
ed ran
– Remove transfer box ⇒ Transfer oris box and final drives; Rep. tee
th or
gr. 34 ; Removing and installing
au transfer box . ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
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spec
Lower manual gearbox slightly as follows:

t to the co
– Fit trolley jack insert -C- in engine and gearbox jack and lay
block of wood on insert -B-.
rrectne
– Position engine and gearbox jack under gearbox.

– Raise gearbox enough that retaining tool - VW 785/1 B- (re‐
ss
quired for removing and installing transfer box) can be re‐

o
cial p
moved from gearbox.

inform
mer
– Lay a piece of wood -A-, about 50 mm high, between gearbox

atio
and subframe.
om
n
c
i
or
– Lower engine and gearbox jack and move aside.

thi
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Touareg 2003 ➤
– Lever off caps -1- for selector cables at top of gearbox.

– Remove securing clips -2- and selector cables -3- from pins
-4- of gearbox selector lever and relay lever.
– Pull securing clips -A- off cable support bracket -D- on gear‐
box.
– Remove gear selector cable -B- and gate selector cable -C-
from cable support bracket.
– Swing down gear lever housing and remove with selector ca‐
bles.
1.5.2 Installing
The holes in the cables have different diameters. agen
AG. Volkswagen AG d
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Allocation ed byV gu
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Hole for: Dimension
aut -a- ra
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Gear selector cable to gearbox 8 mm
ce
le
un
pt
selector lever
an
d
itte
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Gate selector cable to relay lever 10 mm
rm
ab
pe
ility
ot
– Spread a small quantity of grease on pins -4- of gearbox se‐ wit

, is n
lector lever and relay lever. h re

hole
spec
es, in part or in w
t to the co
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

rrectness of i
– Renew securing clips -2- on gearbox selector lever and relay

lever each time they are removed.
l purpos
– Secure each selector cable -3- with a securing clip -2-.

nform
ercia
– Clip caps -1- onto selector cables.

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Touareg 2003 ➤ autho eo
ra
6-speed manual gearbox 08D - Edition 08.2017 ss c
ce
e
nl
pt
du
an
– Secure gear selector cable -B- and gate selector cable -C- to
itte
y li
cable support bracket -D- using securing clips -A-.
erm
ab
ility
ot p
– Install transfer box ⇒ Transfer box and final drives; Rep. gr.
wit
, is n
34 ; Removing and installing transfer box .
h re
hole
spec
Vehicles with 5-cylinder diesel engine
es, in part or in w
t to the co
rrectness of i
l purpos
nform
– Attach connecting hose -A- between intake pipe and charge mercia
air cooler to intake pipe ⇒ 5-cylinder diesel engine; Rep. gr.
at
om
io
21 ; Charge air system with turbocharger .
n
c
in t
or
his
e
Continued for all vehicles

at
do
priv
c
Install selector mechanism cover and ashtray in centre console
um
for
⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,
en
ng
t.
yi Co
covers and trims; Removing and installing centre console . t. Cop py
rig
gh ht
– Adjust selector mechanism ⇒ page 46 . pyri by
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cted agen
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– Install gear knob with gaiter on gear lever and secure with new
clip -arrow- to gear knob using hose clip pliers - V.A.G 1275- .
– Connect battery.
Follow procedure after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

Selector lever hous‐ ⇒ Item 25 (page 40)
ing to body:
1.6 Adjusting selector mechanism

Before attempting to adjust selector mechanism, read instructions
entirely.

Touareg 2003 ➤
♦ Pin - T10027 A-
AG. Volkswagen AG d
agen oes
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1.6.1 The following points are essential to en‐
itte
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erm
ab
sure correct adjustment of selector
ility
ot p
wit
mechanism:
, is n
h re
hole
spec
♦ Moving parts of operating elements and elements transferring
es, in part or in w
force must be in proper condition.
t to the co
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
rrectness of i
condition.
l purpos
• Gearbox must be in neutral.

Preparations
nf
ercia
orm
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Compartments, covers and trims; Removing and installing C py
ht. rig
centre console . rig ht
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co Vo
by lksw
1.6.2 Overview - components for adjusting se‐
cted agen
Prote AG.
lector mechanism
Overview - components on selector housing for adjusting selector
mechanism
1- Access hole for gate selector cable
2- Access hole for gear selector cable
3- Locking mechanism of cable end-pieces for gate and gear
selector cables
♦ Opening locking mechanism: insert a screwdriver through hole
-1- or -2- into slot -arrow A- of locking mechanism -3- and
counterhold while moving gear lever.
♦ Securing locking mechanism: insert a screwdriver through
hole -1- or -2- and press against lug -arrow B- of locking mech‐
anism -3-.
4 - Gear lever
5 - Locating holes for locking pin - T10027 A-

Touareg 2003 ➤ gen AG
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does
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6-speed manual ygearbox
Volk 08D - Edition 08.2017 not
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Overview - components
au
tho
on gearbox for adjusting selector mech‐ or a e
anism ss c
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nl
A - Retaining pin
pt
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B - Deflector lever
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ility
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♦ Move relay lever towards engine (in gate for 1st and 2nd
wit
, is n
gears) in -direction of arrow-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.6.3 Adjusting
Open selector cable end-piece as follows:
nf
ercia
or
– Move gear lever in -direction of arrow 1- towards left to stop.
m
m
atio
om
– Now hold securing mechanism of cable end-piece -B- securely
n in
or c
using a screwdriver -A-. To do this, insert screwdriver in slot
thi
te
sd
of locking mechanism ⇒ page 47 and hold locking mechanism
iva
o
r
in place by gently pressing forwards.

rp
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– Then push gear lever towards 1st gear (forwards in

t.
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-direction of arrow 2-). C py
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rig ht
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This opens selector cable end-piece -direction of arrow 3-. co Vo
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Open gate cable end-piece as follows:

– Hold gear lever at left stop (position for 1st gear).
– Now hold securing mechanism of cable end-piece securely
using a screwdriver -A-. To do this, insert screwdriver in slot
of locking mechanism ⇒ page 47 and hold locking mechanism
in place by gently pressing forwards.
– Then move gear lever to stop in direction of gate for 5th and
6th gears (to right in -direction of arrow 1-.
This opens selector cable end-piece -direction of arrow 2-.

Touareg 2003 ➤
Secure gear lever as follows:

– Move gear lever in neutral leftwards into gate for 1st and 2nd
gears. . Volkswage n AG n AG d
wage oes
– Guide locking pin - T10027 A- throughy Vhole
olks -A- of gear lever not
gu
into hole -B- of selector housing. ised b ara
nte
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– Raise vehicle. aut ra
c
ss
– Remove noise insulation below gearbox.
ce
le
un
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an
d
itte
Then, locate selector shaft of gearbox.
y li
erm
ab
ility
ot p
wit
is n
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ole,
To do this, the relay lever -arrow- for the gate selector cable must
spec
be moved towards engine.
t to the co
The relay lever -arrow- is located above the slave cylinder -1- in
front of cable support bracket -2- of selector mechanism.
rrectness o
cial p
f inform
mer
atio
om
n
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– Move relay lever -B- in direction of engine (forwards in

i
o
pr
cum
r
-direction of arrow 1-) in gate for 1st and 2nd gears.

fo
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Note
ht
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♦ The gate for 1st and 2nd gears lies between the gate for 3rd
AG.
and 4th gears (to rear, in direction of travel) and the gate for
reverse gear (to front in direction of travel).
♦ No stop or detent point can be felt when the relay lever is
moved.
– While moving relay lever, turn locking pin -A- in

-direction of arrow 2-. If gate for 1st and 2nd gears has been
correctly selected, the angled rod can be easily turned and
pushed in.
This locks the selector shaft; it cannot be moved any more.
– Now carefully press lug -B- of securing mechanism of gate

selector cable end-piece in -direction of arrow- using a screw‐
driver -A-.
The spring presses the securing mechanism of the cable end-
piece into its initial position.

Touareg 2003 ➤
– Then press lug -B- of securing mechanism of gear selector

cable end-piece in -direction of arrow- using a screwdriver
-A-.
The spring presses the securing mechanism of the cable end-
piece into its initial position.
AG. Volkswagen AG d
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ility
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ole,
spec
t to the co
– Turn locking pin -A- for locking selector shaft in
rrectne
-direction of arrow- back to its initial position.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
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t.
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Cop py
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gh ht
– Pull locking pin out of holes -A- and -B-. yri
p by
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by c lksw
cted agen
Prote AG.
1.6.4 Function
• With gearbox in neutral, gear lever must rest in gate for 3rd
and 4th gears.
– Operate clutch.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.
If it continues to be difficult to engage gears after repeating proc‐
ess several times, repeat adjustment of selector mechanism
⇒ page 46 .
– Install noise insulation below gearbox.

Touareg 2003 ➤
– Install shift mechanism cover and ashtray in centre console ⇒

General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trims; Removing and installing centre console .
– Install noise insulation in centre console.
– Clip gear knob gaiter into selector mechanism cover.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
ss c
ce
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un
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an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
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
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Prote AG.

Touareg 2003 ➤
2 Removing and installing gearbox

The manual gearbox can be removed and installed after the
transfer box has been removed.
AG. Volkswagen n AG do
wage es
olks
⇒ “2.1 Removing andy Vinstalling gearbox, vehicles with
not 5-cylinder
gu
diesel engines”,ripage
sed b
52 ara
nt ee
tho o
⇒ “2.2 Removing
au and installing gearbox, vehicles with 6-cylinder
ra
c
ss
diesel engines”, page 59
ce
e
nl
pt
du
⇒ “2.3 Removing and installing gearbox, vehicles with 6-cylinder
an
itte
y li
petrol engine”, page 66
erm
ab
ility
ot p
⇒ “2.4 Transporting gearbox”, page 77
wit
, is n
h re
2.1 Removing and installing gearbox, vehicles with 5-cylinder diesel engines
hole
spec
es, in part or in w
t to the co
equipment required
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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thi
te
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pyri by
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Prote AG.
♦ Gearbox support - 3282-

♦ Adapter - 3282/54-
♦ Adjustment plate - 3282/55-

Touareg 2003 ➤


2.1.1 Removing gearbox

– Pull cover for gear lever
agen
AG. Vknob
olkswaupwards
gen AG
do off centre console.
w es n
olks ot g
– Pull cover
d b over gear knob.
yV ua
ran
e
ris tee
– Then
au
tho destroy clip -A- using pliers -B-. or
ac
ss
ce
le
un
pt
an
d

itte
y li
rm
ab

pe
ility
ot
wit
, is n

h re

hole
spec

es, in part or in w
centre console .
t to the co
rrectness of i

l purpos

body.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.
2. Removing and installing gearbox 53

Touareg 2003 ➤

console.
body.
– Remove complete air filter housing ⇒ 5-cylinder diesel engine;
Rep. gr. 23 ; Repairing diesel direct injection system .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
– Pull connecting hose -A- between intake pipe and charge air
ce
le
un
pt
cooler off intake pipe ⇒ 5-cylinder diesel engine; Rep. gr. 21 ;
an
d
itte
y li
Charge air system with turbocharger .
erm
ab
ility
ot p
– If there is a skid plate under the gearbox, remove it ⇒ General
wit
body repairs, exterior; Rep. gr. 50 ; Skid plate .
is n
h re
ole,
– Remove transfer box ⇒ Transfer box and final drives; Rep.
spec
gr. 34 ; Removing and installing transfer box .
t to the co
rrectness o
– Remove noise insulation tray bracket -A-.
cial p
f inform
– Remove front exhaust pipe with catalytic converter or partic‐
mer
ulate filter ⇒ Rep. gr. 26 ; Removing and installing parts of atio

om
exhaust system .
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.

Touareg 2003 ➤

– Raise gearbox enough that
gen Aretaining
G. Volkswagtool - dVW
en AG
oes 785/1 B- (re‐
quired for removing ol swa installing transfer box)
kand ncan
ot g be re‐
y V ua
moved from igearbox.
se
d b ran
r tee
ho
– Lay a piece
au of wood -A-, about 50 mm high, between gearbox
t or
ac
ss
and subframe.
ce
le
un
pt
an
d
itte
y li
rm
ab
– Remove front exhaust pipe bracket from starter securing bolts.
pe
ility
ot
wit
– Unbolt starter from engine/gearbox and secure as necessary
, is n
h re
⇒ Electrical system; Rep. gr. 27 ; Removing and installing
hole
starter .
spec
es, in part or in w
t to the co
Note
rrectness of i
Starter cables do not have to be disconnected.
l purpos
– Remove coolant pipe bracket -1- from bolt -3- -arrow-.
nform
ercia
– Remove engine/gearbox connecting bolts -2- and -3-.

m
a
com
tio
– Remove upper engine/gearbox connecting bolts.
n in
r
te o
thi
– Unclip manual gearbox breather line from bracket.

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

– Tie up slave cylinder making sure not to open hydraulic sys‐
tem.
Caution
Do not depress the clutch pedal, or the slave cylinder will be

destroyed.
To remove manual gearbox “08D”, set up gearbox support - 3282-

with adjustment plate - 3282/55- .
– Insert gearbox support - 3282- into engine and gearbox jack .
– Align arms of gearbox support according to holes in adjust‐
ment plate .
The symbols on the adjusting plate indicate the mounts required;
the arrow points forward.

Touareg 2003 ➤
– Secure adapter - VW 771/40- on left side of gearbox in threa‐

ded hole for securing bolt for slave cylinder.
– Screw adapter - 3282/54- onto front left post of gearbox sup‐
port .
– Position engine and gearbox jack with gearbox support - 3282-
under vehicle.
– Secure gearbox to gearbox support - 3282- using bolts (M10
× 20) -A- and -B- (M10 x 30).
– Now raise gearbox enough so that the piece of wood -A- be‐
tween gearbox and subframe can be removed.
– Carefully lower gearbox until engine touches bulkhead.
– Remove lower engine/gearbox connecting bolts.
– Swing down selector housing and secure together with selec‐
tor cables to gearbox using, e.g. wire.
– Press gearbox away from engine, off dowel sleeves.
– Guide gearbox with housing rib -1- over front final drive -2-
while turning gearbox anti-clockwise -direction of arrow-.
– Then lower gearbox.
– If necessary remove selector cables together with selector
housing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
If the gearbox is to be renewed, transfer the following components
ce
le
un
pt
to new gearbox:
an
d
itte
y li
erm
ab
1 - Breather line
ility
ot p
2 - Deflector lever
wit
is n
h re
ole,

spec
4 - Gearbox support bracket

t to the co
5 - Bracket
rrectness o
cial p
2.1.2 Install gearbox

f inform
mer
– Clean input shaft splines and apply thin coat of grease for
atio
m
clutch plate splines .

o
n
c
i
or
The clutch plate must slide easily to and fro on the input shaft.
thi
te
sd
iva
o
r
– Always renew self-locking bolts and nuts.

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
56
co Vo
by lksw
Rep. gr.34 - Controls, housing cted agen
Prote AG.
Touareg 2003 ➤
– Check whether dowel sleeves for aligning engine and gearbox

are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly
gen AG
. Volkswagseated
en AG on engine.
a does
lksw n
To install manual gearboxdb
y V“08D”, set up gearbox supportt -gu3282-
o o
ara
with adjustment plate
or
is - 3282/55- .
e nte
h eo
ut ra
– Align arms of
ss gearbox support according to holes in adjust‐
a c
ment plate .
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
port .
t to the co
– Place gearbox on gearbox jack .
rrectness of i
– Align adjustment plate and gearbox parallel to one another.
l purpos

× 20) -A- and -B- (M10 x 30).
nform
ercia
• Selector cables are attached to gearbox and selector housing

is secured to gearbox with, e.g., wire.
m
at
om
io
– Carefully guide gearbox onto engine, observing lines in tunnel.
n
c
in t
or
his
ate
do
priv

um
for
en
ng
t.
yi
– Align gearbox to engine and join.
Co
Cop py
ht. rig
– Screw in lower engine/gearbox connecting bolts and tighten rig ht
py by
to specified torque ⇒ page 59 .
co Vo
by lksw
cted agen
Prote AG.
– Now raise gearbox enough so that the piece of wood -A-, about
50 mm high, can be inserted between gearbox and subframe.
– Carefully lower engine and gearbox jack and remove gearbox
support - 3282- from gearbox.
– Attach selector housing to body ⇒ page 42 .
– Screw in upper engine/gearbox connecting bolt and tighten to
specified torque ⇒ page 59 .

Touareg 2003 ➤
– Insert slave cylinder into mounting hole in clutch housing,

keeping it as far as possible in line with direction of push rod
operation and then tighten bolt -1- to specified torque
⇒ page 59 .
– Clip pipe/hose line into retainer -2- on gearbox.
– Clip gearbox breather line into bracket.
– Tighten engine/gearbox connecting bolts -2- and -3- to speci‐

fied torque ⇒ page 59 .
– Install coolant pipe bracket -1- on bolt -3- -arrow-.
– Insert starter and bolt on ⇒ Electrical system; Rep. gr. 27 ;
Removing and installing starter .
– Attach bracket for front exhaust pipe to starter securing bolts
starter .
AG. Volkswagen AG d
agen oes
– Now raise gearbox enough that the retaining yV
olkstool - VW 785/1
w not
gu
B- (required for removing and installing e transfer box ⇒ Trans‐
d b ara
nte
ris
fer case and final drives; Rep. gr. 34tho; Removing and installing eo
transfer case ) can be attachedstos a gearbox.
u ra
c
ce
e
– Then remove piece of wood -A- between gearbox and sub‐

nl
pt
du
an
frame.
itte
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erm
ab

ility
ot p
wit
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– Install front exhaust pipe with catalytic converter or particulate

h re
filter ⇒ Rep. gr. 26 ; Removing and installing parts of exhaust

hole
spec
system .
es, in part or in w
t to the co
– Install noise insulation tray bracket -A-.

rrectness of i

l purpos
– Adjust selector mechanism ⇒ page 46 .

– Check gear oil ⇒ page 78 .
nf
ercia
orm
– If a skid plate was fitted under the gearbox, install it ⇒ General

m
atio
m

o
n in
or c
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te
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Cop py
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Prote AG.

Touareg 2003 ➤
AG. Volkswagen
– Attach connecting hose -A- betweenlkintake wage pipe and chargedoes n
n AG
o s
air cooler to intake pipe ⇒ 5-cylinder
db
y V diesel engine; Rep. gr. ot g
ua
21 ; Charge air system with oturbocharger
ir se . ran
te
h eo
ut ra
– Remove complete air filter
ss housing ⇒ 5-cylinder diesel engine;
a c
Rep. gr. 23 ; Repairing diesel direct injection system .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
2.1.3 Specified torques
rrectness of i
Gearbox to engine (illustration shows gearbox flange)
l purpos
Allocation of bolt, item -1-
nform
ercia
Dimension -a- mm Bolt

m
30 M12 x 85
at
om
ion
c
55 M12 x 110
in t
or
♦ With washer, 2.5 mm thick
his
ate
do
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or
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for
en
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55 M12 x 105
n
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op
♦ Without washer C py
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pyri by
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cted agen
Allocate bolts or washer according to ⇒ Electronic parts cata‐
Prote AG.
logue “ETKA” .
Item Bolt Quantity Nm
1 Allocation ⇒ figure above 1 80
2 M12 x 80 1 80
3 M12 x 155 1 80
4 M10 x 50 1 45
♦ With M8 stud
5 M10 x 50 6 45
6 M12 x 120 1 65
♦ With M8 stud
♦ Additionally, starter to gearbox
7 M12 x 165 1 65
♦ With M8 stud
-A- and -B-: dowel sleeves for centring

Slave cylinder on gear‐ 25 Nm
box:
2.2 Removing and installing gearbox, vehicles with 6-cylinder diesel engines

Touareg 2003 ➤

equipment required
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
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ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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♦ Gearbox support - 3282- Cop py
ht. rig
rig ht
♦ Adapter - 3282/54- py by
co Vo
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♦ Adjustment plate - 3282/55- Prote AG.


Touareg 2003 ➤


G. Volkswagen
– Pull cover for gear lever knob upwards off
lksw
agcentre
en A console.AG does n
o ot g
yV ua
– Pull cover over gear knob. ris
edb ran
tee
tho or
– Then destroy clip -A- using aupliers -B-. ac
ss
ce
e

nl
pt
du
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itte
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erm
ab
ility
ot p
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h re
hole

Compartments, covers and trims; Removing and installing spec
es, in part or in w
t to the co
centre console . rrectness of i
l purpos

nf
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body.
orm
m
atio
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te
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ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤

console.
body.
– If there is a skid plate under the gearbox, remove it ⇒ General
– Remove transfer box ⇒ Transfer box and final drives; Rep.
gr. 34 ; Removing and installing transfer box .
Remove complete selector mechanism ⇒ page 42 .

– Remove front exhaust pipe with catalytic converter or partic‐
ulate filter ⇒ Rep. gr. 26 ; Removing and installing parts of
exhaust system .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
s a ac
s
ce
e
nl
pt
du
an
itte
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ab
ility
ot p
wit
, is n
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hole

spec
es, in part or in w
moved from gearbox. t to the co
– Lay a piece of wood -A-, about 50 mm high, between gearbox

and subframe.
rrectness of i

l purpos
– Unbolt starter from engine/gearbox and secure as necessary

nform
starter .
mercia
at
om
ion
Note
c
in t
or
his
ate
Starter cables do not have to be disconnected.

do
priv
cum
for
en
ng
t.
yi Co
op
– Remove coolant pipe from gearbox only; do not open coolant C py
t. rig
system ⇒ Cooling; Rep. gr. 19 ; Parts of cooling system .
gh ht
pyri by
Vo
co lksw
by
– Remove upper engine/gearbox connecting bolts. cted agen
Prote AG.
– Unclip manual gearbox breather line from bracket.

Touareg 2003 ➤

tem.
Caution

destroyed.
To remove manual gearbox “08D”, set up gearbox support - 3282-

ment plate .

– Screw adapter - 3282/54- onto front left post of gearbox sup‐ AG. Volkswagen AG d
agen
port . Volksw
oes
not
y gu
db ara
– Position engine and gearbox jack with gearbox support
ris
e - 3282- nte
ho eo
under vehicle. au
t ra
ss c
ce
le
un
pt
× 20) -A- and -B- (M10 x 30).
an
d
itte
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erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
– Remove lower engine/gearbox connecting bolts.
rrectne
– Press gearbox away from engine, off dowel sleeves.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
um
r
fo

en
ng
t.
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op
– Then lower gearbox.
C py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤

to new gearbox:
1 - Breather line
2 - Deflector lever
AG. Volkswagen AG d
agen
4 - Gearbox support bracket Volksw
oes
not
gu
d by ara
5 - Bracket orise nte
eo
h
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un
pt
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
– Ensure that intermediate plate is correctly seated on engine.
a
com
tion in
To install manual gearbox “08D”, set up gearbox support - 3282-
r
te o
thi
s
iva
do
r
rp
c
um
fo
ment plate .
en
ng
t.
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op py
The symbols on the adjusting plate indicate the mounts required; t. C rig
gh ht
the arrow points forward. yri
p by
o Vo
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cted
agen
Prote AG.
port .
× 20) -A- and -B- (M10 x 30).
– Carefully guide gearbox onto engine, observing lines in tunnel.
– Screw in lower engine/gearbox connecting bolts and tighten
to specified torque ⇒ page 66 .

Touareg 2003 ➤
swage es n
– Now raise gearbox by Venough so that the piece of wood
olk ot g-A-, about
ua
50 mm high, can ir se be inserted between gearbox and subframe.
d ran
tee
tho
or
– Carefullyss lower
au engine and gearbox jack and remove gearbox ac
ce
e
nl
pt
du
an
– Install selector housing to body ⇒ page 42 .
itte
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erm
ab
– Screw in upper engine/gearbox connecting bolt and tighten to
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
⇒ page 59 .
nform
ercia
– Clip gearbox breather line into bracket.

m
at
om
ion
c
– Tighten engine/gearbox connecting bolts to specified torque
in t
or
⇒ page 59 .
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Attach coolant pipe ⇒ Cooling; Rep. gr. 19 ; Parts of cooling cop Vo
by lksw
system . cted agen
Prote AG.
Install selector mechanism ⇒ page 42 .

– Insert starter and bolt on ⇒ Electrical system; Rep. gr. 27 ;
Removing and installing starter .
– Now raise gearbox enough that the retaining tool - VW 785/1
B- (required for removing and installing transfer box ⇒ Trans‐
fer case and final drives; Rep. gr. 34 ; Removing and installing
transfer case ) can be attached to gearbox.
– Then remove piece of wood -A- between gearbox and sub‐
frame.
– Install front exhaust pipe with catalytic converter or particulate
filter ⇒ Rep. gr. 26 ; Removing and installing parts of exhaust
system .

Touareg 2003 ➤
6-speed manual gearbox 08D - Edition
en AG. V
o08.2017
lkswagen AG
ag does
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Vol gu
– Install noise insulation tray ebracket
db
y -A-. ara
nte
oris eo
– Install transfer box ⇒ aTransfer
ut
h
box and final drives; Rep. gr. ra
34 ; Removing and installing
ss transfer box . 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
2.2.3 Specified torques
ss
Gearbox to engine (illustration shows gearbox flange)
o
cial p
f inform
Item Bolt Quantity Nm
mer
atio
1 M12 x 80 4 80
om
n
c
i
2 M12 x 70 1 80
or
n thi
te
sd
a
3 M10 x 70 3 45
iv
o
pr
cum
r
4 M10 x 70 2 45
fo
en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
-A- and -B-: dowel sleeves for centring op Vo
by c lksw
cted agen
Prote AG.
Slave cylinder on gearbox: 25 Nm
2.3 Removing and installing gearbox, vehicles with 6-cylinder petrol engine

Touareg 2003 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
♦ Gearbox support - 3282-

an
d
itte
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erm
♦ Adapter - 3282/54-
ab
ility
ot p
♦ Adjustment plate - 3282/55-

wit
is n
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ole,

spec

t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
– Then destroy clip -A- using pliers -B-.
atio
om
n in
c

or
thi
te
sd
a

iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
– Remove ashtray and remove shift mechanism cover from cen‐ C py
t. rig
gh ht
pyri by
co Vo
by lksw
cted
centre console .
agen
Prote AG.

body.

Touareg 2003 ➤

console.
body.
– Loosen wheel bolts on front left and front right.
– Raise vehicle.
– Remove front wheels.
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners .
– Remove complete air filter housing -1- with intake hose -2- ⇒
6-cylinder injection engine; Rep. gr. 24 ; Repairing injection
system .
– Then remove throttle valve module - J338- -3- from intake
manifold⇒ 6-cylinder injection engine; Rep. gr. 24 ; Repairing
injection system .
– Then unbolt shield -5- from engine. Loosen the 6 securing nuts
from front exhaust pipe with catalytic converters -4- from ex‐
haust manifold about 3 turns ⇒ 6-cylinder injection engine;
Rep. gr. 26 ; Removing and installing parts of exhaust system .
– If there is a skid plate under the gearbox, remove it w⇒agGeneral
en AG. V
olkswagen AG
does
body repairs, exterior; Rep. gr. 50 ; Skid plate
y V.
o lks not
gu b ara
ed
– Remove transfer box ⇒ Transfer box and ho final drives; Rep.
ris nte
e
aut box .
gr. 34 ; Removing and installing transfer or
ac
s s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in

form
mer
atio
m

o
n
c
i
or
n thi
e

t
sd
iva
o
pr

um
r
fo

en
ng
t.
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moved from gearbox. . Cop py
rig
ht ht
rig
– Lay a piece of wood -A-, about 50 mm high, between gearbox py by
co Vo
and subframe.
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Remove lower engine/gearbox connecting bolts -arrows-.

swage es n
Note byV
olk ot g
ua
d ran
ir se tee
o
The plugs -A-au must be installed after the gearbox is installed.or a
th
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
– Unscrew engine/gearbox connecting bolt -arrow 1- below
t to the co
starter.
– Then remove heat shield -A- and wiring from starter ⇒ Elec‐
rrectness of i
trical system; Rep. gr. 27 ; Removing and installing starter .
l purpos
– The wiring retainer for the battery positive wire -B- must be
removed from exhaust system bracket -C-.
nf
ercia
– Then remove bolt -arrow 2- for exhaust system bracket.
orm
m
– Remove starter securing bolt -arrow 3- from gearbox.
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
– Remove exhaust system bracket -A- from gearbox -arrows-.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove engine/gearbox connecting bolt -arrow A-.

– Remove starter securing bolt -arrow B- and remove starter.

Touareg 2003 ➤
6-speed
en AG. Volkswamanual
gen AG gearbox 08D - Edition 08.2017
ag does
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Vol gu
– Unclip pipe/hose line from retainer -2- ed on gearbox.
by ara
nte
oris eo
– Remove bolt -1- and pull out slave
au cylinder to the rear.
th
ra
ss c
ce
e
nl
pt
tem.
du
an
itte
y li
erm
ab
ility
Caution
ot p
wit
, is n
h re
hole
spec
destroyed.
es, in part or in w
t to the co
– Remove bracket for coolant pipes -4- from gearbox. To do this,
unscrew bolt -3-.
rrectness of i
– Remove engine/gearbox connecting bolts -arrows-.
l purpos
– Unclip breather line -A- for manual gearbox from bracket -B-.
nf
ercia
or
– Remove upper engine/gearbox connecting bolts -arrows-.
m
m
atio
om
n in
or c
thi
Note
te
sd
iva
o
r
rp
cu
These connecting bolts are accessible from behind the gearbox
o
m
f
en
ng
with the appropriate ratchet extensions.

t.
yi Co
Cop py
t. rig
gh ht
yri
To remove manual gearbox “08D”, set up gearbox support - 3282- p by
o Vo
by c lksw
with adjustment plate - 3282/55- . Prote
cted AG.
agen

ment plate .

port .
– Position engine and gearbox jack with gearbox support - 3282-
under vehicle.
× 20) -A- and -B- (M10 x 30).

Touareg 2003 ➤
– Remove last connecting bolt -arrow- above opening for starter.

– Swing down selector housing and secure together with selec‐
tor cables to gearbox using, e.g. wire.
– Press gearbox off engine (dowel sleeves) and guide gearbox
input shaft out of clutch.
– In the process, press front exhaust pipe with catalytic convert‐

ers -C-, which was separated from engine, away from gearbox
-A- slightly -arrow 1-.
– Then lower gearbox and guide past subframe -B- -arrow 2-.
– If necessary remove selector cables together with selector
housing.

to new gearbox:
1 - Breather line
2 - Deflector lever
3 - Gearbox selector lever n AG. Volkswagen AG do
lkswage es n
4 - Gearbox support bracket byV
o ot g
ua
d ran
ir se tee
5 - Bracket utho
or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab

ility
ot p
wit
, is n
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hole

spec
es, in part or in w
t to the co

rrectness of i

l purpos

nf
ercia

orm
m
atio
To install manual gearbox “08D”, set up gearbox support - 3282-

om
n in

or c
thi
te
sd

iva
o
r
ment plate .
rp
cu
o
m
f
en
ng

t.
yi Co
op
the arrow points forward. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤

port .
× 20) -A- and -B- (M10 x 30).
• Selector cables are attached to gearbox and selector housing
is secured to gearbox with, e.g., wire.
– Carefully raise gearbox -A- guiding past subframe -B-

-arrow 2-.
– When installing gearbox, press exhaust pipe with catalytic
converters -C-, which was separated from engine, carefully
away from gearbox -arrow 1-.
– Screw in connecting bolt -arrow- above opening for starter and

tighten to specified torque ⇒ page 76 .
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
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Screw in lower engine/gearbox connecting bolts -arrows- and

t to the co

rrectness of i
Note
l purpos
Check that plugs -A- are installed and install if necessary.

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.

Touareg 2003 ➤
– Now raise gearbox enough so that the piece of wood -A-, about
50 mm high, can be inserted between gearbox and subframe.
– Carefully lower engine and gearbox jack and remove gearbox
– Attach selector housing to body ⇒ page 42 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Clip breather line -A- for manual gearbox into bracket -B-.
ce
le
un
pt
an
d
itte
– Screw in upper engine/gearbox connecting bolts -arrows- and
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
These connecting bolts are accessible from behind the gearbox
t to the co
with the appropriate ratchet extensions.
rrectness of i
l purpos
nform
ercia

m
a
com
t
⇒ page 76 .
ion in
r
te o
thi
s
iva
do
– Tighten engine/gearbox connecting bolts -arrows- to specified
r
rp
cum
fo
torque ⇒ page 76 .
en
ng
t.
yi Co
op
– Install bracket for coolant pipes -4- to gearbox. To do this, C py
t. rig
tighten bolt -3-.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Tighten engine/gearbox connecting bolt -arrow A- to specified

– Insert starter and tighten starter securing bolt -arrow B- to

Touareg 2003 ➤
– Then attach bracket -A- for exhaust system to gearbox

-arrow-.
– Tighten starter securing bolt -arrow 3- on gearbox to specified

– Tighten engine/gearbox connecting bolt -arrow 1- below start‐
er to specified torque ⇒ page 76 .
– Secure lines and insulation mat -A- to starter ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing and installing starter .
– Attach wiring retainer for battery positive wire -B- to bracket
-C- for exhaust system -arrow 2-.
– Now raise gearbox enough that the retaining tool - VW 785/1
B- (required for removing and installing transfer box ⇒ Trans‐
fer case and final drives; Rep. gr. 34 ; Removing and installing
transfer case ) can be attached to gearbox. agen
AG. Volkswagen AG d
o w es n
olks ot g
– Then remove piece of wood -A- between
db
yV gearbox and sub‐ ua
ran
frame. rise tee
ho t or
au ac
– Lower engine and gearboxss jack and move aside.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Secure front exhaust pipe with catalytic converters -4- on ex‐

haust manifold. Bolt shield -5- to engine ⇒ Rep. gr. 26 ;
Removing and installing parts of exhaust system .
– Then attach throttle valve module - J338- -3- to intake mani‐
fold⇒ 6-cylinder injection engine; Rep. gr. 24 ; Repairing
injection system .
– Install complete air filter housing -1- with intake hose -2- ⇒ 6-
cylinder injection engine; Rep. gr. 24 ; Repairing injection
system .
– Install noise insulation tray bracket.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation .
– Install front right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner .
– Install front wheels ⇒ Running gear, axles, steering; Rep. gr.
44 ; Torque settings for wheel bolts and tyre fitting .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
. Volkswagen AG
gen AG
2.3.3 Specified torques y Volkswa
does
not
b gu
d ara
Gearbox to engine rise
(illustrationhshows gearbox flange) nte
t o eo
au ra
s c
Item Bolt
s Quantity Nm
ce
e
nl
pt
du
1 M12 x 60 2 80
an
itte
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2 M12 x 140 1 80
erm
ab
ility
♦ With nut
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3 M12 x 140 1 80
hole
spec
4 M10 x 50 4 45
es, in part or in w
t to the co
5 M12 x 60 1 65
♦ For starter on gearbox
rrectness of i
6 M12 x 60 1 65
♦ For starter on gearbox
l purpos
♦ With M8 stud
nform
ercia
7 M12 x 70 1 80
m
at
om
8 M12 x 60 1 80
ion
c
♦ With M8 stud
in t
or
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ate
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-A- and -B-: dowel sleeves for centring

um
for
en
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t.
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Slave cylinder on gearbox: 25 Nm
Co
Cop py
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Touareg 2003 ➤
2.4 Transporting gearbox

♦ Lifting tackle - 2024 A-
♦ Hook - 10 - 222 A /2-
olkswagen AG
en AG. V
– Attach lifting tackle - 2024 A- as follows to lifting eyes of gear‐
ksw
ag does
not
Vol
box and transport using workshop hoist . ed
by gu
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Input shaft side: utho eo
ra
a c
ss
4th hole of hook rail in position 1 of lifting tackle -arrow B-.
ce
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nl
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Output shaft side:
itte
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erm
ab
2nd hole of hook rail in position 8 of lifting tackle -arrow B-.
ility
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hole
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es, in part or in w
The hooks and locating pins must be secured with locking pins!
t to the co
rrectness of i
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AG. Volkswagen AG d
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Touareg 2003 thor➤ eo
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6-speed manual
ss a gearbox 08D - Edition 08.2017 c
ce
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3 itte Checking gear oil
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Gearbox oil specification ⇒ Electronic parts catalogue “ETKA” .
r
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– Remove noise insulation below gearbox.
ng
t.
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op py
– If there is a skid plate under the gearbox, remove it ⇒ General t. C rig
gh ht
body repairs, exterior; Rep. gr. 50 ; Skid plate . pyri by
Vo
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by
cted agen
– To check gear oil, remove oil plug -arrow-. Prote AG.
The oil level is correct, when the gearbox is filled to lower edge
of filler hole.
– Tighten oil plug -arrow- to specified torque.
When filling with oil, note the following:
– Remove oil plug -arrow-
– Top-up gearbox oil to lower edge of filler plug drilling.
– Screw in plug -arrow-.
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
– Stop engine and remove plug -arrow-.
– Top up with gear oil to lower edge of filler hole.
– Tighten oil plug -arrow- to specified torque.
– Install noise insulation below gearbox.
Specified torque:
Oil filler plug to gearbox: 35 Nm

Touareg 2003 ➤
4 Gearbox
⇒ “4.1 Assembly overview - components on gearbox”,
page 79
⇒ “4.2 Installing to engine and gearbox support”, page 81
⇒ “4.3 Renewing locking pin”, page 82
4.1 Assembly overview - components on gearbox
1 - Selector unit
❑ Renew seals for rotary
gear selector shaft and
gate selector shaft
⇒ page 90
⇒ page 90
2 - Bolt, 21 Nm
3 - Dowel sleeve
❑ Qty. 2
❑ For centring selector
unit on clutch housing
4 - Breather line
❑ ⇒ page 56
5 - Cap
❑ For breather line
6 - Bracket
❑ Depending on vehicleVolkswa
equipment differentagen ver‐
AG. gen AG
does
ksw
sions may y V be fitted
ol not
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edb ara
❑ ⇒hpage oris 56 nte
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❑ ss Allocate via ⇒ Electron‐
a ra
c
ic Parts Catalogue “ET‐
ce
le
un
KA”
pt
an
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7 - Spring-type clip
rm
ab
pe
ility
❑ For breather line

ot
wit
, is n
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8 - Bleeder
hole
spec
❑ Depending on vehicle
es, in part or in w
equipment different ver‐

t to the co
sions may be fitted

❑ Allocate via ⇒ Electron‐
rrectness of i
ic Parts Catalogue “ET‐

KA”
l purpos
❑ Insert to stop
9 - Input shaft seal
nform
ercia
❑ Renew after removal ⇒ page 83

m
a
com
tio
10 - Cap
n in
r
te o
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❑ For layshaft.
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iva
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11 - Plug
n
t.
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op
❑ Not installed in all gearboxes; allocate via ⇒ Electronics parts catalogue “ETKA”
C py
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❑ Installing ⇒ page 81
p by
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Prote AG.
4. Gearbox 79
Touareg 2003 ➤
12 - Oil drain plug, 35 Nm

13 - O-ring
❑ Always renew
❑ Insert in circumferential groove of gearbox input speed sender - G182-
14 - Bolt, 12 Nm
❑ For gearbox input speed sender - G182-
15 - Gearbox input speed sender - G182-
❑ Fitting position ⇒ page lkswage
80 es n
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yV ua
❑ Allocate via ⇒ Electronic
ir se
d b
Parts Catalogue “ETKA” ran
t ee
tho or
16 - Oil filler plug,s a35
u Nm ac
s
ce
le

un
pt
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17 - Retaining pin
rm
ab
pe
ility
❑ For adjusting selector mechanism
ot
wit
, is n
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hole
spec
18 - Bolt, 12 Nm
es, in part or in w
❑ For reversing light switch - F4-
t to the co
19 - Reversing light switch - F4-
rrectness of i
20 - O-ring
l purpos
❑ Always renew nform

ercia
❑ Insert in annular groove of reversing light switch - F4-

m
21 - Seal
a
com
tion in
❑ For output shaft

r
te o
thi

s
iva
do
r
❑ Can be renewed with gearbox installed after transfer box has been removed
rp
cum
fo
en
ng
22 - Bolt, 12 Nm
t.
yi Co
Cop py
. rig
For idling speed switch - F60-
t
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23 - Idling switch - F60-
cted agen
Prote AG.
24 - O-ring
❑ Always renew
❑ Insert in annular groove in idling speed switch - F60-
Installation position of gearbox input speed sender - G182-

-arrow-
It is located below pivot pin -A- and locking pin -C- next to bolts
-B- for securing clutch housing to gearbox housing.
The illustration shows the gearbox fitted on the gearbox support
- T10321- .

Touareg 2003 ➤
Installation position of reversing light switch - F4- -B-

It is located on the right side in the area of the pivot pin -A-.
The illustration shows the gearbox fitted on the gearbox support
- T10321- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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Inserting plug -A- in clutch housing -B- horis nte
eo
aut ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
4.2 Installing to engine and gearbox support
l purpos
nform
ercia
♦ Support clamp - VW 313-

m
a
com
tion in
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Cop py
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Prote AG.
♦ Gearbox support - T10321-
4. Gearbox 81
Touareg 2003 ➤
– Secure gearbox to gearbox support - T10321- using bolts

-A-.
– Place drip tray underneath.
4.3 Renewing locking pin
4.3.1 Removing
The locking pin -A- is located on the right side on the clutch hous‐
ing. n AG. Volkswagen AG age does
ksw not
– Remove outer part of locking pin. by Vol gu
ara
ed nte
ris
– Then, carefully lever out lockingthopin in -direction of arrow- us‐ eo
ing a screwdriver. ss
au ra
c
ce
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ab
pe
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spec
es, in part or in w
t to the co
4.3.2 Installing
Installation position:
rrectness of i
The adjusting pin -A- of the retaining pin must point about 45°
l purpos
towards rear, towards the joint of the gearbox housing and the
clutch housing.
nform
ercia
– Driving locking pin into clutch housing

m
a
com
tion in
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iva
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by
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Prote AG.

AG. Volkswagen AG d
agen oes
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byV gu
ara
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aut
h
Touareg 2003 ➤
ra
s c
s 6-speed manual gearbox 08D - Edition 08.2017
ce
le
un
pt
an
d
itte
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5 Renewing seals and sealing covers
erm
ab
ility
ot p
wit
⇒ “5.1 Renewing input shaft seal”, page 83
is n
h re
ole,
⇒ “5.2 Renewing output shaft seal”, page 84
spec
⇒ “5.3 Renewing seals for rotary gear and gate selector shafts”,
t to the co
page 86
⇒ “5.4 Renewing layshaft cap”, page 88
rrectne
5.1 Renewing input shaft seal
ss o
cial p
f inform
5.1.1 Removing
mer
atio
om
n
c
i
or
n
thi
te
equipment required
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.
♦ Puller - T10055-
♦ Adapter - T10055/2-
♦ Thrust piece - T10180-
♦ Sealing grease
(ETKA) .
5. Renewing seals and sealing covers 83

Touareg 2003 ➤
♦ Not required: sleeve - T10186-

– Remove gearbox ⇒ page 52 .
– Remove clutch release lever together with release bearing
and retaining spring ⇒ page 24 .
– To pull out seal, screw self-tapping screw with about 4 mm
diameter -arrow B- into one of the existing holes -arrows A-.
Note
♦ The metal cover of seal is predrilled in 2 places -arrows A- and

covered with rubber coating.
♦ Do not screw in sheet metal screw too far to avoid damaging
bearing behind it.
– Pull out input shaft oil seal

A - Self-tapping screw
lkswage es n
o ot g
byV ua
d ran
ir se tee
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pt
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erm
ab
ility
ot p
5.1.2 Installing
wit
, is n
h re
hole
– Half-fill space between sealing lip and dust lip of new seal with
spec
sealing grease .
es, in part or in w
t to the co
– Drive in new input shaft seal to stop, being careful not to not
cant seal.
rrectness of i
– Install clutch release lever together with release bearing and

retaining spring ⇒ page 24 .
l purpos
– Install gearbox ⇒ page 52 .

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
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5.2 Renewing output shaft seal Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Puller - T10055-
nform
ercia
♦ Adapter - T10055/2-
m
at

om
ion
c
in t
r
♦ Sleeve - T10186-
o
his
ate
do
riv
♦ Sealing grease
p
cum
for
en

ng
t.
yi Co
(ETKA) . t. Cop py
rig
gh ht
yri
5.2.1 Removing
p by
o Vo
by c lksw
cted agen
Prote AG.
– Remove transfer box ⇒ Rep. gr. 34 ; Removing and installing
transfer box .

Touareg 2003 ➤
– To pull out seal, screw self-tapping screw of about 4 mm in

diameter into one of the existing holes in the seal -arrow-.
Note
♦ The metal cover of seal is predrilled in 2 places -arrows A- and

covered with rubber coating.
♦ Do not screw in sheet metal screw too far to avoid damaging
bearing behind it.
5.2.2 Installing
sealing grease .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
– First, fit sleeve - T10186- onto output shaft. This prevents the
hole
spec
seal from being damaged.
es, in part or in w
t to the co
– Then, drive in new seal onto stop using thrust piece - T10180- .
Do not cant oil seal in the process.
– Install transfer box ⇒ Rep. gr. 34 ; Removing and installing
rrectness of i
transfer box .
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.
5.3 Renewing seals for rotary gear and gate

selector shafts

Touareg 2003 ➤
♦ Extractor hook - T20143-
♦ Thrust piece - VW 431-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
pt
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itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
♦ or tube - VW 423-
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
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cum
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♦ Sealing grease
en
ng
t.
yi Co
op
♦ For grease allocation, refer to ⇒ Electronic parts catalogue C py
t. rig
(ETKA) .
gh ht
pyri by
Vo
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by c lksw
5.3.1 Removing
cted agen
Prote AG.

– Lever cap of selector mechanism cover off rotary gear and
gate selector shafts using a screwdriver.
– Remove seal using screwdriver or extractor tool - T20143- .

Touareg 2003 ➤
5.3.2 Installing
sealing grease .
Driving in seal for rotary gear and gate selector shafts flush
Note
The seal can be driven in flush with rotary gear and gate selector
shafts installed using tube - VW 423- .
– Clip cap by hand onto respective shaft.

– Install gearbox ⇒ page 52 .
5.4 Renewing layshaft cap

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Puller - T10055-
♦ Adapter - T10055/2-

Touareg 2003 ➤
♦ Not required: sleeve - T10186-
5.4.1 Removing
– Use a self-tapping screw -A- of approx. 4 mm in diameter.
– In order to screw self-tapping screw -A- into sealing cover, first
punch a hole in the outer section of the sealing cover using,
e.g., a punch .
Note
Carefully drive in punch (but not deeper than 5 mm) to avoid

damaging the bearing located behind it.
5.4.2 Installing
en AG. Volkswagen A
– Drive in new sealing cover
olks
wagfor layshaft to stop, being
G do
es n careful
ot g
not to not cant sealing
db
y V cover. ua
r e an
ris tee
– Install gearbox
ut ⇒ page 52 .
ho or
a ac
ss ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
6 Selector unit
⇒ “5.3 Renewing seals for rotary gear and gate selector shafts”,
page 86
⇒ “6.1 Removing and installing selector unit”, page 90
Note
♦ The selector mechanism cover ⇒ Item 3 (page 90) , the nee‐

dle bearings ⇒ Item 4 (page 90) , the rotary gear selector
shaft ⇒ Item 5 (page 90) and the rotary gate selector shaft
⇒ Item 6 (page 90) are available as a single replacement
part.
♦ The needle bearings ⇒ Item 7 (page 90) are no replacement
part.
♦ Refer to ⇒ Electronic Parts Catalogue (ETKA) .
1 - Cap
❑ Pry off rotary gear and
gate selector shafts us‐
ing a screwdriver
AG. Volkswagen AG d
❑ Clip on to respective agen oes
olksw not
shaft by hand ed by V gu
ara
ris nte
2 - Seal tho eo
s au ra
c
❑ Renew after removal
s
ce
e
⇒ page 86
nl
pt
du
an
itte
y li
3 - Selector mechanism cover

erm
ab
ility
ot p
4 - Needle bearing
wit
, is n
h re
5 - Rotary gear selector shaft

hole
spec
es, in part or in w
⇒ page 91
t to the co
6 - Rotary gate selector shaft

rrectness of i
⇒ page 91
l purpos
7 - Needle bearing
❑ No replacement part
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.
6.1 Removing and installing selector unit


Touareg 2003 ➤
♦ For allocation of sealant , refer to ⇒ Electronic Parts Catalogue

(ETKA) .
6.1.1 Removing
– Remove bolts -arrows- securing selector unit to gearbox.
– Carefully lever off selector unit.
Do not damage sealing surfaces of gearbox and selector mech‐
anism cover in the process.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
ce
e
nl
pt
du
an
itte
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6.1.2 Installing
erm
ab
ility
ot p
Installation position of rotary gear and gate selector shafts in se‐

wit
, is n
lector mechanism cover

h re
hole
spec
A - Rotary gear selector shaft

es, in part or in w
t to the co
B - Rotary gate selector shaft

– The pin -arrow- of the selector mechanism cover is located in
rrectness of i
the recess of the rotary gate selector shaft -B-.

l purpos
nf
ercia
orm
• The dowel sleeves for centring the selector unit -arrows- must
m
atio
m
be inserted.
o
n in
or c
– Move selector shaft to neutral.

thi
te
sd
iva
– Apply sealant evenly to sealing surface of selector mechanism

r
rp
cu
o
cover.
f
en
ng
t.
yi Co
op
– Set selector unit in place, guiding rotary gear selector shaft
C py
t. rig
and rotary gate selector shaft into yoke -A- of selector shaft.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Selector unit 91
Touareg 2003 ➤
– Tighten bolts -arrows- to specified torque ⇒ page 79 .

– Shift through all gears.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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Service

Service Department. Technical Information

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Copyright © 2017 Volkswagen AG, Wolfsburg K0058961820

2.1 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.4 III - Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . 40

2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.3 Renewing locking pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6.1 Removing and installing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.1 Location on gearbox

Glean following data from ⇒ Electronic parts catalogue (ETKA) :

2 Overview - power transmission

1 - 6-speed manual gearbox

2. Overview - power transmission 3

3 Calculating overall gear ratio “i”

4 Rep. gr.00 - Technical data

To ensure flawless and successful gearbox repairs, the greatest

see ⇒ Workshop equipment and special tools .

♦ The removal and installation of components on the outside of

6 Rep. gr.00 - Technical data

♦ Renew retaining rings.

threaded holes into which self-locking bolts are to be screwed.

quently being removed.

♦ Check pitch of thread, to ensure correct thread chaser is used

to clean threads and to ensure the threads are not damaged.

♦ When removing gearbox, remove clutch slave cylinder without

♦ If the clutch slave cylinder is removed with the hydraulic line

en bolts diagonally and in several gradual stages.

♦ In order to reduce the smell of a burned clutch, the clutch

♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

8 Rep. gr.30 - Clutch

I - Assembly overview - pedal

1. Repairing clutch mechanism 9

bracket for pedal clus‐

♦ Removing and installing

♦ Removing and installing

dash panel ⇒ Rep. gr. 70 ;

10 Rep. gr.30 - Clutch

❑ Lock locating mechanism in mounting bracket for clutch pedal ⇒ page 15 .

22 - Clutch pedal switch - F36-

23 - Clutch pedal switch - F194-

❑ Vehicle can be started only when clutch pedal is completely depressed.

Note installation position of compression spring ⇒ page 11 .

1. Repairing clutch mechanism 11

1.3 Removing, installing and adjusting

wise and pull out of support.

1.3.2 Installing and adjusting new clutch pedal

Install in the reverse order of removal, observing the following.

Distinguishing between clutch pedal switches

Clutch pedal switch

• Clutch pedal must be in rest position.

12 Rep. gr.30 - Clutch

♦ First, check the clutch pedal switch.

– To lock, turn clutch pedal switch - F36- on housing clockwise

gr. 70 ; Removing and installing dash panel .

switch - F194- (interlock switch)

1. Repairing clutch mechanism 13

1.4.2 Installing and adjusting new clutch pedal

terior; Rep. gr. 68 ; Removing and installing footwell covers .

– Remove lower cover on driver side ⇒ General body repairs,

14 Rep. gr.30 - Clutch