Transmission

2005 Audi A4 Quattro
TRANSMISSION 5 Spd. Automatic Transmission 01V
TRANSMISSION
5 Spd. Automatic Transmission 01V
00 - GENERAL, TECHNICAL DATA

TRANSMISSION IDENTIFICATION
The 5-speed automatic transmission 01V is installed in the Audi A4 2002 and up in conjunction with the 4 and
6-cylinder engines. Allocation --> Code letters, allocation, ratios, equipment.
Code letter allocation at transmission
Fig. 1: Location Of Code Letters On Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.
Transmission code letters are located on the data plate under the transmission (arrow).
There is another identical data plate on side of transmission which is not accessible with the transmission
installed.
Fig. 2: Location Of Transmission Code Number And Transmission Serial Number

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Transmission code number and transmission serial number.
Transmission serial number (arrow 1)
Transmission identification (arrow 2)
Code letter (arrow 3)
The transmission code letters are also listed on the vehicle data plates.
NOTES ON 5-SPEED AUTOMATIC TRANSMISSION 01V
Notes on 5-speed automatic transmission 01V
Self-study program number. 180 informs extensively about the function of this transmission.
Torque converter
The torque converter is equipped with a lock-up clutch. The lock-up clutch is closed load- and speed-dependant
with minimum pulsations and mechanically drives all forward gears independent of slip.
Transmission
5-speed automatic transmission 01V is equipped with 5 hydraulically activated forward gears. By passing the
torque converter slip, these forward gears become mechanically driven gears if the lock-up clutch is closed.
On Board Diagnostic (OBD)
Before performing service work on the automatic transmission, cause of damage must be exactly determined via
"Guided Fault Finding".
"Guided Fault Finding" is performed using the tester VAS5051.
Transmission Control Module (TCM) J217 with driving situation shifting (fuzzy logic)
Driving situation- and driving resistance dependent shift point determination is performed automatically.
Advantages:
 It is shifted depending on consumption

 Highest engine performance is always available
 Individual adaptation of shift points in all driving situations
 Arbitrarily changed shift points
Shift point change when driving up- or downhill ranges
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At uphill or downhill ranges, the shifts are automatically selected dependent on the accelerator pedal position
and vehicle speed via additional shift characteristics maps.
 Shift characteristics map for extreme uphill driving is adapted to the engine performance.
 Shift characteristics map for extreme downhill driving is adapted to the braking effect of the engine.
CODE LETTERS, ALLOCATION, RATIOS, EQUIPMENT
Code letters, allocation, ratios, equipment
All Wheel Drive (AWD)
Automatic transmission 01V.4 01V.4

Transmission Code letters FEP FEQ
Manufactured From to 27.01 27.01
Torque Code letters A33 F35
converter
Allocation Model Audi A4 2002 --> USA Audi A4 2002 --> USA
Engine 1.8 L 5VT - 125 kW 3.0 L 5V - 162 kW * See
note
Ratios 1. Gear 3.665 3.665
2. Gear 1.999 1.999
3. Gear 1.407 1.407
4. Gear 1.000 1.000
5. Gear 0.742 0.742
Reverse gear 4.096 4.096
*11 mm intermediate plate is installed between engine and transmission.
Transmission Code FEP FEQ

letters
Intermediate Number of Drive gear 29 29
drive-Va teeth
Output 35 35
gear
Ratio 1.207 1.207
Final drive- Number of Drive 11 11
VA teeth pinion
Ring gear 34 34
Ratio 3.091 3.091
Intermediate Number of Drive gear 41 41
drive-HA teeth
Output 37 37
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gear
Ratio 0.902 0.902
Final drive- Number of Drive 9 9
HA teeth pinion
Ring gear 37 37
Ratio 4.111 4.111
CAN-bus with CAN-bus with CAN-bus
E-Gas with E-Gas with E-Gas
Hydraulic control Rear Fog Light Switch Rear Fog Light Switch
E18/2 E18/2
REAR FINAL DRIVE, IDENTIFICATION
Rear final drive, identification
Vehicles with all wheel drive automatic transmission 01V are equipped with rear final drive 01R.
Allocation:
-->
 00 GENERAL, TECHNICAL DATA for REAR FINAL DRIVE

 00 - GENERAL, TECHNICAL DATA for REAR FINAL DRIVE 0AR
Fig. 3: Locations Of Final Drive Identification

Location on rear final drive
Code letters and date of manufacture (arrow 1)
Rear final drive 01R (arrow 2)
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Fig. 4: Final Drive 01R

Rear final drive 01R (arrow 2)
Fig. 5: Locating Code Letters And Date Of Manufacture Of Final Drive

Code letters and date of manufacture of final drive.
Example: EUB 26 04 00
I I I I
I I I I
Code letters Day Month Year (2000) of
manufacture
Additional information depends on manufacturing.
CODE LETTERS, ALLOCATION, RATIOS
Code letters, allocation, ratios
Rear final drive 01R
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Code letters ETQ

Manufactured From 09.00
To -
Allocation Model Audi A4 2002 --> USA
Engine 1.8 L 5VT - 125 kW 3.0 L 5V -
162 kW
Ratio Final drive Z2:Z1 = i 37 : 9 = 4.111
Capacity 1.5 Liter
Specification Gear oil GL 5 SAE 90
Drive axle flange 75.5 mm
Allocation of automatic transmission 01V all wheel drive Code letters FEP FEQ
CAPACITY
Capacity
Planet gear
Capacity Planet gear Automatic transmission
New filling 9.0 L 01V
Change approx. 2.6 - 3.0 L * See note
Lubricant ATF
*Filled for life: Replacement only after repair, when oil pan is removed, up to 3 liters.
ATF is available as a replacement part (is also referred to as VW ATF).
Container size 0.5 L -part number G 052 162 A1
Container size 20 L -part number G 052 162 A6
Only ATF available as a replacement part must be used in the planetary gear of the automatic transmission 01V.
Checking ATF level or replacing ATF --> Automatic Transmission Fluid (ATF), checking and changing.
Final drive-front
Capacity Final drive-front Automatic transmission
Change Filled for life, no replacement
Lubricant Gear oil SAE75 W90 (synthetic-
oil)
Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part in the following container sizes:
1:40:05 AM Page 6
Checking oil level in front final drive --> Gear oil in front final drive, checking.
Center differential
Capacity Center differential Automatic transmission
Change Filled for life, no replacement
Lubricant Gear oil SAE75 W90 (synthetic-
oil)
Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part in the following container sizes:
Filling transfer housing with gear oil and checking oil level --> Gear oil in center differential, checking and
topping off.
Rear final drive
Capacity
-->

ROLL STARTING AND TOWING NOTES
Roll starting and towing notes
CAUTION: When towing the vehicle, selector lever must be in position N and the
vehicle must not be towed for more than 50 km and no faster than 50 km/h,
since the transmission will otherwise be destroyed.
NOTE:  Tow starting for starting engine, e.g. if the battery is too weak or the
starter does not work is not possible.
SERVICING NOTES
Servicing notes
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The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful
transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned
at various points in the article, are summarized here. They apply to this article.
Special tools and workshop equipment
For a complete list of special tools used in this article: see "Special tools and equipment" or "Special tools".
Transmission
 Rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on
automatic transmissions.
 Do not run engine with the oil pan removed or without ATF filling and do not tow vehicle.
 Clean ATF lines and ATF cooler when replacing automatic transmission --> ATF lines and ATF cooler,
cleaning.
 Secure torque converter on removed transmission to keep it from falling out.
 Thoroughly clean all connections and the surrounding area before disconnecting.
 Check installation dimension of torque converter before installing transmission --> Torque converter,
installing
 When installing transmission, make sure centering sleeves are correctly seated in engine.
 Place parts that have been removed on a clean surface and cover. Use foils and paper. Use lint-free cloths
only!
 Carefully cover over opened components or seal, if repairs are not carried out immediately.
 Only install clean components: Only unpack replacement parts immediately prior to installation.
 Check, and if necessary correct amount of the following fluids when replacing the automatic
transmission. ATF in planetary gear --> ATF level, checking , gear oil in front final drive --> Gear oil in
front final drive, checking , gear oil in center differential --> Gear oil in center differential, checking
and topping off. Capacities and specifications --> Capacity onward.
 When replacing the rear final drive, check and if necessary, correct oil level in rear final drive. Capacities
and specifications --> Capacity. -->
 39 FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE
 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR
O-rings, gaskets, seals
 Always replace O-rings, gaskets and sealing rings.

 After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs
resulting from removal or for other signs of damage.
 Thoroughly clean housing sealing surfaces before assembling.
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 Lightly lubricate O-rings before installing, this prevents the rings from being pinched when inserting.
Fig. 6: Identifying Space Between Oil Seal Sealing Lips

 Before installing, fill gap between sealing lips (arrow) of radial-shaft seals half way with sealing grease
052 128 A1.
 The open side of the seals face toward the fluid to be sealed in.
 For installation, lightly coat outer circumference and sealing lip with ATF or transmission oil, depending
on the installation location.
 Use only ATF in areas near ATF. Other lubricating substances cause functional problems in the hydraulic
transmission control.
 When pressing in new seals, make sure the sealing lip does not run on the same point as the sealing lip of
the old seal (use insertion depth tolerances).
 After installing, check and if necessary correct fluid levels in the affected area. ATF in planetary gear -->
ATF level, checking , gear oil in front final drive --> Gear oil in front final drive, checking , gear oil in
center differential --> Gear oil in center differential, checking and topping off , gear oil in rear final
drive -->
Capacities and specifications --> Capacity onward.
Nuts, bolts
 Loosen bolts in reverse order of tightening sequence.

 Tighten and loosen bolts or nuts for securing covers and housings without tightening sequence in
diagonal sequence in stages.
 Do not cant, and loosen and tighten especially sensitive parts - e.g. valve body - in diagonal manner in
stages.
 The tightening torques stated apply to non-oiled nuts and bolts.
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 Always replace self-locking nuts and bolts.

 Using a wire brush, clean threads of bolts which are secured with locking compound. Next, insert bolts
using AMV 185 101 A1.
 Threaded bores into which self-locking bolts or bolts with locking compound are threaded in, must be
cleaned (e.g. using threaded tap). Otherwise there is danger that the bolts may shear when removed again.
Circlips
 Do not over-stretch circlips.

 Always replace damaged or over-stretched circlips.
 Circlips must be fully seated in groove.
Mount
 Install needle bearings with the lettering on the bearing (the side with thicker metal) facing the drift.
 Insert bearing with transmission oil or ATF, depending on installation location.
Valve body
 Replace transmission if shift members are burnt.
Guided Troubleshooting, Vehicle On Board Diagnostic (OBD) and Test Instruments
Fig. 7: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051
 Before performing repairs on the automatic transmission, the malfunction cause must be determined as
exact as possible via the tester VAS5051 in the operating modes "Guided Fault Finding ", " Vehicle Self-
Diagnosis " and " Test Instruments."
32 - TORQUE CONVERTER
TORQUE CONVERTER
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Torque converter
CAUTION: Check installation dimension of torque converter before installing

transmission --> Torque converter, installing
NOTE:  Rules of cleanliness for working on automatic transmissions --> Rules of

cleanliness for working on automatic transmissions.
 General repair notes --> Servicing notes.
 Lightly coat sealing ring with ATF. Other lubricating substances lead to
functional problems in the hydraulic transmission control.
Fig. 8: Identifying Torque Converter, Seal & Contact Ring

1 - Torque converter
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 Secure on removed transmission to keep it from falling out.

 Identification --> Torque converter, identification
 Installing --> Torque converter, installing
2 - Seal
 Always replace --> Torque converter oil seal, replacing
3 - Contact ring
 Behind sealing ring

 Replace if damaged
Torque converter, identification
Fig. 9: Torque Converter, Identification

Different types of torque converters exist. Identification is performed via code letters (arrow).
Allocation of torque converter/transmission --> Code letters, allocation, ratios, equipment.
Torque converter, checking
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Fig. 10: Inspect Torque Converter Hub For Irregular Grooves

 Checking converter hub for wear grooves (arrow).
NOTE:  The torque converter is welded in and must be completely replaced if

damaged or in case of malfunctions.
Torque converter, draining
Special tools, testers and auxiliary items required
Fig. 11: Special Tool - Oil Extraction Unit V.A.G 1358 A

 Oil siphoning unit VAG1358A

 Oil siphoning probe VAG1358 A/1
In case of soiling of the ATF via shavings, torque converter must be drained:
1:40:06 AM Page 13
Fig. 12: Extracting ATF From Torque Converter

 Drain ATF from torque converter using oil siphoning unit VAG1358A and Oil siphoning probe
VAG1358 A/1.
Torque converter oil seal, replacing
Fig. 13: Special Tool - Oil Seal Extractor Lever VW 681

 Extractor lever VW681
1:40:06 AM Page 14
Fig. 14: 3295 Thrust Piece

 Thrust piece 3295
Removing
 Removing transmission --> Transmission, removing and installing.

 Secure transmission to assembly stand --> Transmission, attaching to assembly stand.
Fig. 15: Applying Extractor Lever VW 681 Directly Behind Sealing Lip Of Oil Seal
 Insert extractor lever VW681 directly behind the sealing lip of the sealing ring, so that the contact ring
which is behind it is not damaged.
Installing
 Insert contact ring.

 Coat outer circumference and sealing lips of sealing ring with ATF.
 Installation position: The open side of the sealing ring faces the transmission.
1:40:06 AM Page 15
Fig. 16: Driving In Torque Converter Oil Seal Until Stop Of Thrust Piece 3295
 Using thrust piece 3295 , drive in sealing ring for torque converter up to thrust piece stop.
Torque converter, installing
 Depth gauge
 Slide in converter hub through the sealing ring up to the first stop.
 Rotate torque converter inward with light pressure, until the groove of the torque converter hub engages
in the coupling plate of the pump wheel and the torque converter slides inward noticeably.
Installation dimension for torque converter, checking
Fig. 17: Checking Torque Converter Is Correctly Positioned

When torque converter is installed correctly, distance between lower contact surface of threaded holes at torque
converter and contact surface of converter housing on Automatic Transmission 01V is approx. 23 mm.
If the torque converter is not inserted completely, this distance will be approx. 11 mm.
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CAUTION: In case of an incorrectly inserted torque converter, the coupling plate of

the torque converter or the ATF-pump will be destroyed, if the
transmission is flanged to the engine.
Pay particular attention to the following when installing the transmission.
CAUTION: Keep checking to make sure the torque converter behind the drive plate
can be turned before and during tightening the bolts at the
engine/transmission flange.
If the torque converter cannot be turned, it must be assumed that it has

not been inserted properly and that the coupling plate of the torque
converter or the ATF pump will be destroyed during final tightening of the
bolts.
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLED LOCATIONS
1:40:06 AM Page 17
Fig. 18: Electrical/Electronic Components And Installed Locations

1 - Transmission Control Module J217
 Component location and removing and installing --> Component location of Transmission Control
Module (TCM) J217
 Disconnecting multi-pin connector --> Disconnecting Transmission Control Module (TCM) J217
from multi-pin harness connector
 May be checked using tester VAS5051 in "Guided Fault Finding"
2 - Data Link Connector (DLC)
 Installation location Data Link Connector (DLC)
3 - Multi-Function Transmission Range (TR) Switch F125
1:40:06 AM Page 18
 Component location and removing and installing --> Multi-Function Transmission Range (TR) Switch
F125
4 - Internal transmission wiring harness with integrated Transmission Fluid Temperature Sensor G93 (ATF)
 Component location and removing and installing --> Internal transmission wiring harness with
integrated Transmission Fluid Temperature Sensor G93 (ATF)
5 - Valve body
 Component location and removing and installing Valve body

6 - Sensor for transmission RPM G182
 Calculates transmission RPM

 Component location and removing and installing --> Sensor for transmission RPM G182
7 - Transmission Vehicle Speed Sensor (VSS) G38 (also designated as Sender for transmission output RPM
G195 )
 Calculates transmission output RPM

 Component location and removing and installing --> Transmission Vehicle Speed Sensor (VSS) G38
8 - Tiptronic Switch F189
 Component location and removing and installing --> Tiptronic Switch F189
9 - Shift Lock Solenoid N110
 Component location and removing and installing --> Shift lock solenoid N110
10 - Throttle Position (TP) Sensor G79 and G185
 Component location and removing and installing and under Throttle Position (TP) sensor G79 and
G185
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11 - Starting Interlock Relay J207
 Installation location --> Starting Interlock Relay J207
12 - Transmission Range (TR) Selector Lever Display Y6
 Component location and removing and installing --> Transmission Range (TR) Selector Lever Display
Y6
 Unlit selected gear display indicates emergency mode with inactive Transmission Control Module
(TCM).
 Completely lit selected gear display indicates emergency mode with active Transmission Control Module
(TCM).
13 - Brake light switch F
 Component location and removing and installing --> Brake light switch F
Component location of Transmission Control Module (TCM) J217
Fig. 19: Component Location Of Transmission Control Module (TCM) J217

Control module is located in left plenum chamber in e-box under Engine Control Module (ECM).
Removing and installing the control module
-->
 97 WIRING
 97 WIRING for ELECTRICAL EQUIPMENT, CABRIOLET
If control module for engine or transmission is replaced, the system must be put into basic setting.
1:40:06 AM Page 20
 Perform basic setting in "Vehicle Self-Diagnosis" using the tester VAS5051.
Disconnecting Transmission Control Module (TCM) J217 from multi-pin harness connector
Fig. 20: Disconnecting Transmission Control Module (TCM) J217 From Multi-Pin Harness Connector
 Disengage harness connector (arrow) and disconnect it from Transmission Control Module (TCM).
Installation is the reverse of removal.
Data Link Connector (DLC)
Fig. 21: Data Link Connector (DLC)

Installation location: Data Link Connector (DLC) is located under driverside storage compartment.
 Connect tester VAS5051 to Data Link Connector (DLC) using diagnostic cable VAS5051/1 and adapter
VAS6017 with ignition switched off.
Valve body
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Fig. 22: Locating Valve Body Bolts

Installation location: Valve body is bolted on to transmission housing below and covered by transmission oil
pan.
Solenoid valves N88 , N89 , N90 , and pressure control valves N215 , N216 , N217 , N218 are fastened to valve
body.
Removing and installing valve body
--> Valve body, removing and installing
Internal transmission wiring harness with integrated Transmission Fluid Temperature Sensor G93 (ATF)
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Fig. 23: Internal Transmission Wiring Harness With Integrated Transmission Fluid Temperature Sensor
G93 (ATF)
Installation location: Transmission Fluid Temperature Sensor (arrow) is located in the wiring harness on valve
body.
Wiring harness may be replaced with transmission installed and valve body removed.
Wiring harness in transmission, removing and installing
--> Wiring harness inside transmission, removing and installing
Transmission Vehicle Speed Sensor (VSS) G38
Fig. 24: Transmission Vehicle Speed Sensor -G38-

Installation location: Transmission Vehicle Speed Sensor is located on rear right of transmission. Also referred
to as the sender for transmission output RPM G195.
Removing and installing Transmission Vehicle Speed Sensor (VSS)
--> Transmission Vehicle Speed Sensor (VSS) G38 , removing and installing
1:40:06 AM Page 23
Sensor for transmission RPM G182
Fig. 25: Sensor For Transmission RPM (Transmissions With Hydraulic Regulation -E18/2-)
Sensor for transmission RPM - A - is fastened to transmission housing behind valve body. This sensor is a Hall
sensor.
Removing and installing Sensor for transmission RPM G182
--> Sensor for transmission RPM G182 , removing and installing
Multi-Function Transmission Range (TR) Switch F125
Fig. 26: Location Of Multi-Function Transmission Range (TR) Switch

Installation location: Multi-Function Transmission Range (TR) Switch - 1 - is located at left on transmission;
1:40:06 AM Page 24
multi-pin connector for Multi-Function Transmission Range (TR) Switch - 2 -.
Removing and installing Multi-Function Transmission Range (TR) Switch
--> Multi-Function Transmission Range (TR) Switch F125 , removing and installing
Tiptronic Switch F189
Fig. 27: Tiptronic Switch F189

Installation location: Tiptronic switch is integrated into circuit board of symbol insert, which is located in shift
mechanism cover.
Tiptronic Switch F189 , removing and installing
--> Tiptronic Switch F189 , removing and installing
Shift lock solenoid N110
Fig. 28: Shift Lock Solenoid N110

Installation location: Shift lock solenoid is located in the shift mechanism - arrow -.
1:40:06 AM Page 25
Shift lock solenoid, removing and installing
--> Shift Lock Solenoid N110 , removing and installing
Starting Interlock Relay J207
Fig. 29: Starting Interlock Relay J207

Installation location: Relay is located in central electronics.
Assignment
--> Electrical Wiring Diagrams, Troubleshooting and Component Locations
Throttle Position (TP) sensor G79 and G185
Fig. 30: Throttle Position (TP) Sensors -G69- and -G79- Accelerator Pedal Position Sensor and Kickdown
Switch -F8- For Vehicles With EPC
Throttle Position (TP) sensor G79 and G185 (arrow), component of electronic engine power control (E-Gas), is
located at pedal assembly.
1:40:06 AM Page 26
The kick down function is performed (controlled) via Throttle Position (TP) sensor G79 and G185.
Checking, removing and installing Throttle Position (TP) sensor:
--> 20 - FUEL SUPPLY SYSTEM
Brake light switch F
Fig. 31: Brake Light Switch F

Installation location: Brake light switch (arrow) is located in foot pedal assembly.
Brake light switch, removing and installing
--> 46 - BRAKES - MECHANICAL COMPONENTS
Transmission Range (TR) Selector Lever Display Y6
Fig. 32: Transmission Range (TR) Selector Lever Display Y6

Installation location: in instrument cluster
1:40:06 AM Page 27
Removing and installing Transmission Range (TR) Selector Lever Display
-->
 90 INSTRUMENTS
 90 INSTRUMENTS for ELECTRICAL EQUIPMENT, CABRIOLET
SELECTOR LEVER MECHANISM, SERVICING
Selector lever mechanism, servicing
CAUTION: Before beginning repairs on the electrical system:
 Obtain the anti-theft radio security code.

 Switch the ignition off.
 Disconnect the battery Ground (GND) strap.
 On vehicles equipped with Audi Telematics by OnStar, switch-off the
emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery -->
 91 - COMMUNICATION
 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER for

COMMUNICATION, CABRIOLET
.
 After reconnecting vehicle battery, re-code and check operation of

anti-theft radio. Also check operation of clock and power windows
according to article and/or Owners Manual.
 After reconnecting vehicle battery on vehicles equipped with Audi
Telematics by OnStar, switch-on the emergency (back-up) battery for
the Telematic/Telephone Control Module -->

.
CAUTION: Shift selector lever into position "P" and engage parking brake before
working with the engine running.
Ignition key removal lock, checking
 Switch ignition key to driving position (ignition on).

 Depress brake pedal and hold.
1:40:06 AM Page 28
 Shifting selector lever out of position "P" must be possible with the button at shift lever depressed without
"sticking".
 It must not be possible to remove ignition key with selector lever in any position other than "P".
 Shift selector lever into position "P".
 It must be possible to move ignition key into removal position without "sticking".
 Remove ignition key.
 It must only be possible to remove ignition key in "P" position.

 Selector lever cannot be shifted out of position "P" with the button pressed and foot brake operated.
Shift mechanism, checking
Selector lever in position "P" and ignition switched on:
 Brake pedal is not being operated:
Selector lever is locked and cannot be shifted out of position "P" with the button at selector lever pressed. Shift
lock solenoid is locking the selector lever.
 Brake pedal is being operated:
Shift lock solenoid enables the selector lever. Selecting a driving mode must be possible with the button at shift
handle pressed without "sticking".
Slowly shift selector lever from "P" through "R, N, D, S" checking whether selector lever position in dash panel
insert agrees with selector lever position.
Selector lever in position "N" and ignition switched on:
Selector lever is locked and cannot be shifted out of position "N" with the button at selector lever handle
pressed. Shift lock solenoid is locking the selector lever.
Selector lever in position "D" , ignition and lights switched on:
Move selector lever in Tiptronic gate. The "D" symbol must no longer be illuminated and "+" and "-" symbols
must illuminate.
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 Start engine and let run at idle

 Engage parking brake and operate brake pedal
The selector lever display in dash panel insert must change from "PRNDS" to "54321" when selector lever is
moved in Tiptronic gate.
NOTE:  The starter must not operate in the selector lever positions "D" , "S" and
"R".
 For speeds exceeding 5 km/h and shifting into selector lever position "N" ,
the shift lock solenoid must not engage to lock the selector lever. Selector
lever can be shifted into a driving mode.
 For speeds below 2 km/h (almost standstill) and shifting into selector lever
position "N" , the shift lock solenoid must only engage after approx. 1
second. Selector lever can only be shifted out of position "N" with the
brake pedal operated.
Shift mechanism cover and selector lever knob, exploded view
NOTE:  Lubricate bearing areas and slide surfaces with polycarbamide grease G
052 142 A2.
1:40:06 AM Page 30
Fig. 33: Shift Mechanism Cover And Selector Lever Knob, Exploded View
1 - Selector lever
2 - Shaft piece for selector lever
 Removing and installing selector lever knob --> Selector lever handle, removing and installing
3 - Selector lever handle
 Removing and installing --> Selector lever handle, removing and installing
4 - Cover
 With selector scale and Tiptronic gate and selector lever lock indicator
1:40:06 AM Page 31
 Removing and installing Tiptronic switch F189 --> Tiptronic Switch F189 , removing and installing
and additionally unclipping cover
5 - Symbol insert
 Clipped in cover
6 - Printed circuit board
 with integrated Tiptronic Switch F189

 Removing and installing --> Tiptronic Switch F189 , removing and installing
7 - Masking panel
 With solenoid for Tiptronic switch F189 on reverse slide

 Removing and installing Tiptronic Switch F189 --> Tiptronic Switch F189 , removing and installing
8 - Guide
 For masking panel

 Separate both halves by applying careful levering movements
Selector lever handle, removing and installing
Removing
 Shift selector lever into position "D".
Fig. 34: Selector Lever Handle, Removing And Installing

 Turn sleeve - 1 - to left and push downward as far as stop.

 Carefully pull switch - 2 - just enough out of selector lever knob - 3 - until a cable tie can be inserted
between button and selector lever.
1:40:06 AM Page 32
NOTE:  Do not remove button further under any circumstances, otherwise the
selector lever knob will be damaged.
 Secure button in pulled-out position using cable tie - arrow - as shown in illustration.
 Remove selector lever knob upward.
Installing
Installation is reverse of removal, noting the following:

NOTE:  To install new selector lever knob - 3 - , button 2 must be pulled out as far
as stop and secured with a cable tie - arrow - or using assembly aid
included with new knob.
 If the button was accidentally not secured, then it must not be pulled from
selector lever knob using mechanical tools. Apply compressed air gun to
bottom of knob and carefully press button out with compressed air.
 Position complete selector lever knob - 3 - on selector lever - button 2 faces driver. During this, the knob
must engage into ring groove of the selector lever.
 Remove cable tie - arrow - or assembly aid, then button actuation engages in vertical groove of selector
lever. If necessary press button into selector lever knob.
 Pull sleeve - 1 - upward and engage by turning clockwise.
Shift mechanism cover, removing and installing
Removing
 Selector lever handle, removing --> Selector lever handle, removing and installing.
1:40:06 AM Page 33
Fig. 36: Opening Ashtray In Center Console And Removing Trim

 Open ashtray in center console and remove trim (arrows).

 Remove ashtray in center console: -->
 68 - INTERIOR EQUIPMENT
 68 - INTERIOR EQUIPMENT for BODY INTERIOR - CABRIOLET
Fig. 37: Releasing Clips And Pulling Cover With Guide Upward To Remove
 Release all 4 clips (arrows) and pull cover - 1 - with guide upward to remove.
 Disconnect electrical harness connector on side of guide.
Installing
 Remove selector lever handle.
Tiptronic switch is integrated into circuit board ( ), which is located in shift mechanism cover.
1:40:06 AM Page 34
It consists of 3 camshaft position sensors, which are activated by a magnet on the cross slide masking panel.
To replace Tiptronic switch, circuit board ( ) must be replaced.
Check also whether solenoid is correctly fixed on transverse slide of masking panel, replace masking panel with
guide if necessary.
Removing
 Remove shift mechanism cover --> Shift mechanism cover, removing and installing.
Fig. 38: Pressing Lugs Inward And Removing Cover From Guide
 Press the 4 lugs (arrows) inward and remove cover - 2 - from guide - 1 -.
 Remove circuit board with integrated Tiptronic Switch F189 from cover - 2 -.
NOTE:  If necessary, masking panel with solenoid for Tiptronic Switch F189 can be
removed as described below. As replacement part the masking panel is
only available together with guide.
1:40:07 AM Page 35
Fig. 39: Separating Both Guide Parts By Applying Careful Levering Movements
 Separate both guide parts by applying careful levering movements (arrows).

 Remove masking panel with solenoid for Tiptronic Switch F189.
Installing
 Install shift mechanism cover --> Shift mechanism cover, removing and installing.
Shift mechanism, overview
052 142 A2.
1:40:07 AM Page 36
Fig. 40: Shift Mechanism, Disassembling And Assembling (Sequence)

1 - Shift mechanism bottom cover
2 - Retaining bracket
 For selector lever
3 - Bearing bushing
4 - Tiptronic locking lever
5 - Pivot pin
6 - Selector lever
1:40:07 AM Page 37
7 - Shift lock solenoid N110
 Removing and installing --> Shift Lock Solenoid N110 , removing and installing
8 - Actuating lever
 For locking cable
9 - Lock
10 - Lever
11 - Catch lever
12 - Gate
13 - 10 Nm
14 - Selector housing
15 - Bearing bushing
17 - Retaining clip
 Always replace
19 - Pivot pin
20 - 10 Nm
Shift mechanism, removing and installing
Additional information
 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
1:40:07 AM Page 38
 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF


Removing


 Remove air conditioning operating unit: --> 87 AIR CONDITIONING
1:40:07 AM Page 39
 Disconnect electrical harness connector on Shift Lock Solenoid N110.
Fig. 43: Disengaging Locking Cable

 Disengage locking cable (arrows).

 Shift selector lever into position "S".
 Remove front exhaust system with catalytic converter. -->
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO
ENGINE MECHANICAL, ENGINE CODE(S): AMB
ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE
MECHANICAL, ENGINE CODE(S): AVK, BGN
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL,
ENGINE CODE(S): BKH
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE
1:40:07 AM Page 40
MECHANICAL, ENGINE CODE(S): BNS

MECHANICAL, ENGINE CODE(S): BHF
 Remove heat shield for driveshaft from body of the vehicle.
Fig. 44: Identifying Heat Shield Fasteners For Torsen Differential

 Remove heat shield for driveshaft from cover for Torsen differential (arrows).
 Unbolt driveshaft from transmission and hang or support. -->
 Unbolt front heat shield, if installed, from below shift mechanism housing.
Fig. 45: Removing Lower Cover From Shift Mechanism

 Remove lower cover from shift mechanism (arrows).

 Remove boot of selector lever cable from lower shift mechanism cover and slide back.
1:40:07 AM Page 41
Fig. 46: Identifying Retaining Clip, Securing Spring, Push Pin & Selector Lever Cable
 Remove retaining clip - 1 - for selector lever cable on shift mechanism downward.
 Pull plastic securing spring - 2 - slightly to front and push pin - 3 - up only as far as necessary (arrow).
 Pull selector lever cable - 4 - out of shift mechanism at the same time, and do not bend.
NOTE:  Do not bend or kink selector lever cable.
Fig. 47: Unscrewing Nuts

 Unscrew nuts (arrows).
NOTE:  A second mechanic is required when detaching shift mechanism below

vehicle.
 Press holder clips - 1 - and - 2 - inward, at the same time pushing shift mechanism downward.
Installing
1:40:07 AM Page 42
 Install selector lever cable.
Fig. 48: Inserting End Of Selector Lever Cable Into Joint Of Selector Lever
 Fit new retaining clip - 1 - for selector lever cable on shift mechanism.
Installation position:
Angled end of retaining clip faces to inside of shift mechanism.
 Install locking cable Installing.

 Adjust locking cable --> Locking cable, adjusting.
 Fit driveshaft to transmission. -->
 Install front exhaust system with catalytic converter. -->

ENGINE CODE(S): BKH
Tightening torques
1:40:07 AM Page 43
Component Nm
Shift mechanism to body 10
Bottom cover to shift mechanism 10
Shift mechanism, disassembling and assembling (sequence)
NOTE:  Removing and installing securing spring for locking cable Securing spring
for locking cable, removing and installing.
Disassembly of suspension strut
 Move selector lever into position "S".

 Remove selector lever lock solenoid - 7 - --> Shift Lock Solenoid N110 , removing and installing.
 Carefully unbolt gate - 12 -.
NOTE:  If gate - 12 - or selector housing - 14 - is damaged, complete selector

housing with gate must be replaced.
 Release pivot pins - 5 - and - 19 - and pull them out from the side.
 Unclip retainers - 2 - and - 16 -.
 Remove retaining clip - 17 -.
 Swing locking lever - 11 - fully upward.
 Pull selector lever - 6 - with bushes - 3 - and - 15 - together with locking levers for Tiptronic - 4 - and - 18
- downward out of selector housing - 14 -.
Assembly of suspension strut
 Check whether selector lever is still in position "S".

 Insert selector lever - 6 - into selector housing - 14 - from below.
 Push locking levers for Tiptronic - 4 - and - 18 - along with bushes - 3 - and - 15 - onto selector lever.
 Press selector lever - 6 - with bushes into selector housing and position it with retaining clip - 17 -.
 Engage retainers - 2 - and - 16 - to selector housing.
 Press pivot pins - 5 - and - 19 - into mounting bracket until they engage.
 Check whether pivot pins engage in locking lever for Tiptronic.
 Install selector lever lock solenoid - 7 - --> Shift Lock Solenoid N110 , removing and installing.
 Tighten gate - 12 - to selector housing - 14 - with the 3 securing bolts to 0.4 Nm.
NOTE:
1:40:07 AM Page 44
 If gate - 12 - or selector housing - 14 - is damaged by tightening too much,

complete selector housing with gate must be replaced.
 Gate is matched to selector housing and cannot be replaced separately.

Securing spring for locking cable, removing and installing
1:40:07 AM Page 45
Fig. 50: Securing Spring For Locking Cable, Removing And Installing
Removing
 Slightly lift spring at top (arrow B) and remove locking cable from shift mechanism.
 Unhook spring (arrow A) at retaining clip (arrow C) and remove toward top.
Installing
 Insert spring (arrow B) from top and hook in at retaining clip (arrow C).
 Align spring so that it is seated evenly in groove (arrow A).
 Slightly lift spring at top (arrow B) and insert locking cable into shift mechanism.
Shift Lock Solenoid N110 , removing and installing
Removing
Fig. 51: Releasing Lugs And Selector Lever Lock Solenoid Forward
1:40:07 AM Page 46
 Release lugs and remove selector lever lock solenoid forward (arrows).
Installing
Fig. 52: Pressing Selector Lever Lock Solenoid Into Guide Until It Engages
 Press selector lever lock solenoid into guide until it engages; actuating lever - 2 - of solenoid must engage
in locking lever - 1 - on shift mechanism.
Selector lever cable and locking cable, assembly overview

 Lubricate pull ring and ball socket with polycarbamide grease, part no. G
052 142 A2.
1:40:07 AM Page 47
Fig. 53: Selector Lever Cable And Locking Cable, Assembly Overview
1 - Selector lever cable
 Must not be kinked

 Removing and installing --> Selector lever cable, removing and installing
 Adjusting --> Selector lever cable, checking and adjusting
2 - Lock nuts - 12 Nm
3 - Boot
 For selector lever cable

 Fasten into bottom cover of shift mechanism
1:40:07 AM Page 48
4 - Locking clamp
5 - Ignition/Starter Switch
 With ignition key removal lock
6 - Locking cable
 For ignition key removal lock

 Removing and installing --> Locking cable, removing and installing
 Adjusting --> Locking cable, adjusting
7 - Hex-bolt - 9 Nm
8 - Clamping screw - 13 Nm

 To adjust, loosen by approx. 1 turn, do not fully remove
9 - Pin

 To remove selector lever cable, pull plastic securing spring on shift mechanism slightly forward and push
pin up only as far as necessary
10 - Retaining clip

 Always replace
11 - Pivot
 For selector lever cable to transmission
12 - Hex-bolt, 23 Nm
Selector lever cable, removing and installing
1:40:07 AM Page 49
Fig. 54: Identifying Pry Lever 80-200

 Pry lever 80-200



Removing

 Raise vehicle.
ENGINE CODE(S): BKH
1:40:07 AM Page 50


 Remove shielding plate/selector lever cable, if installed.
Fig. 56: Location Of Support Bracket For Selector Lever Cable

 Remove mounting bracket for selector lever cable (arrow).

 Removing left transmission support --> Right and left transmission mounts, removing and installing.
1:40:07 AM Page 51
Fig. 57: Removing Selector Lever Cable From Selector Shaft Lever
 Pry off selector lever cable from lever/shift rod using prying lever 80-200 (arrows).


1:40:07 AM Page 52
NOTE:  Make sure that pin is not pushed fully out.
 Remove selector lever cable - 4 - from shift mechanism.
Installing
1:40:07 AM Page 53
 Insert end of selector lever cable - 4 - into selector lever joint.

 Press pin - 3 - downward (arrow)
 Check whether plastic securing spring - 2 - has locked pin.
 Fasten selector lever cable boot into lower cover of shift mechanism.

 Bolt lower cover to shift mechanism (arrows).
 Install front heat shield, if present, under shift mechanism housing.
1:40:07 AM Page 54
Fig. 63: Pushing Lever/Selector Shaft On Transmission Fully Forward Into Position "S"
 Push lever/selector shaft - 2 - on transmission fully forward into position "S" - arrow -.
 Shift selector lever into "S" and carefully press up ball head of selector lever cable - 1 - on lever/shift rod
- 2 - using a pair of pliers.
NOTE:  Do not deform lever/shift rod when pressing up or else shifting cannot be
precisely adjusted any more.

 Bolt on mounting bracket for selector lever cable in this position (arrow).
 Install shielding plate/selector lever cable, if present.
 Install left transmission support with transmission mount --> Right and left transmission mounts,
removing and installing
1:40:08 AM Page 55

 Bolt heat shield for driveshaft onto transfer box (arrows).

ENGINE CODE(S): BKH
 Adjust selector lever cable --> Selector lever cable, checking and adjusting.
Tightening torques
Component Nm
Selector lever cable to mounting bracket 12
Mounting bracket to transmission (2 x M8) 23 Nm
Heat shield/selector lever cable to transmission, M8 23 Nm
Selector lever cable, checking and adjusting
 Special tool T40031
1:40:08 AM Page 56

Procedure
For 6 cylinder gasoline engines:
 Remove left front exhaust pipe. -->

ENGINE CODE(S): BKH
 Remove shielding plate/selector lever cable.
All:
1:40:08 AM Page 57


 Grasp selector lever cable - 1 - and push lever/selector shaft - 2 - fully forward into position "S" - arrow -
.
1:40:08 AM Page 58

Fig. 69: Loosening Rear Clamping Screw On Selector Lever Cable Approx. 1 Turn Through Hole In
Shift Mechanism Using Special Tool T40031
 Loosen rear clamping screw on selector lever cable approx. 1 turn through the hole in shift mechanism
using special tool T40031.
NOTE:  Loosen clamping screw approx. 1 turn. Do not remove.

 Clamping screw is only accessible in selector lever position "S".
 Selector lever must remain in position "S" while clamping screw is loose.
Fig. 70: Checking Exact Position Of Selector Lever In Position "S" By Pushing Selector Lever Lightly
Toward Drivers Seat
 Check exact position of selector lever in position "S" by pushing selector lever lightly toward drivers seat
1:40:08 AM Page 59
(arrow - A - ).
NOTE:  When adjusting, do not move selector lever backward or forward, or

adjustment will be falsified.
 Tighten clamping screw to 13 Nm in this position using special tool T40031.

 Installing left transmission support --> Right and left transmission mounts, removing and installing.
 Install shielding plate/selector lever cable.

 Install left front exhaust pipe. -->
ENGINE CODE(S): BKH
Tightening torques
Component Nm
Clamping screw to selector lever cable 13
Locking cable, removing and installing
Removing
NOTE:  Locking cable must not be kinked.

 Note radio code (for vehicles equipped with coded anti-theft radio/radio navigation system).
See Caution before beginning repairs on electrical system --> Selector lever mechanism, servicing
1:40:08 AM Page 60
 Disconnect Ground (GND) strap from battery.

 Remove storage compartment on drivers side -->
 Remove steering column cover: -->


 Lift retaining clip - 2 - from interlock lever and pull locking cable - 1 - out of ignition/starter switch.
 Lift securing spring - 4 - for locking cable and pull locking cable support bracket - 5 - on shift mechanism
sideways and disengage locking cable eye.
Installing
 Route locking cable kink-free behind dash panel strut (arrow).

 Insert locking cable - 1 - into ignition/starter switch.
 Check that interlock lever - 2 - is locked.
 Bring ignition/starter switch into locking position (ignition off).

 Check whether selector lever is still in position "P".
 Engage locking cable eye in pin - 3 -.
 Slightly lift securing spring - 4 -.
 Push locking cable support bracket - 5 - into shift mechanism from the right until securing spring - 4 -
engages.
 Adjusting locking cable --> Locking cable, adjusting.
See Caution for connecting Telematics battery --> Selector lever mechanism, servicing
NOTE:  Be sure to activate vehicle features (radio/radio-navigation system, clock,
1:40:08 AM Page 61
electric window regulators) according to owners manual when the battery

is reconnected.
 Further measures after re-connecting power supply: -->
 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V
TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V
TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT
 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL
INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V ENGINE MECHANICAL,
ENGINE CODE(S): BKH
 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BNS
 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BHF
1:40:08 AM Page 62
Fig. 71: Locking Cable Remove/Install Components

Locking cable, adjusting
1:40:08 AM Page 63
Fig. 72: Identifying Special Tools - Adjustment Pin For Shiftlock 3 3352A
 Adjusting gauge 3352A for locking cable

 Protective glasses
Preliminary work
NOTE:  The following described procedure saves the work of removing center
console.
Fig. 73: Identifying Cutting Area Of Adjusting Gauge 3352A

 Cut through adjusting gauge 3352A at rear end of flat area - arrow - using a parting grinder.
CAUTION: Wear protective glasses.
 Order a new adjusting gauge 3352A for locking cable as replacement for later use.
Procedure
1:40:08 AM Page 64
 Remove center console trim --> Shift mechanism cover, removing and installing.
NOTE:  Selector lever knob and cover can remain installed.

Adjustment requirements:
 Locking cable in installation position

 Selector lever in position "P".
 Ignition key in removal position.
Fig. 74: Removing Adjusting Gauge

 Loosen bolt - 1 -.
 Support bracket - 2 - of locking cable must be movable by hand
 Push modified adjusting gauge 3352A between pin on lever for locking cable and locking cable eye.
 Move locking cable in direction of arrow to stop and tighten bolt - 1 - to 9 Nm.
 It must be possible to easily remove and insert adjusting gauge 3352A in this position.
 Remove adjusting gauge.
 Check ignition key removal lock after every adjustment of the locking cable --> Ignition key removal
lock, checking.
Tightening torque
Component Nm
1:40:08 AM Page 65
Locking cable to support bracket 9
TRANSMISSION, REMOVING AND INSTALLING
Transmission, removing and installing


.


.
1:40:08 AM Page 66
Fig. 75: Identifying Special Tools - Transmission, Removing And Installing (1 Of 2)

 Engine support bridge 10-222A

 Support 10-222A/1
 Adapter 10-222A/3
 Shackle 10-222A/12
 Pry lever 80-200 for removing outside mirror

 Transmission support 3282
1:40:08 AM Page 67

 Adjustment plate 3282/19

 Testing Mandrels 3393
 Transport device 3457
 Drip tray VAG1306
 Engine/transmission support VAG1383A engine/gearbox jack

 Ladder VAS5085
Removing
1:40:08 AM Page 68
NOTE:  All cable ties opened or cut during engine removal must be reinstalled at
the same locations.
 First determine whether a coded radio is installed. If so, determine the correct coding.
See Caution before beginning repairs on the electrical system --> Transmission, removing and installing
 Switch ignition off and disconnect battery Ground (GND) strap.
Fig. 77: Removing Cover In Engine Compartment (Left Side)

 Remove cover - 1 - in engine compartment (left side).
Fig. 78: Removing Cover In Engine Compartment (Right Side)

 Remove cover - 1 - in engine compartment (right side).
1:40:08 AM Page 69
Fig. 79: Removing Rear Engine Cover

 Remove engine cover (arrows).

 Remove intake air duct from intake manifold.
Fig. 80: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
 Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 -.

 Remove bolts (arrows) and remove intake air guide - 2 -.
1:40:09 AM Page 70
Fig. 81: Fitting Support Bar 10-222A Together With Supports 10-222A/1 And Fit Adapters 10-222A/3
 Fit support bar 10-222A together with supports 10-222A/1 and fit adapters 10-222A/3.
 Secure spindles to engine. To do so, additionally use a shackle 10-222A/12 at the front side of the engine
to avoid damage.
 Take up weight of engine/transmission assembly on spindles.
 Loosen wheel bolts.
 Raise vehicle.
 Remove front wheels.
Fig. 82: Identifying Noise Insulation Panel Retainers

 Remove noise insulation panel (arrows).
1:40:09 AM Page 71

ENGINE CODE(S): BKH
Fig. 83: Axle Shaft Shielding Plate

 Remove heat shields for left, if installed, and right drive axles (arrows).
Third bolt is not visible in the illustration.
 Unbolt left and right drive axles - 1 - from transmission flanges and tie up. --> 40 - FRONT
SUSPENSION
1:40:09 AM Page 72
Fig. 84: Identifying Noise Insulation Tray Bracket, Multi-Function Switch Connector, Locking Lever
And Cable Tie
 Remove noise insulation bracket - 1 -.

 Disconnect connector - 2 - of wire for multi-function switch.
 Swing securing lever - 3 - , disconnect connector for transmission wiring harness.
 Cut cable ties - 4 -.
Make sure the wire for multi-function switch is not damaged when doing this.
Fig. 85: Location of Speedometer Vehicle Speed Sensor (VSS) G22, and Engine Speed (RPM) Sensor G28
 Disconnect connector from Speedometer Vehicle Speed Sensor (arrow - A - ).

 Unbolt Engine Speed (RPM) Sensor G28 (arrow - B - ) from transmission.
1:40:09 AM Page 73
Fig. 86: Unscrewing Nut For Clamp For ATF Lines

 Unscrew nut - 2 - for clamp for ATF lines.

 Place drip tray VAG1306 underneath.
 Always clean area of ATF line/transmission connection.
 Mark ATF lines if no color markings are present.
Fig. 87: Disconnecting ATF Lines

 Disconnect ATF lines - 1 -.

 Plug ATF lines with clean plug.
 Remove starter. -->
 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL

EQUIPMENT, CABRIOLET
1:40:09 AM Page 74
Fig. 88: Identifying Torque Converter To Drive Plate Bolts (3 Total)

 Unbolt 3 torque converter bolts from drive plate (turn crank shaft an additional 1/3 turn every time).

 Remove heat shield for driveshaft at transmission (arrows).
Fig. 90: Unbolting Driveshaft On Transmission And Securing To Panel With Wire
1:40:09 AM Page 75
 Unbolt driveshaft - 1 - on transmission and secure to panel - 2 - with wire (arrow). -->

 Mark position of mounting bracket for selector lever cable to transmission housing for re-installation,
unbolt mounting bracket (arrow).
 Remove left transmission support with transmission mount --> Right and left transmission mounts,
removing and installing.
1:40:09 AM Page 76
Fig. 93: Unbolting Multi-Function Transmission Range (TR) Switch F125 For Protection Against
Damage
 Unbolt multi-function Transmission Range (TR) switch F125 for protection against damage (arrows) and
expose wiring harness.
Fig. 94: Setting Up Transmission Support 3282

 Prepare transmission support 3282 for Automatic Transmission 01V with adjustment plate 3282/10 and
place it on the engine/transmission hoist VAG1383A.
NOTE:  The symbols on the adjustment plate indicate the necessary mounts for
Automatic Transmission 01V and the arrow points toward front of vehicle.
1:40:09 AM Page 77
Fig. 95: Supporting Transaxle

 Roll engine/transmission hoist VAG1383A with transmission support 3282 under transmission, align
adjustment plate parallel to transmission and support transmission.
 Secure transmission on transmission support 3282 using bolt - A -.
 Fill space between gearbox support and sump with washers.
Automatic Transmission 01V with All Wheel Drive is supported at the same positions as the Front Wheel Drive
version.
 Remove right transmission support with transmission mount --> Right and left transmission mounts,
Fig. 96: Unclipping Clamp For Coupling Rod For Left Front Level Control System Sensor G78 From
Control Arm
 Unclip retaining clip for coupling rods - 1 - of Left Front Level Control System Sensor G78 from left
front control arm - 2 -.
Vehicles with six-cylinder engine:
1:40:09 AM Page 78
Fig. 97: Unbolting Bolts For Stop/Torque Support

 Unbolt bolts (arrows) for stop/torque support - 1 -.
All:
Fig. 98: Identifying Engine Mount Bolts and Positioning Sleeves

 Mark installation positions for threaded assemblies - 1 - and positioning sleeves - 2 -.

 Remove nuts - 1 - on left and right engine mounts.
NOTE:  When installing, make sure that locating sleeves - 2 - engage again.
1:40:09 AM Page 79
Fig. 99: Checking Holes Align Using Testing Mandrel 3393

 Before loosening subframe, check on both sides of vehicle, using testing Mandrels 3393 , that at least
holes - 1 - and - 2 - align.
If this is not the case, axle alignment must be carried out after tightening of subframe.
Hole - 3 - is not applicable here.
Fig. 100: Identifying Fasteners Requiring Removing To Lower Transmission

 Remove bolts - 1 - and - 2 - at rear of subframe on both sides of vehicle.

 Remove bolts - 3 - at front of subframe on both sides of vehicle.
 Remove bolts - 4 - (2 bolts at each vehicle side).
 Remove lower connecting bolts for engine/transmission.
1:40:09 AM Page 80
 Lower engine-transmission-subframe using the spindles approx. 4 turns. To do this use Support
VAS5058.
 To do this lower engine/gearbox assembly using spindles in turn, 2 turns at a time.
 At the same time lower engine-transmission-subframe using lifter VAG1383A (second mechanic).
NOTE:  When lowering transmission, ensure that no components are damaged.
 Remove upper connecting bolts for engine/transmission.

 Press transmission off engine, while pressing torque converter out of drive plate.
Fig. 102: Press Torque Converter Against ATF Pump

1:40:09 AM Page 81
 Press torque converter against the ATF pump (arrow).

 Lower transmission.
Fig. 103: Securing Torque Converter

 Secure converter so it does not fall out.
For disassembly and assembly, secure transmission to assembly stand using Transport device 3457 and Holding
plate VW309 --> Transmission, attaching to assembly stand.
Installing
Installation of transmission is the reverse of removal. The following points must also be observed:
Before installing:
 Clean threads in output flange/driveshaft flange using a tap.

 Clean ATF lines --> ATF lines and ATF cooler, cleaning.
 Insert torque converter correctly into transmission

1:40:09 AM Page 82

 Make sure bushings are correctly seated.
NOTE:  If the bushings get stuck in the transmission housing, they must be
removed and new bushings must be installed on the engine.
Fig. 105: Engine Cover Bolt Location And Tightening Torque

For 4 cylinder engines:
Item A = bushings
1:40:10 AM Page 83
Fig. 106: Identifying Engine/Transmission Tightening Sequence

Item A = bushings

 Place transmission onto transmission support.
1:40:10 AM Page 84


 Move transmission into position between the lowered subframe and vehicle floor.
 Align transmission properly to engine.
 Tighten one engine/transmission connecting bolt at either side by hand.
 Make sure that wires do not get pinched as transmission is docked at engine.
CAUTION: Keep checking whether the torque converter behind the drive plate can be
turned before and during tightening of the bolts at engine/transmission
flange. If the torque converter cannot be turned, it must be assumed that it
has not been inserted properly and that the coupling plate of the torque
bolts.

 Bolt together torque converter and drive plate.

 To do this insert bolts by hand and tighten to tightening torque.
1:40:10 AM Page 85
 Insert top engine/transmission connecting bolts and tighten to tightening torque.
NOTE:  Some bolts also have a bracket or a Ground (GND) connection attached
refer to tightening torque tables starting on --> --> Tightening torques.
 Raise engine-transmission-subframe using the spindles approx. 4 turns. To do this use Support VAS5058.
 To do this raise engine/gearbox assembly using spindles in turn, 2 turns at a time.
 At the same time raise engine-transmission-subframe using lifter VAG1383A (second mechanic).
 Insert remaining engine/transmission connecting bolts and tighten to tightening torque

1:40:10 AM Page 86
 Install subframe, observe tightening sequence and alignment with master bore hole. --> 40 - FRONT
SUSPENSION
 Only perform vehicle alignment if necessary. --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT
 Install right transmission support with transmission mount --> Right and left transmission mounts,
Fig. 112: Screwing On Lower Nuts On Left And Right Engine Mounts
 Screw on lower nuts - A - on left and right engine mounts. -->

ENGINE CODE(S): BKH
1:40:10 AM Page 87

 Bolt on torque support stop - 1 - (arrows). -->

 10 - ENGINE - ASSEMBLY for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL,
ENGINE CODE(S): AMB
ENGINE CODE(S): BPG, BWT
 10 ENGINE - ASSEMBLY for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE
CODE(S): AVK, BGN
 10 - ENGINE - ASSEMBLY for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE

(S): BNS
(S): BHF
All:
 Attach retaining clip for coupling rods of Left Front Level Control System Sensor G78 to left front
control arm, if present. --> 40 - FRONT SUSPENSION
1:40:10 AM Page 88
 After subframe is installed, remove bolt - A - and remove transmission jack VAG1383A.
 Apply corrosion protection to contact surface between bolt - A - and oil pan.
 Push lever/selector shaft - 2 - on transmission fully forward (on illustration fully left).

 Bolt on mounting bracket for selector lever cable to transmission corresponding to marking for re-
installation of transmission.
1:40:10 AM Page 89
Damage
 Install Multi-Function Transmission Range (TR) Switch F125 --> Multi-Function Transmission Range
(TR) Switch F125 , removing and installing ; removing and installing Multi-Function Transmission
Range (TR) Switch F125
 Bolt driveshaft to transmission. -->

 Install heat shield for driveshaft at transmission (arrows).

 Install starter. -->

1:40:10 AM Page 90

 Connect ATF lines - 1 - according to the respective color markings.

 Engage clamp for ATF lines and tighten nut - 2 -.
Fig. 121: Location of Speedometer Vehicle Speed Sensor (VSS) G22, and Engine Speed (RPM) Sensor
G28
1:40:10 AM Page 91
 Connect connector of Speedometer Vehicle Speed Sensor (arrow A-).

 Bolt Engine Speed (RPM) Sensor G28 (arrow - B - ) to transmission.
And Cable Tie
 Install noise insulation bracket - 1 -.

 Connect connector - 2 - of wire for multi-function switch.
 Connect connector for transmission wiring harness and swivel securing lever - 3 -.
 Replace cable ties - 4 -.

 Bolt on left and right driveshafts - 1 - to transmission flanges. --> 40 - FRONT SUSPENSION
 Install heat shields for left, if present, and right drive axles (arrows).
1:40:10 AM Page 92

ENGINE CODE(S): BKH

 Install noise insulation panel (arrows).

 Install front wheels. --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT
 Remove engine support bridge 10-222A.
 Fit intake air duct to intake manifold.
 Install intake air guides.

 Install engine cover.
 Install left and right covers in engine compartment.
See Caution for connecting Telematics battery --> Transmission, removing and installing
 After connecting battery, enter anti-theft code for radio operating manual.
 Check adjustment of selector lever cable --> Selector lever cable, checking and adjusting.
 Check gear oil in front final drive with transmission installed --> Gear oil in front final drive, checking.
1:40:10 AM Page 93
 Then check ATF level and top off onward --> Automatic Transmission Fluid (ATF), checking and
changing.
 Fully close power windows to stop.

 Then activate all power window switches ( "up" ) for at least one second to activate automatic window
raising/lowering.
 Set clock to correct time.
Tightening torques
NOTE:  Tightening torques are valid only for nuts and bolts that are lightly
greased, oiled, covered with a thin coat of phosphate or blackened.
 Other lubricants are permitted, e.g. engine oil or transmission fluid,
however they may not contain graphite.
 Do not use any degreased parts.

Engine/transmission mount for 4-cylinder gasoline engines
Item no. Bolt Nm

1 M12 X 67 65
2 * See note M12 x 110 65
3 M12 x 90 65
4 * See note M10 x 60 45
5 M10 X 45 45
6 * See note M12 X 67 65
*with nut
*with bracket for wiring harness
1:40:10 AM Page 94
*with cable bracket
Item A = bushings

Item no. Bolt Nm

1 M10 x 60 45
2 M10 x 90 65
3 M12 x 110 65
4 M12 x 80 65
5 M12 x 90 65
6 M12 x 90 65
7 M10 x 100 45
8 M12 x 90 65
9 * See note M10 x 70 45
10 M10 x 60 45
11 M10 x 60 45
*with nut
Item A = bushings
1:40:11 AM Page 95
Fig. 127: Identifying Noise Insulation And Fasteners

Valid for all engine/transmission types:
Components Tightening torques

Support bracket -B- to transmission (2x M8), item no. 2 and 3 23 Nm
Heat shield/selector lever cable -A- to transmission, M8, item no. 1 and 23 Nm
4
Component Nm
Nuts/Bolts M6 10
M8 20
M10 45
M12 65
Except for the following:
Drive plate to
Torque converter M10 x1 85
Installing ATF lines --> ATF lines, removing and
installing (overview) onward
Multi-function Transmission Range (TR) switch F125 to transmission onward
Bracket for noise insulation to subframe 10
Transmission, transporting
1:40:11 AM Page 96
Fig. 128: Identifying Special Tools - Automatic Transmission, Transporting

 Attachment and holding rig 3457
The attachment and holding rig 3457 can be used when transporting the transmission and for setting up the
transmission support 3282.
 Remove ATF lines from transmission (only for vehicles with 6-cylinder engine).
 Plug ATF connections with plugs.
 Unbolt left and right transmission supports.
Fig. 129: Special Tool 3457 Attachment To Transmission Housing

 Attach the attachment and holding rig 3457 at the transmission housing mounts and secure.
Transmission, attaching to assembly stand
1:40:11 AM Page 97
Fig. 130: Identifying Special Tools - Transmission, Attaching To Assembly Stand


 Holding fixture VW540 (only for FWD transmissions) (Not for US/Canada)
 Holding fixture VW313
 Holding plate VW309
 Engine Hoist VAG1202A
1:40:11 AM Page 98

 Bolt the attachment and holding rig to the holding plate VW309 and place this into the holding fixture
VW313 using a workshop crane.
For transmissions with Front Wheel Drive (FWD), the holding fixture VW540 can also be used to secure the
transmission to the holding fixture VW313 (Not for US/Canada).
Fig. 132: Securing Transmission To Holding Fixture VW540 And Inserting In Holding Fixture VW313
 Secure transmission to holding fixture VW540 (arrows) and insert in holding fixture VW313.
CAUTION: The center of gravity of the transmission is located outside the turning
center at holding fixture. To turn the transmission, a second technician
must hold the transmission housing to prevent back-swing.
NOTE:  Vents for the transmission housing and final drive must be closed before
turning a filled transmission on the assembly stand so that the oil pan
faces upward.
1:40:11 AM Page 99
Right and left transmission mounts, removing and installing
Fig. 133: Identifying Special Tools - Right And Left Transmission Mounts, Removing And Installing

Removing
NOTE:  Transmission must be supported as indicated when both transmission

supports are removed. Transmission does not need to be supported this
1:40:11 AM Page 100

way when only one of the transmission supports is being removed.


NOTE:  If transmission support 3282 is not available, transmission can be

supported using the transmission lift VAG1383A and the 1359/2 universal
mount.
1:40:11 AM Page 101

Right transmission support
Fig. 136: Identifying Right-Hand Transmission Bracket And Fasteners

 Remove bolts - B -.
 Remove heat shield - C -.
 Remove right heat shield -D- by removing bolts - A - from transmission.
Left transmission support
Fig. 137: Identifying Left-Hand Transmission Bracket And Fasteners

NOTE:  The left heat shield is not installed on 4 cylinder gasoline engines.
 Remove left heat shield -D- by removing bolts - A - from transmission.
Left and right transmission supports
1:40:11 AM Page 102

 Unscrew nuts - A - on subframe.
Fig. 138: Removing Transmission Supports

 Remove transmission supports -E-.
NOTE:  Items - C - and - B - are not installed on vehicles with hydraulic

transmission bearing H, because bolt G is threaded directly into the
transmission bearing.
Installing
Tightening torques for left and right transmission supports
Item no. Nut/Bolt Number of pieces Nm

A M8 2 each 23
B to F M 10 x 70 1 50
G M 10 x 35 1 50
Tightening torques for left transmission support
1:40:11 AM Page 103


Item no. Bolt Number of pieces Nm

A M 10 x 30 M 10 x 50 21 40
B M 6 x 22 3 10
Tightening torques for right transmission support


A M 10 x 30 3 40
B M 6 x 22 3 10
AUTOMATIC TRANSMISSION FLUID (ATF), CHECKING AND CHANGING
ATF level, checking
1:40:11 AM Page 104

Fig. 141: Identifying Special Tools - ATF Level, Checking

 Tester VAS5051
 Diagnostic cable VAS5051/1 or VAS5051/3
 ATF filler tool VAG1924
Test requirements:
 Transmission must not be in emergency running mode.
1:40:11 AM Page 105

 Vehicle on level ground.

 Selector lever in "P" , let engine run at idle.
 A/C system and heating switched off.
NOTE:  ATF level changes with ATF temperature.

 Performing ATF level check when ATF temperature is too low causes
overfilling.
 Performing ATF level check when ATF temperature is too high causes
insufficient filling.
 Excess filling and insufficient filling both affect the function of the
transmission.
 ATF temperature is read off using the tester VAS5051.
Procedure
Fig. 142: Securing Container Of ATF Filler Tool VAG1924 As High Up On Vehicle As Possible
 Secure container of ATF filler tool VAG1924 as high up on vehicle as possible.
1:40:12 AM Page 106

Connect tester VAS5051
All functions previously performed with the VAG1551 can also be performed using the new tester VAS5051 in
operating mode "Vehicle On Board Diagnostic (OBD)" :
Checking ATF temperature
Fig. 144: Identifying Vehicle Diagnosis, Testing and Information System VAS 5051 and Data Link
Connector (DLC)
 Connect tester VAS5051 to Data Link Connector (DLC) using diagnostic cable VAS5051/1 with ignition
switched off.
1:40:12 AM Page 107

Fig. 145: Special Tool - VAS 5051 & On Switch

 Switch on tester (arrow).
The tester now requires up to 3 minutes to finish booting.
 Switch on ignition.
 Select operating mode: Press "Vehicle Self-Diagnosis" selection on display.
 Press "02 - Transmission electronics" on display.
 Perform dialog to confirm control module number belonging to selected system.
 Select "08 - Read Measuring Value Block" on display.

 Choose Display Group 4 via the "Read Measuring Value Block" and "Change Display Group" touch
screen displays.
Fig. 146: Display On VAS5051 (ATF Temperature)

Display on VAS5051 :
The first line of display field - 1 - displays ATF temperature.
Checking and correcting ATF level
NOTE:  ATF level is checked at the ATF check plug.

 ATF level is correct if a little bit of fluid still escapes at the ATF check plug
between 35 ° and 45 ° C * See note (dependent on the fluid level when
warming up).
* For warm countries 50 ° C
 Start engine.
1:40:12 AM Page 108

 Raise vehicle.
 Place drip tray VAG1306 under transmission.
Fig. 147: Removing And Installing ATF Inspection Plug From Oil Pan
 Once an ATF temperature of 35 ° C is reached, remove ATF check plug (arrow) and drain excess ATF if
necessary.
Fig. 148: Correct ATF Level

 If ATF flows out from the ATF filler plug hole before the ATF reaches 40 ° C, the ATF level (arrow) is
OK.
NOTE:  ATF check plug must be closed again by 45 ° C * See note at the latest.
1:40:12 AM Page 109

 Add ATF if no ATF has escaped from the ATF check plug hole by 40 ° C.
 ATF specification --> Capacity
Fig. 149: Inserting ATF Filler Tool VAG1924 Into An Opening In Protective Cap
 Insert ATF filler tool VAG1924 into an opening (arrow) in the protective cap, but do not knock cap
upward.
Fig. 150: Fill With ATF Using V.A.G 1924

 Fill with ATF using ATF filler tool VAG1924 until ATF exits from the check hole.
1:40:12 AM Page 110

Fig. 151: Replacing Seal For ATF Check Plug

 Always replace seal (arrow) for ATF check plug.

 Tighten ATF check plug to 80 Nm.
 Switch off motor.
 Select diagnostic function "06 - end output" in selection.
Fig. 152: Diagnostic System VAS 5051: Display

 Switch off ignition and disconnect diagnostic connector after this indication is displayed.
 Install noise insulation.
ATF, changing or topping off after repairs
1:40:12 AM Page 111

Fig. 153: Identifying Drip Tray V.A.G 1306

Fig. 154: V.A.G 1924 Reservoir


 Engine switched off.
1:40:12 AM Page 112


 Raise vehicle.

NOTE:  Observe disposal regulations.

 Engine must not be started without ATF and vehicle must not be towed!
 Place Drip tray VAG1306 under transmission.
Fig. 157: Identifying ATF Drain Plug and ATF Inspection Plug
 Remove drain plug (arrow - 1 - ).

 Let ATF drain.
 Tighten new drain plug (arrow - 1 - ) to 40 Nm.
1:40:12 AM Page 113

NOTE:  Drain plug and oil seal must both be replaced.
 Remove ATF check plug (arrow - 2 - ).
Fig. 158: Guiding V.A.G 1924 In Through An Opening In Deflector Cap

upward.

 Start engine.
 Keeping the brake pedal depressed, shift into all selector lever positions at idle speed. Each position must
remain selected for at least 10 seconds.
1:40:12 AM Page 114

 Check ATF level and top off --> ATF level, checking onward.
NOTE:  Observe all notes and test requirements for "Checking ATF level".
POWER TRANSFER, OVERVIEW
Transmission diagram (All Wheel Drive (AWD) vehicles)
Fig. 160: Transmission Diagram (All Wheel Drive (AWD) Vehicles)

A - Clutch A
B - Clutch B
1:40:13 AM Page 115

E - Clutch E
F - Clutch F
C - Brake C
D - Brake D
G - Brake G
F1 - Freewheel 1
1 - Engine
2 - Torque converter with lock-up clutch
3 - Front differential
4 - Automatic transmission
5 - Drive pinion
6 - Output shaft
7 - Center differential
8 - Driveshaft
9 - Rear differential
Z1, Z2 and Z3 = spur gears of front intermediate drive; ratio --> Code letters, allocation, ratios, equipment
Z4, Z5 = front gear set; ratio --> Code letters, allocation, ratios, equipment
Z6, Z7 = spur gears of rear intermediate drive; ratio All Wheel Drive (AWD)
Z8, Z9 = rear ring gear, ratio All Wheel Drive (AWD)
NOTE:  Arrows point in direction of travel.
Shift element positions
 When dealing with problems relating to poor acceleration and performance or general malfunctions, the
following chart indicates which selector elements are actuated in the various gears. This should help to
identify the selector elements that are not working properly.
1:40:13 AM Page 116

Solenoid valves Clutches

Solenoid valves Pressure regulation Clutch Brake Freewheel
valves
Position/gear N88 N89 N90 N215 N216 N217 N218 A B E F C D G 1. Gear
R = Reverse x x x x x x
N = Neutral x x x x x
D, 1st gear x x x x x x x
D, 2nd gear x x x x x x x x
D, 3rd gear x x-x x x x x x
D, 4th gear x-x x x x x
D, 5th gear x x-x x x x x x
2, 1. Gear x x x x x x x
D, 5th to 4th x x x x x (x) x x (x)
gear
x = Component is actuated
- = Component is not actuated
(x) = Component actuation is dependent on driving condition
TRANSMISSION, DISASSEMBLING AND ASSEMBLING
Transmission, disassembling and assembling
 Observe general repair instructions --> Servicing notes.
Rules of cleanliness for working on automatic transmissions
only!

 Check the following fluid levels after installing, top off if necessary. ATF in planetary gear --> ATF
level, checking , gear oil in front final drive --> Gear oil in front final drive, checking , gear oil in
center differential --> Gear oil in center differential, checking and topping off. Capacities and
specifications --> Capacity onward.
1:40:13 AM Page 117

ATF lines, removing and installing (overview)

Removing and installing ATF lines for 4 cylinder gasoline engines --> ATF lines, removing and installing,
(vehicles with 4 cyl. engine)
ATF lines, removing and installing, (vehicles with 4 cyl. engine)
NOTE:  Place drip tray VAG1306 underneath.
1:40:13 AM Page 118

Fig. 162: ATF Lines, Removing And Installing, Overview (Vehicles With 4-Cylinder Engine)
1 - Bolt (21Nm)
 Insert line until impact by hand before tightening
2 - Oil line to cooler
 Note marking on transmission housing
3 - Oil line from cooler
4 - O-ring
1:40:13 AM Page 119

 Apply ATF when inserting

 Always replace
5 - O-ring

 Always replace
6 - Bolt (5Nm)
7 - O-ring

 Always replace
8 - Bolt (5Nm)
9 - Union nut - 29 Nm
10 - Bracket
11 - Hex bolt
 Does not need to be removed when removing and installing ATF lines.
12 - Nut - 5 Nm
13 - Clamp
14 - Bracket
 On engine/transmission support
1:40:13 AM Page 120

Fig. 163: ATF Lines, Removing And Installing Overview (Vehicles With 6 Cyl. Engine)
1 - Bolt (21Nm)

 Note color identification (arrow)

1:40:13 AM Page 121

4 - O-ring

 Always replace
5 - O-ring

 Always replace
6 - Bolt (5Nm)
7 - O-ring

 Always replace
9 - Bracket
10 - Bolt (5Nm)
11 - Double bolt - 10 Nm
12 - Bracket
13 - Combination nut - 10 Nm
14 - Clamp
ATF lines and ATF cooler, cleaning
1:40:13 AM Page 122



 Hose, approx. 18 mm
 Compressed air gun, standard
NOTE:  Always blow compressed air through oil cooler and ATF lines (max. 10
mbar) before installing a replacement transmission.
 When installing ATF lines, insert into transmission or cooler by hand until
impact first and then tighten bolts.
Fig. 165: Location Of ATF Lines At Transmission

1:40:13 AM Page 123

 Remove bolt - 2 -.
 Disconnect ATF lines from transmission.
 Slide a hose with approx. 18 mm diameter onto ATF line - A - and secure with hose clamp. Place the
other end of the hose into an appropriate container.
 Blow through ATF line - B - with compressed air gun.
 Change hose from ATF line - A - to ATF line - B - and repeat procedure.
 Replace O-ring - 1 -.
 Coat O-ring with ATF.
 Insert ATF lines completely into transmission by hand until stop.
 Re-secure ATF lines.

 Then check ATF level and top off --> ATF level, checking onward.
38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS

OIL PAN, OIL STRAINER AND VALVE BODY, REMOVING AND INSTALLING
Oil pan, oil strainer and valve body, removing and installing
CAUTION: Do not run engine with the oil pan removed or without ATF filling and do
not tow vehicle.
NOTE:  Always replace a soiled or faulty valve body.

 Rules of cleanliness for working on automatic transmissions --> Rules of
 Coat O-rings and sealing rings with ATF. Other lubricating substances
lead to functional problems in the hydraulic transmission control.
Removed parts for transmission with hydraulic control E18/2, overview
1:40:13 AM Page 124

Fig. 166: Valve Body For Transmissions With Hydraulic Control Type E18/2, Assembly Overview
1 - Drain plug - 40 Nm
 With seal
 Always replace
 5 mm socket-head bolt
 Remove to drain ATF
2 - Bolt - 10 Nm
 Tighten bolts for oil pan in several stages in diagonal sequence
3 - Oil pan
1:40:14 AM Page 125

 Removing and installing --> Oil pan, removing and installing
4 - Gasket
 Always replace
5 - Oil strainer
 Removing and installing --> Oil strainer, removing and installing
6 - Bolt - 8 Nm
 For mounting valve body: 16 bolts M6 x 60

 Observe tightening sequence --> Fig. 177
7 - Valve body
 Removing and installing --> Valve body, removing and installing
8 - Bolt - 8 Nm
9 - Bracket
 For wiring harness

 Hook in wiring harness
 Mounted with valve body bolts
10 - Bolt - 6 Nm
G195 )
 Removing and installing --> Transmission Vehicle Speed Sensor (VSS) G38 , removing and installing
12 - Spacer sleeve
 Height: 8 mm
13 - Inner oil line
 Always replace
 Removing and installing --> Oil line inside transmission, removing and installing
14 - O-ring
1:40:14 AM Page 126

 Always replace
15 - Speedometer Vehicle Speed Sensor (VSS) G22
 Removing and installing --> Speedometer Vehicle Speed Sensor (VSS) G22 , removing and installing
16 - O-ring
 Always replace
 Coat with gear oil and insert
 Removing and installing --> Multi-Function Transmission Range (TR) Switch F125 , removing and
installing
 Replacing shift rod sealing ring --> Shift rod seal, replacing
18 - Bolt - 8 Nm
19 - O-ring
 Always replace
 Coat with ATF and insert
20 - Locking clamp
 Always replace
21 - Wiring harness in transmission
 Always replace --> Wiring harness inside transmission, removing and installing
 Transmission Fluid Temperature Sensor G93 is integrated into the wiring harness
 Remove and install valve body to replace --> Valve body, removing and installing
 Unhook from bracket for wiring harness, item 10
 Installation position wiring harness connector: Flat part of rear collar points toward oil pan, the tabs at
collar are horizontal
22 - Bolt - 9 Nm
 Removing and installing --> Sensor for transmission RPM G182 , removing and installing
24 - Connector
1:40:14 AM Page 127

 Is connected at wiring harness in transmission

 Must be disconnected before removing the valve body
25 - Bolt - 6 Nm
26 - Bracket
 For solenoid valve
27 - Pressure Control Valve 1 for Auto. Transmission N215
 With O-ring
28 - Solenoid valve 3 N90
 Without O-ring
 Remove and install oil pan to replace --> Oil pan, removing and installing
 Without O-ring
30 - Bolt - 6 Nm
31 - Bracket
 For solenoid valves
 With O-ring
 With O-ring
 With O-ring
1:40:14 AM Page 128

 Without O-ring
 Remove and install oil pan to replace --> Oil pan, removing and installing and unbolt guide plate for
park locking mechanism
 When installing, do not tighten bolts for guide plate (23 Nm) in selector lever position "P".
36 - Bolt - 6 Nm
37 - Magnet
 4 pieces in the oil pan recesses

 Clean after every removal of oil pan
 Ensure full surface contact in oil pan
38 - O-ring
 Always replace
39 - ATF check plug - 80 Nm
Oil pan, removing and installing

Removing
1:40:14 AM Page 129



Fig. 169: Identifying ATF Drain Plug And ATF Inspection Plug
 Remove ATF drain plug (arrow) and drain ATF.

 Loosen oil pan bolts diagonally and remove oil pan.
Installing
 Clean all 4 magnets in oil pan recesses. Ensure full surface contact of the magnets on the oil pan.
 Replace gaskets.
 Fill up ATF --> ATF, changing or topping off after repairs.
1:40:14 AM Page 130

Tightening torques
Component Nm
Drain plug to oil pan 40
Oil pan to transmission housing (diagonally in 10
sequence)
Oil strainer, removing and installing
Removing
 Removing oil pan --> Oil pan, removing and installing.
Fig. 170: ATF Screen Fasteners

 Removing oil strainer bolts (arrows).

 Pull oil strainer off of valve body.
Installing
 Lightly coat seal on suction collar of oil strainer with ATF.

 Carefully press suction collar of oil strainer into the opening at valve body up to stop.
 Bolt on oil strainer.
 Installing oil pan.
Tightening torque
Component Nm
Oil strainer to valve body 6
Valve body, removing and installing
1:40:14 AM Page 131


Removing

 Removing oil strainer --> Oil strainer, removing and installing.
Fig. 171: Location Of Wiring Harness/Harness Connector Securing Circlip

 Disconnect clip for wiring harness connectors (arrow).
Fig. 172: Identifying Connector Transmission Vehicle Speed Sensor -G38- And Connector transmission
RPM Sensor -G182-
 Disconnect harness connector from Transmission Vehicle Speed Sensor (VSS) G38 ( - A - ).
 Disconnect harness connector from Sensor for transmission RPM G182 ( - B - ).
1:40:14 AM Page 132

Fig. 173: Remove/Install Bolts From Valve Body Which Are Marked With An Arrow (Bolt Is Shorter
Than The Other Bolts)
 Loosen mounting bolts (arrows) of valve body and remove valve body with wiring harness.
NOTE:  Only the marked mounting bolts (arrows) must be loosened.

 When loosening other bolts, the function of the valve body can be
influenced or the valve body splits up.
 The bolt (arrow A) is not installed on transmissions with hydraulic control
E18/2 and can therefore be disregarded.
 Remove valve body from transmission while advancing the wiring harness connector.
Installing
 Lightly coat O-rings of wiring harness connector with ATF.

 Insert wiring harness connector into transmission housing.
 Installation position: Flat part of rear collar points downward, the tabs at collar are horizontal
1:40:15 AM Page 133

 Route wire with connector - C - according to illustration, so that the wire is not pinched when installing
the valve body.
Fig. 175: Installing Valve Body, Note Position Of A, B And C

 Insert connector with flat part (arrow - A - ) facing toward oil pan into transmission housing.
 Align valve body to hole in transmission housing (arrow - C - ) using alignment pin (arrow - B - ).
1:40:15 AM Page 134

Fig. 176: Installing Valve Body, Note Position Of Pin Of Detent Plate And Selector Slide
 Set valve body in place without force while placing bolt of notched disc - 1 - into the groove of the
selector register - 2 -.
 Next, tighten valve body bolts (arrows) by hand.
NOTE:  The bolt (arrow A) is not installed on transmissions with hydraulic control
 Then tighten valve body bolts from inside out to final tension.
1:40:15 AM Page 135

Fig. 178: Connecting Connector To Connector At Wiring Harness

 Pull wiring with connector - B - of Sensor for transmission RPM G182 between valve body and wiring
harness upward.
 Connect connector - B - to connector - A - at wiring harness.
 Connect connector - C - to Transmission Vehicle Speed Sensor (VSS) G38.

 Connect clip to wiring harness connector (arrow).

 Installing oil strainer --> Oil strainer, removing and installing.
Tightening torque
Component Nm
Valve body to transmission housing (from inside 8
out)
1:40:15 AM Page 136

Oil line inside transmission, removing and installing
Fig. 180: 3381 Fitting tool

 3381oil line installer
NOTE:  Faulty O-rings at inner oil line allow ATF to enter the differential, which
becomes over-filled and oil escapes at differential vent.
 A removed oil line generally must be replaced.
 The oil line must only be inserted using 3381oil line installer. Otherwise
there is a risk of leaks because of bending of the oil line.
Removing
 Removing valve body --> Valve body, removing and installing.
Fig. 181: Pry Internal Oil Line Off Transmission Housing Using Screwdriver
 Lever off inner oil line evenly from transmission housing.
1:40:15 AM Page 137

Installing
 Replace O-rings.
Fig. 182: Open Side Of Fitting Tool 3381 Faces Toward Outside Of Transmission
 Insert oil line into oil line installer 3381.

 Drive oil line into transmission housing by lightly tapping on the oil line installer 3381 up to stop using a
plastic mallet.
NOTE:  The open side of oil line installer 3381 faces toward the outer wall of the
transmission.
 Do not cant oil line. Drive in both line ends uniformly.
 Installing valve body.

 Check oil level in front final drive --> Gear oil in front final drive, checking.
Shift rod seal, replacing
1:40:15 AM Page 138

Fig. 183: 3385 Thrust piece

 Sealing ring installer 3385

Removing
 Removing Multi-Function Transmission Range (TR) Switch F125 --> Multi-Function Transmission
Range (TR) Switch F125 , removing and installing.
1:40:15 AM Page 139

 Pry off selector lever cable from lever/shift rod (arrow).
Fig. 186: Driving Out Spring Dowel Sleeve At Lever/Shift Rod Of Travel Toward Front
 Drive out spring dowel sleeve - 1 - at lever/shift rod - 2 - in direction of travel toward the front (arrow),
until the lever/shift rod can be pulled off the shift rod.
Fig. 187: Prying Seal Out With A Screwdriver
1:40:15 AM Page 140

 Pierce sealing ring using a small screwdriver and pull out.
Installing
 Coat outer circumference and gap between sealing lips with ATF.
Fig. 188: Drive In New Seal Until Using Thrust Piece 3385
 Slide new sealing ring onto sealing ring installer 3385 without canting and drive in up to stop of pressure
piece.
 Installing Multi-function switch --> Multi-Function Transmission Range (TR) Switch F125 ,
 Drive back spring dowel sleeve with transmission not yet removed in opposite direction through the lever.
 Slide transmission shift lever onto shift rod and drive in spring dowel sleeve.
1:40:16 AM Page 141

Fig. 190: Location Of 10 Pin Harness Connector & Multi-Function Transmission Range (TR) Switch
 Rotate multi-function switch - 3 - until the alignment bore - 4 - at switch housing can be fitted on the
alignment pin - 2 - at transmission housing.
Tightening torques
Component Nm
Multi-function Transmission Range (TR) switch 8
F125 to transmission
Multi-Function Transmission Range (TR) Switch F125 , removing and installing
Removing
 Unbolt Multi-Function Transmission Range (TR) Switch F125 from transmission and pull off from shift
rod.
Installing
1:40:16 AM Page 142

 Connect Multi-Function Transmission Range (TR) Switch F125 to shift rod. Flap part at splines in switch
- 3 - must align with flat part of shift rod - 1 -.
NOTE:  Set Multi-Function Transmission Range (TR) Switch F125 onto shift rod in
centered manner. Do not cant and do not set with force. Risk of damage at
switch terminals.
 Rotate switch until the alignment bore - 4 - at switch housing can be fitted on the alignment pin - 2 - at
transmission housing.
Tightening torques
Component Nm
1:40:16 AM Page 143

Speedometer Vehicle Speed Sensor (VSS) G22 , removing and installing
Removing

 Remove heat shield - 1 - for left drive axle (arrows), if installed.
Fig. 194: Removing Speedometer Vehicle Speed Sensor -G22- And Vehicle Speed Sensor -G68-
 Disconnect harness connector from Speedometer Vehicle Speed Sensor (VSS) G22 (arrow - A - ).
 Push retaining bracket of sensor downward, and turn (arrow).
 Remove sensor.
Installing
1:40:16 AM Page 144

Fig. 195: Installing Speedometer Vehicle Speed Sensor -G22- And Vehicle Speed Sensor -G68-
 Replace sealing rings (arrows).

 Insert O-rings with gear oil.
 Insert sensor.
 Engage retaining bracket at mounting bracket for flange shaft.

 Install heat shield - 1 - for left drive axle (arrows), if present.
Sensor for transmission RPM G182 , removing and installing
Removing
1:40:16 AM Page 145

 Unbolt Sensor for transmission RPM - A - from transmission.
Installing
 Bolt on Sensor for transmission RPM - A - at transmission via bolt - B -. Tightening torque is 9 Nm.
the valve body.
Transmission Vehicle Speed Sensor (VSS) G38 , removing and installing
Also referred to as Sender for transmission output RPM G195.
Removing
1:40:16 AM Page 146

Fig. 198: Transmission Vehicle Speed Sensor -G38- Connector

 Disconnect harness connector from Transmission Vehicle Speed Sensor (VSS) G38 (arrow).
Fig. 199: Identifying Transmission Vehicle Speed Sensor (VSS) And Spacer
 Remove Transmission Vehicle Speed Sensor (VSS) - 2 -.
Installing
1:40:16 AM Page 147

 Install and tighten Transmission Vehicle Speed Sensor (VSS) - 2 - using spacer sleeve - 1 - (height: 8
mm) to 6 Nm.

 Connect connector at Transmission Vehicle Speed Sensor (VSS) G38.

Wiring harness inside transmission, removing and installing
Removing
1:40:16 AM Page 148

Fig. 202: Identifying Solenoid Valve Connectors And Wiring Harness Retainers
 Lever out retainer straps of connectors at solenoid valves and pressure control valves using a small
screwdriver and disconnect connectors - A - in sequence.
 Unhook wiring harness at side retainer straps - B - of valve body.
1:40:17 AM Page 149

Fig. 203: Identifying Pressure Control Valve 1 (-N125-) And Wiring Harness Retainers
 Turn valve body on its back side and loosen connector - 1 - at Pressure Control Valve 1 for Auto.
Transmission N215.
 Remove retaining clip (arrow A) and unclip wiring harness from retaining clip (arrow B).
Installing
 When installing, connect connectors of wiring harness to the corresponding solenoid valves and pressure
control valves.
 Clip wiring harness into the respective retaining clips. In case of deviations, the wiring harness can be
pinched during installation of the valve body.
Transmission Fluid Temperature Sensor G93 , replacing
NOTE:  Transmission Fluid Temperature Sensor G93 is integrated in the

transmission wiring harness.
Removal
 Remove wiring harness in transmission --> Wiring harness inside transmission, removing and
installing.
Installing
Installation is the reverse of removal. Also carry out the following procedure.
 Replace wiring harness with a new one.

 Install new wiring harness in transmission --> Wiring harness inside transmission, removing and
1:40:17 AM Page 150

installing.
39 - FINAL DRIVE, DIFFERENTIAL

GEAR OIL IN FRONT FINAL DRIVE, CHECKING

Fig. 205: 3247 Socket AF 8

 Plug insert 3247 (8mm)
Procedure
 Warm up gear oil in front final drive to approx. 60 ° C by performing a short road test.
 Drive vehicle onto a 4-column lift or over a work pit.
1:40:17 AM Page 151

NOTE:  The vehicle must be on a level surface.
Fig. 206: Locating Sealing Plug

 Remove locking screw (arrow).
NOTE:  Loosen locking bolt using an angled socket-head wrench, but do not use
hex ball socket 3247. For improved accessibility it may be necessary to
remove the heat shield and drive axle and to set them aside.
 If hex ball socket 3247 is used for loosening the bolt, it could be
destroyed.
 With engine switched off, allow gear oil to drip out for approx. 2 minutes.
Oil level is correct when the front final drive is filled up to lower edge of oil filler hole.
 Let excessive gear oil drain or top up gear oil --> Gear oil in front final drive, filling up after servicing.
NOTE:  Replace locking screw with seal.
 When the oil level is correct, tighten locking bolt using hex ball socket 3247 (8mm socket) to 30 Nm.
GEAR OIL IN FRONT FINAL DRIVE, FILLING UP AFTER SERVICING
Gear oil in front final drive, filling up after servicing
1:40:17 AM Page 152



Procedure
1:40:17 AM Page 153


destroyed.
 Slowly and uniformly fill front final drive over a time period of at least 5 minutes until gear oil escapes at
lower edge of oil filler hole.
 Specification --> Capacity
NOTE:  Filling time of at least 5 minutes is essential, so that the internal oil level
compensation between differential and retaining area can occur.

1:40:17 AM Page 154

 Screw in old locking screw (arrow).

 Perform a short test drive to warm gear oil to approx. 60 ° C.
 Check front final drive oil level --> Gear oil in front final drive, checking.
 When the oil level is correct, tighten locking bolt using hex ball socket 3247 (8 mm socket) to 30 Nm.
FRONT FINAL DRIVE, SERVICING
Front final drive, servicing
 Transmission installed
NOTE:  General repair notes --> Servicing notes.

1:40:17 AM Page 155

Fig. 211: Front Final Drive, Overview

1 - Seal
 Between final drive and transmission housing

 Always replace --> Final drive sealing ring/transmission housing, replacing
2 - Adjustment shim
 Behind tapered roller bearing outer race
3 - Tapered roller bearing outer race
4 - Locking screw - 30 Nm
1:40:17 AM Page 156

 With seal
 Always replace
5 - Bolt - 23 Nm
6 - Right drive flange
7 - Right drive flange seal
 Always replace --> Sealing ring for right drive flange, replacing
8 - Bolt - 23 Nm
 Observe tightening sequence
9 - Cover for final drive
10 - Adjustment shim
12 - O-ring
 Always replace --> O-ring at cover for final drive, replacing
13 - Differential
14 - Bolt - 23 Nm
 Observe tightening sequence Tightening sequence:
15 - Cover for front final drive
 Front wheel drive version shown
16 - Bushing
17 - Gasket
 Always replace --> Seal for front final drive, replacing
18 - Spring dowel sleeve
19 - Lever
1:40:18 AM Page 157

 For shift rod
20 - Seal
 For shift rod

 Always replace --> Shift rod seal, replacing
21 - Bolt - 23 Nm
22 - Left drive flange seal
 Always replace --> Sealing ring and grooved ball bearing for left drive flange, replacing
23 - Drive gear
 For speedometer Vehicle Speed Sensor (VSS) G22

 Installation position --> Fig. 231
24 - Left drive flange
 Removing and installing --> Sealing ring and grooved ball bearing for left drive flange, replacing
onward
25 - Mounting bracket for drive flange
26 - Grooved ball bearing for drive flange
27 - Snap ring
28 - O-ring
 Square cross section

 Remove and install left drive flange to replace --> Sealing ring and grooved ball bearing for left drive
flange, replacing
Sealing ring for right drive flange, replacing
1:40:18 AM Page 158

Fig. 212: Identifying Special Tools - Sealing Ring For Right Drive Flange, Replacing

 Right sealing ring installer 3382
 SUSPENSION, WHEELS, STEERING
Removing
1:40:18 AM Page 159

Fig. 213: Wheel Hex Bolt

 Loosen bolt drive axle/wheel hub while the vehicle is still standing on its wheels. --> 40 - FRONT
SUSPENSION
 Remove wheel.

 Remove heat shield for right drive axle (arrows).
 Unbolt right drive axle - 1 - from transmission flange and remove. --> 40 - FRONT SUSPENSION
1:40:18 AM Page 160

Fig. 215: Flange Shaft Bolt

 Remove bolt for flange shaft (arrow) while securing against turning using a drift.
 Remove right drive flange.
Fig. 216: Removing Flange Shaft Oil Seal

 Pull out drive flange seal.
Installing
 Coat outer edge of oil seal with gear oil.
1:40:18 AM Page 161

Fig. 217: Driving New Seal Using Drift 3382

 Drive in new seal to stop, without canting seal.
 Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.
 Install right drive flange.

 Install bolt for drive flange (arrow, 23 Nm) while securing drive flange against turning, using a drift.
1:40:18 AM Page 162


 Install right drive axle - 1 -. --> 40 - FRONT SUSPENSION

 Install heat shield for right drive axle (arrows).
 Install front wheel. --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT

Tightening torques
Component Nm
Drive flange to transmission 23
Heat shield for driveshaft to transmission 23
Sealing ring and grooved ball bearing for left drive flange, replacing
1:40:18 AM Page 163

Fig. 220: Identifying Special Tools - Sealing Ring And Grooved Ball Bearing For Left Drive Flange,
Replacing (1 Of 2)
 Thrust plate VW401

 Punch VW407
 Punch VW412

 Driving sleeve 32-109
1:40:19 AM Page 164

Replacing (2 Of 2)
 Press tube 2040

 Assembly mandrel 3384
Remove left drive flange
1:40:19 AM Page 165


SUSPENSION
 Remove wheel.

 Remove heat shield for left drive axle (arrows), if installed.
 Unbolt left drive axle - 1 - from transmission flange and remove. --> 40 - FRONT SUSPENSION
1:40:19 AM Page 166

Fig. 224: Extracting Gear Oil From Front Final Drive Using VAG 1358 A
 Remove oil filler plug (arrow) and siphon off at least 0.5 L gear oil from front final drive using oil
siphoning unit VAG1358A
NOTE:  Oil must be siphoned from final drive, otherwise there is a risk that the
gear oil could mix with the ATF.
 Remove Speedometer Vehicle Speed Sensor (VSS) --> Speedometer Vehicle Speed Sensor (VSS) G22 ,
 Remove harness connector bracket from mounting bracket for drive flange.
Fig. 225: Removing/Installing Left Drive Flange Mounting Bracket

 Remove drive flange mounting bracket (arrows).

 Pull out drive flange.
1:40:19 AM Page 167

NOTE:  The left drive flange can be pulled out between body and subframe with
the transmission installed if the mounting bracket for drive flange is
turned approx. 60 ° to the right against the installation position.
Removing seal
Fig. 226: Removing/Installing Circlip And Seal At Grooved Ball Bearing

 Remove circlip (arrow A) for grooved ball bearing.
Fig. 227: Pressing Flange Shaft Out Of Flange Shaft Bearing Bracket
1:40:19 AM Page 168

 Press drive flange out of drive flange mounting bracket.

 Remove drive flange seal using extractor lever VW681.
Removing grooved ball bearing
Fig. 228: Pressing Grooved Ball Bearing Out Of Bearing Bracket

 Press grooved ball bearing out of mounting bracket.
Installing grooved ball bearing
1:40:19 AM Page 169

Fig. 229: Pressing New Grooved Ball Bearing Into Bearing Bracket
 Press new grooved ball bearing into mounting bracket.
Installing sealing ring
 Coat outer edge and sealing lip of oil seal with gear oil.
Fig. 230: Driving In New Seal

 Drive in new sealing ring to stop, without canting.
1:40:19 AM Page 170

Fig. 231: Installation Position Of Speedometer Drive Gear On Flange Shaft

 Set drive gear for Speedometer Vehicle Speed Sensor (VSS) G22 on drive flange (arrow).
 Installation position: The carriers at drive wheel must engage in grooves of drive flange
NOTE:  If necessary, coat contact surface with grease to affix drive wheel in
installation position.
Fig. 232: Pressing Bearing Bracket With Grooved Ball Bearing Onto Flange Shaft
 Press mounting bracket with grooved ball bearing onto drive flange.
1:40:20 AM Page 171


 Insert circlip (arrow - A - ).
Installing left drive flange

 Replace sealing ring (arrow B) in mounting bracket for drive flange.
1:40:20 AM Page 172

Fig. 235: Checking That There Are No Sharp Edges On Transmission End Of Flange Shaft
 Check drive flange for sharp edges on transmission side of flange end (arrow) and if necessary, deburr.
 Insert left drive flange into transmission.
NOTE:  When sliding in, left drive flange must be carefully guided by hand to
prevent damage to the double sealing ring in transmission.
 Secure mounting bracket for drive flange.

 Bolt on harness connector bracket to mounting bracket for drive flange.
 Install speedometer Vehicle Speed Sensor (VSS) G22 --> Speedometer Vehicle Speed Sensor (VSS)
G22 , removing and installing.

 Install left drive axle - 1 -. --> 40 - FRONT SUSPENSION

 Install heat shield for left drive axle (arrows).
1:40:20 AM Page 173

 Install left front wheel. --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT

Tightening torques
Component Nm
Mounting bracket for left drive flange at 23
transmission
O-ring at cover for final drive, replacing




Removing
1:40:20 AM Page 174


SUSPENSION
 Remove right wheel.
 Remove heat shield for right drive axle.
 Remove right drive axle: --> 40 - FRONT SUSPENSION
 Remove right front exhaust pipe. -->

ENGINE CODE(S): BKH
 Remove right transmission support --> Right and left transmission mounts, removing and installing.
1:40:20 AM Page 175


Fig. 240: Installing Cover For Front Final Drive, Tightening Sequence
 Remove bolts for final drive cover opposite of shown tightening sequence and remove cover.
Installing
1:40:20 AM Page 176

Fig. 241: Identifying Cover For Front Final Drive And O-Ring
 Replace sealing ring (arrow).
 Install cover for final drive.
Tightening sequence:
 1. Stage: Tighten bolts - 1 - to - 3 - by hand

 2. Stage: Tighten bolts - 1 - to - 12 - in specified sequence to tightening torque
1:40:20 AM Page 177


 Install transmission support --> Right and left transmission mounts, removing and installing.
 Install right front exhaust pipe. -->
ENGINE CODE(S): BKH
 Install drive axle. --> 40 - FRONT SUSPENSION
 Top-up and check gear oil in front final drive --> Gear oil in front final drive, checking.
Tightening torques
Component Nm
Cover for front final drive to transmission housing 23
Final drive sealing ring/transmission housing, replacing
1:40:21 AM Page 178

Fig. 243: Identifying Special Tools - Final Drive Sealing Ring/Transmission Housing, Replacing

 Double sealing ring installer 3383
NOTE:  A faulty sealing ring lets ATF or gear oil escape into the converter housing
via the center vent of the shaft seal (between the two sealing lips).
 In addition, a faulty sealing ring can let ATF escape into the center
differential. It over-fills and oil escapes at the differential vent.
1:40:21 AM Page 179

Removing
 Remove cover for front final drive --> O-ring at cover for final drive, replacing.
 Pull out differential and remove.
Fig. 244: Identifying Tapered Roller Bearing Outer Race For Differential And Shim
 Remove tapered roller bearing outer race of differential - 1 - and shim - 2 - which is behind it from
transmission housing by hand.
NOTE:  Shim is pre-determined and must not be exchanged for a shim with
another thickness.
 Remove left drive flange --> Sealing ring and grooved ball bearing for left drive flange, replacing.
Fig. 245: Pulling Out Oil Seal

 Pull out seal.
NOTE:  Extractor lever must be positioned behind both sealing lips of the sealing
1:40:21 AM Page 180

ring. Do not position at outer circumference of sealing ring, otherwise the

contact surface in transmission housing will be damaged. When levering
out, carefully guide extractor lever.
Installing
 Check seal seat in transmission housing for damage; rework if necessary.

 Coat outer circumference and sealing lip of sealing ring with ATF.
Fig. 246: Placing Seal Onto Press Piece 3383 With Protruding Sealing Lip On Seal Facing Toward Tool
 Slide seal onto double sealing ring installer 3383 so that the projecting sealing lip (arrow) of sealing ring
faces tool.

 Drive in new sealing ring to stop.

 Install left drive flange --> Sealing ring and grooved ball bearing for left drive flange, replacing.
1:40:21 AM Page 181

 Insert adjustment shim - 2 - and tapered roller bearing outer race for differential - 1 - into transmission
housing up to stop by hand.
 Insert differential into transmission housing.
 Install cover for front final drive.
ENGINE CODE(S): BKH
Tightening torques
Component Nm
transmission
1:40:21 AM Page 182


Seal for front final drive, replacing
Fig. 249: Identifying Engine/Transmission Jack V.A.G. 1383 A

 Engine/transmission jack VAG1383 with plate VAG1359/2

Removing

ENGINE CODE(S): BKH
1:40:21 AM Page 183

26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE


 Remove heat shield for selector lever cable, if installed.
 Remove center differential --> Center differential, removing and installing.
Fig. 250: Seal In Front Final Drive Intermediate Flange, Replacing

 Remove bolts (arrows) at intermediate flange for front final drive.
CAUTION:  Slowly and carefully remove cover for front final drive/intermediate
flange from transmission housing. The spur gears can otherwise fall
out of the transmission.
 Do not reinstall spur gears that have fallen to the ground. The
transmission must be swapped in this case.
 Lift off cover i.e. intermediate flange for front final drive.
NOTE:  Do not remove spur gears for front final drive. Secure spur gears so they
do not fall out.
 If the spur gears for front final drive were removed, the wheel marking
must face outward (away from transmission) for re installation.
Installing
1:40:22 AM Page 184

Fig. 251: Identifying Alignment Sleeve And Front Final Drive Cover Bolts
 Make sure centering sleeve - A - is correctly seated before installing.

 Install gasket
 Set on cover i.e. intermediate flange for front final drive.
NOTE:  If installing the intermediate flange to the output shaft carelessly, the
sealing lips of the sealing ring can be damaged.
1:40:22 AM Page 185

NOTE:  When tightening bolts by hand, make sure the housing gap between cover
and transmission housing decreases evenly around circumference.
 2. Stage: Tighten bolts - 1 - to - 14 - in specified sequence to tightening
torque
 Install center differential.
Tightening torques
1:40:22 AM Page 186

Component Nm
Intermediate flange for front final drive to 23
transmission housing
Center differential to transmission housing 23
GEAR OIL IN CENTER DIFFERENTIAL, CHECKING AND TOPPING OFF
Gear oil in center differential, checking and topping off


Procedure
1:40:22 AM Page 187

Fig. 254: Location Of Locking Bolt

 If necessary, loosen or remove relevant parts of the exhaust system to gain access to oil filler plug (arrow
B). -->
ENGINE CODE(S): BKH
 Remove oil filler plug (arrow B).
Oil level is correct when the final drive is filled up to lower edge of oil filler hole.
 Let excessive gear oil drain or top up gear oil --> Gear oil in center differential, changing or topping
up after repair.
 Always replace oil filler plug.
 Thread in new oil filler plug and tighten to 35 Nm.
 Secure or reinstall exhaust system free of stress. -->
1:40:22 AM Page 188


ENGINE CODE(S): BKH
GEAR OIL IN CENTER DIFFERENTIAL, CHANGING OR TOPPING UP AFTER REPAIR
Gear oil in center differential, changing or topping up after repair


Procedure
1:40:22 AM Page 189

Drain gear oil

 Removing drain plug (arrow A) and draining gear oil.

 Always replace drain plug.
 Thread in new drain plug (arrow A) again and tighten to 20 Nm.
Filling up gear oil

B). -->
1:40:23 AM Page 190


ENGINE CODE(S): BKH
NOTE:  There is a distinction made between two cases:

 A - Center differential was not removed.
 B - Center differential was removed
A - Center differential was not removed (e.g. after removing and installing drive flange/drive shaft)


 Top up transmission fluid to lower edge of oil filler hole. Specification and capacity Center differential.
 Thread in old oil filler plug and tighten to 35 Nm.
NOTE:  If it was necessary to loosen or remove the exhaust system, this must be
re-secured or reinstalled for the road test. It must be removed and
installed again for the final oil level check.
 Road test vehicle (15 minutes pure driving).
NOTE:  During road test, gear oil enters output cover and Torsen differential; oil
1:40:23 AM Page 191

level in center differential housing will drop.
 Fill transfer housing with gear oil and check oil level --> Gear oil in center differential, checking and
topping off.
B - Center differential was removed and disassembled
 Add 200 ml. gear oil to output cover.

 Center differential, assembling and installing.


 Add 600 ml. gear oil to center differential housing.
NOTE:  Oil level does not need to be re-checked.
All:
 Secure or re-install exhaust system free of stress. -->

ENGINE CODE(S): BKH
1:40:23 AM Page 192


CENTER DIFFERENTIAL, SERVICING
Center differential, servicing
Transmission installed
Fig. 260: Identifying Special Tools - Center Differential, Servicing (1 Of 2)

1:40:23 AM Page 193

 Punch VW412
 Thrust tube VW454
 Punch VW407
 Sleeve 3021

 Sleeve 40-20
 Press support 3118
 Item 3 Kukko 17/2 separating tool
1:40:23 AM Page 194

CAUTION: Do not run engine with the center differential removed or without gear oil
and do not tow vehicle.

The parts listed in the following illustration can be removed with the transmission installed.
Fig. 262: Center Differential Remove/Install Components

1 - Socket head bolt- 25 Nm
2 - Output flange/driveshaft
1:40:23 AM Page 195

3 - Seal
 Always replace --> O-ring for output flange/driveshaft, replacing
4 - Bolt - 23 Nm
 4x
5 - Housing cover
 With dampener
6 - O-ring
 Coat with transmission fluid
7 - Snap ring
8 - Grooved ball bearing
 Pressing off Press off grooved ball bearing for spur gear 1
 Pressing on Press on grooved ball bearing for spur gear 1
9 - Spur gear 1
 For rear gear set
10 - Snap ring
11 - Needle bearing
 Only remove for replacement

 To replace, heat up transfer gear housing to approx. 100 ° C and drive out needle bearing toward rear
using drift (Warning! Wear protective gloves)
 Drive in to stop using 30-21 sleeve
12 - Bolt - 23 Nm
 Loosen or tighten in stages and in diagonal sequence
13 - Center differential housing
14 - Tension nut
15 - Needle bearing
1:40:24 AM Page 196


 Always replace --> Needle bearing for spur gear 2, replacing
16 - Snap ring
17 - Spur gear 2
19 - Snap ring
20 - Washer
21 - Alignment plate
22 - Bolt - 10 Nm
23 - Snap ring
24 - Gasket
 Always replace --> Center differential, removing and installing
25 - Torsen differential
 If damaged replace as complete unit

 Removing and installing --> Center differential, removing and installing
26 - Seal
 Always replace --> Sealing ring in intermediate flange for front final drive, replacing
27 - Magnet
28 - Bushing
 2x
1:40:24 AM Page 197

29 - Breather
 For transfer gear

 With cap installed
 Installation position: Without cover, breather must project 10 - 11 mm out of housing
30 - Bolt - 23 Nm
31 - Intermediate flange for front final drive
32 - Gasket
33 - Bushing
34 - Drive pinion
 For front final drive

 Removing and installing --> Sealing ring in drive pinion, replacing
35 - Intermediate pinion

 Installation position: gear identification faces toward transfer gear
36 - Output pinion

37 - Seal
 Always replace --> Sealing ring in drive pinion, replacing
Press off grooved ball bearing for spur gear 1
1:40:24 AM Page 198

Fig. 263: Pressing Off Grooved Ball Bearing For Spur Gear 1
A - Separating device 22-115 mm, e.g. Kukko 17/2 separating tool
Press on grooved ball bearing for spur gear 1
Fig. 264: Pressing On Grooved Ball Bearing For Spur Gear 1

1:40:24 AM Page 199


Center differential, removing and installing
(Transmission installed)

 Engine/transmission lifter VAG1383A with universal transmission holder VAG1359/2
1:40:24 AM Page 200




Removing

ENGINE CODE(S): BKH

1:40:24 AM Page 201

Fig. 269: Securing Driveshaft To Fuel Pipe Bracket With Wire

 Unbolt driveshaft - 1 - from transmission and let rest on heat shield - 2 - -->
 Secure driveshaft using wire (arrow) to bracket - 3 - of fuel lines or support driveshaft using
engine/transmission hoist VAG1383A.
 Drain center differential gear oil --> Gear oil in center differential, changing or topping up after
repair.
Fig. 270: Transfer Case, Removing And Installing

 Loosen mounting bolts - A - and - C - for transfer housing - 2 - in diagonal sequence and remove.
 Do not remove bolts - B -.
1:40:25 AM Page 202

CAUTION: Carefully pull center differential housing off of transmission toward rear.
The Torsen differential could otherwise fall out of the transmission.
Fig. 271: Pulling Torsen Differential From Output Shaft

 Pull Torsen differential off output shaft toward rear.
Installing
Fig. 272: Location Of Alignment Pins -A/B-, Magnet and Seal Surface
 Check for presence of dowel sleeves (arrows - A - and - B - ).
1:40:25 AM Page 203

 Install gasket
NOTE:  Lightly coat sealing surface -D- with gear oil to prevent the seal from
slipping.
 Slide cleaned magnets into cast holding pocket - 1 - in intermediate flange.

 Add 200 ml. gear oil to output housing (comparable to gear oil, topping up on removed and disassembled
center differential).

 Install Torsen differential onto splines of output shaft and bottom spur gear while turning slowly.
 Check whether installed Torsen differential can be turned by hand.
1:40:25 AM Page 204

 Install fully assembled transfer housing with installed spur gears and drive flange/drive shaft onto
transmission flange.
 Insert bolts - A - and - C - for transfer housing - 2 - and tighten to final tightening torque in diagonal
sequence in several stages.
 Bolt driveshaft to output flange/driveshaft -->

ENGINE CODE(S): BKH
 Fill transfer housing with gear oil and check oil level --> Gear oil in center differential, changing or
topping up after repair.
Tightening torques
Component Nm
Center differential housing to transmission housing 23
O-ring for output flange/driveshaft, replacing
1:40:25 AM Page 205

Fig. 275: Pressure Piece 3402

 Pressure piece 3402

 Engine/transmission lifter VAG1383A with Universal transmission holder VAG1359/2



1:40:25 AM Page 206

Removing

ENGINE CODE(S): BKH

1:40:26 AM Page 207

repair.
Fig. 279: Removing/Installing Flanged Shaft

 Unbolt output flange driveshaft while securing output flange/driveshaft against turning using a drift.
 Pull out output flange/driveshaft.
1:40:26 AM Page 208

Fig. 280: Removing O-Ring Using Appropriate Screwdriver

 Remove O-ring using appropriate screwdriver.
Installing
Fig. 281: Driving In Sealing Ring To Stop Using Pressure Piece 3402
 Drive O-ring in to stop using pressure piece 3402.

 Secure output flange/driveshaft with socket-head bolt.
1:40:26 AM Page 209



ENGINE CODE(S): BKH
Tightening torques
Component Nm
Socket-head bolt for output flange/driveshaft, rear 25
Sealing ring in intermediate flange for front final drive, replacing
1:40:26 AM Page 210

Fig. 282: Thrust Piece 3404

Fig. 283: Oil Leak Inspection Opening For Shaft Seal In Drive Pinion And Shaft Seal In Intermediate
Flange
NOTE:  An inspection opening is provided on the left side of the intermediate

flange to check for oil leaks (arrow) for the sealing ring in drive pinion and
the sealing ring in intermediate flange.
 If oil escapes at this oil leak inspection opening, this double sealing ring
must be replaced.
Removing

 Removing intermediate flange for front final drive --> Seal for front final drive, replacing.
Fig. 284: Identifying Drive Shaft Seal

1:40:26 AM Page 211

 Drive out sealing ring (arrow) in direction of transfer gear using a mandrel.
Installing
 Check seal seat in intermediate flange for damage; rework if necessary.

Fig. 285: Slide Shaft Seal Onto Thrust Piece 3404

 Slide sealing ring onto thrust piece 3404 so that the larger and projecting outer ring (arrow) of sealing
ring faces tool.
 Drive in sealing ring up to thrust piece 3404 stop.
sealing lip of the sealing ring can be damaged.
 Installing intermediate flange for front final drive --> Seal for front final drive, replacing.
Sealing ring in drive pinion, replacing
1:40:26 AM Page 212


Flange

 If oil escapes at this inspection opening, this sealing ring must be
replaced.
Removing

1:40:27 AM Page 213

Fig. 288: Identifying Output Pinion, Intermediate Pinion And Drive Pinion
 Remove intermediate pinion - 2 - for front final drive from transfer housing.
 Pull drive pinion - 3 - from output shaft.
CAUTION: Do not reinstall spur gears that have fallen to the ground. The
transmission must be replaced in this case.
Output pinion - 1 - remains on the drive pinion.
 Drive out sealing ring using drift.
Installing
1:40:27 AM Page 214

Fig. 289: Installing Driveshaft Seal

 Slide sealing ring onto thrust piece 3403.

 Drive sealing ring in up to thrust piece 3403 stop.
Contact surface - A - of thrust piece must lie against drive pinion - B -.
Fig. 290: Identifying Input Shaft

 Completely cover splines on end of shaft (arrow) with insulating tape without creasing or overlapping the
tape, to prevent damage to sealing ring when sliding on drive pinion.
 Install drive pinion on center of output shaft. (Installation position )
1:40:27 AM Page 215

NOTE:  If installing the intermediate flange on the output shaft carelessly, the
 Slide drive pinion - 3 - together with the intermediate pinion - 2 - into final drive housing up to stop
(tapered roller bearing).
Observe installation position of spur gears (pinion):
Wheel identification (arrows) point outward, away from final drive.
Needle bearing for spur gear 2, replacing
1:40:27 AM Page 216

Fig. 292: Identifying Special Tools - Needle Bearing For Spur Gear 2, Replacing

 Punch VW408A
 Press sleeve for sleeve 2080A
 Item 1 Kukko 21/4 extractor
 Item 3 Kukko 22/1 support

 Hot air blower VAG1416
Removing
1:40:27 AM Page 217

Fig. 293: Unbolting Rear Flanged Shaft

 Unbolt rear output flange/driveshaft while securing output flange/driveshaft against turning.
Fig. 294: Identifying Tension Nut, Guide Plate And Shim

 Pull tension nut - A - out of spur gear shaft.

 Remove bolts (arrows).
 Remove guide plate - B - and shim - C -.
 Remove securing ring for securing grooved ball bearing in center differential housing
1:40:28 AM Page 218

Fig. 295: Needle Bearing For Spur Gear -2, Removing (As Shown)
 Attach support - A - at internal extractor - B - as shown and insert spur gear shaft - 2 -.
A - Support, e.g. 22/1 Kukko
B- extractor, e.g. 21/2 Kukko
 Support retainer - A - using thrust plate VW402 and pre-tension at nut - 1 - of retainer.
 Pull out spur gear and carefully remove upward.
 Remove needle bearing securing ring.
Fig. 296: Needle Bearing For Spur Gear 2, Replacing

1:40:28 AM Page 219

NOTE:  The upper part of the illustration shows how the pulling hooks of extractor
- B - must be inserted into needle bearing.
 Slide centering sleeve - 2 - of extractor - B - approx. 4 mm into direction of arrow in order to be able to
open pulling hooks of extractor far enough.

 Spread extractor - B - into upper lip of needle bearing - 1 - and secure extractor at nut.
 Install retainer - A - on extractor - B - as illustrated.
 Using hot air blower, e.g. VAG141, quickly heat up outside of transfer housing in vicinity of needle
bearing seat to approx. 80 to 100 ° C.
CAUTION: Wear protective gloves!
 Quickly pull out needle bearing.
Installing
1:40:28 AM Page 220

 Check needle bearing seat in transfer housing for damage, rework if necessary.
Fig. 298: Inserting New Needle Bearing And Set Sleeve 2080A Onto New Needle Bearing
 Insert new needle bearing and set sleeve 2080A onto new needle bearing - 1 -.
Sleeve 2080A must be centered when set onto sleeve.
 Drive needle bearing into transfer housing up to stop using punch VW408A.
DRIVESHAFT, SERVICING
Driveshaft, servicing
-->

Driveshaft, removing and installing
1:40:28 AM Page 221

-->

1:40:28 AM Page 222

TRANSMISSION 5 Spd. Automatic Transmission 01V Front and All Wheel Drive - Internal Components, Servicing
TRANSMISSION
5 Spd. Automatic Transmission 01V Front and All Wheel Drive - Internal Components,
Servicing

REPAIR INSTRUCTIONS
General Repair Notes
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful
transmission repairs. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.
Transmission
 Rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on
automatic transmissions.

 On removed transmission, support torque converter against falling down with Bracket 30-211 A.
 Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in
the transmission hydraulics.
 After repair work on the transmission, clean ATF lines and ATF cooler, replace ATF filter.
 Check the following fluid levels after installing, top off if necessary. ATF in planetary gear --> 37 -
AUTOMATIC TRANSMISSION - CONTROLS, HOUSING , axle oil for front final drive --> 39 -
FINAL DRIVE, DIFFERENTIAL , axle oil in transfer case --> 39 - FINAL DRIVE,
DIFFERENTIAL . Install driveshaft --> 00 - GENERAL, TECHNICAL DATA .
1:48:08 AM
1:48:49 Page 1
Impurities in ATF area
If ATF area is very soiled caused by worn friction linings:
 Disassemble transmission completely and clean, replace ATF oil tubes.

 Disassemble and check all clutches.
 Replace torque converter (cannot be cleaned).
 Replace valve body (cannot be cleaned).
 Clean ATF lines and ATF cooler, replace ATF filter.
O-rings, gaskets, shaft seals and seals.
 Always replace O-rings, gaskets, shaft seals and seals.

 After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for
other signs of damage.
 The open side of the shaft seals point toward the fluid to be sealed in.
 To install, thinly coat shaft seals along outer circumference and on sealing lip with ATF.
 Lightly lubricate O-rings with ATF or Vaseline before installing, this prevents the rings from being
pinched when inserting.
 Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old
shaft seal (use insertion depth tolerances).
 Replace paper gaskets, thoroughly clean sealing surfaces and completely remove old seals.
Bolts and nuts
 Loosen bolts in reverse order of tightening.

 Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages,
when no tightening sequence is specified.
 The tightening torques stated apply to unoiled bolts and nuts.
 Replace self-locking bolts and nuts.
Locking elements

 Always replace circlips which have been damaged or over-tensioned.
 Circlips must be properly seated in the base of the groove.
1:48:09 AM Page 2
Fig. 2: Identifying Spring Pins Installation Position

 Replace spring pins. Installation position: Slit is longitudinal to direction of force - arrow -.
Bearings
 Slightly grease mount with ATF before inserting.

 Attach mount and adjustment shims only with Vaseline. Other lubricants cause malfunctions of the
hydraulic transmission controls.
Oil tubes
 Once removed, oil tubes must always be replaced.

 If transmission is very dirty, oil tubes must be replaced.
Special tools
Special tools and equipment
1:48:09 AM Page 3
Fig. 3: Identifying Special Tools - Transmission Internal Components, Servicing (1 Of 8)

 Holding plate VW 309

 Measuring bar VW 382/7 from Special socket measuring tools VW 382
 Dial gauge holder VW 387
 Thrust plate VW 401

 Punch VW 407
1:48:09 AM Page 4

 Punch VW 408 A
 Punch VW 412
 Thrust piece VW 454
 Sleeve 30-21
 Bracket 30-211 A
 Sleeve 40-20
1:48:09 AM Page 5

 Seal installer 2080 A

 Thrust piece 3301/4 from assembly tool 3301
 Oil line installer 3381

1:48:09 AM Page 6


 Hook 3438
 Old oil collecting and extracting device V.A.G 1782
 Vehicle diagnostic, testing, and information system VAS 5051 (VAS 5051 B version shown as example
only)
 Dial gauge VAS 6080
1:48:09 AM Page 7

 Digital depth gauge VAS 6087

 Engine and Transmission Holder VAS 6095
 Workshop crane VAS 6100
 Extracting handle T10271
 Installation bracket T10276

1:48:09 AM Page 8

 Mounting device T10282

 Mounting device T10283
 Adapter for torque converter T10284
 Pre-tensioning tool T10285
 Puller for ATF supply T10286

 Lifting device T10287
1:48:09 AM Page 9

 Centering tool T10288

 Assembly sleeve T10290
 Plate T10291
 Plate T10292
 Plate T10293
1:48:09 AM Page 10

 Plate T10294
 Plate T10295
 - 1 - Internal extractor Kukko 21/4
 - 3 - Separating tool 22 to 115 mm Kukko 17/2
 - 4 - Support Kukko 22/1

 Heat gun
 Safety glasses
RULES OF CLEANLINESS FOR WORKING ON AUTOMATIC TRANSMISSIONS
1:48:09 AM Page 11
 Carefully clean all joints and adjacent areas before disconnecting.

 Place removed parts on a clean surface and cover them. Use sheeting or paper. Use lint-free cloths only!
 Carefully cover or plug unpacked components if repairs cannot be performed immediately.
 Only install clean parts: Remove packing from replacement parts immediately prior to installation and not
before.
FREQUENT DAMAGES
Frequent damages
NOTE:  Check DTC memory of Transmission Control Module (TCM) J217 before
troubleshooting.
 Check also DTC memory of Engine Control Module (ECM), as DTCs of the
Engine Control Module (ECM) can lead to transmission malfunctions.
 Check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS,
HOUSING before troubleshooting.
Slipping problems in all gears
 Possible damage:
Fig. 11: Identifying ATF Pump Wheel Coupling Plate

Coupling plate - arrows - on ATF pump wheel broken off
1:48:09 AM Page 12
 Causes

A - Torque converter not completely inserted during transmission or engine installation. Check installation
dimension --> 32 - TORQUE CONVERTER .
Fig. 13: Torque Converter Centering Bushing

B - Centering bushing for torque converter - arrow - not properly installed in crankshaft -->
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.8 LITER 4-CYL. 5V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): AMB
MECHANICAL, ENGINE CODE(S): BPG, BWT
 13 ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.0 LITER 6-CYL. 5V ENGINE
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.2 V6 4V ENGINE MECHANICAL,
ENGINE CODE(S): BKH
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 4V ENGINE
1:48:09 AM Page 13

Fig. 14: Location of Alignment Sleeves

C - One or both alignment sleeves - A - for centering not installed on engine/transmission flange. Alignment
sleeves or bores in transmission flange damaged.
NOTE:  Disregard items - 1 to 9 -.
Fig. 15: Identifying Shim, Drive Plate And Washer

D - Incorrect installation position of drive plate for torque converter, drive plate secured to engine with incorrect
shim - 1 - or shim - 1 - and washer - 2 - interchanged -->
1:48:09 AM Page 14
MECHANICAL, ENGINE CODE(S): BPG, BWT

 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.2 V6 4V ENGINE MECHANICAL,
ENGINE CODE(S): BKH
 Required actions:
 Disassemble and check ATF pump, remove broken coupling plates.
CAUTION: Always check for broken coupling plates and remove.
Hard shifting procedures, individual gears not fully locked, shifting procedures too long
NOTE:  Illustration shows the damage on a disassembled valve body. Valve body
must not be disassembled in customer service.
Fig. 16: Rubber Shock Absorbers (3 Total)
1:48:09 AM Page 15
One of 3 rubber shock absorbers broken - arrow -.
 Check ATF level --> Evaluating wear by evaluating ATF color and impurities.
ATF is OK:
 Replace valve body --> Valve body, removing and installing.
ATF is not OK, damage was not repaired in a timely manner. In this case, clutch "G" is possibly damaged:
 Completely disassemble and clean transmission.

 Clean ATF lines and ATF cooler.
 Disassemble and check all clutches.
Hard shifting, slipping in 4th and 5th gear
Fig. 17: Cylinder "E", Overview

Plates - 3 - of clutch "E" burnt out.
1:48:09 AM Page 16
 Cause:
Worn or faulty torque converter clutch
 Check torque converter clutch while driving --> Torque converter clutch, checking.
 Completely disassemble and clean transmission.
 Clean ATF lines and ATF cooler.
 Disassemble and check all clutches.
 If there is heavy soiling --> Evaluating wear by evaluating ATF color and impurities , replace torque
converter (cannot be cleaned).
 Replace components - 2 to 5 - of clutch "E".
 Replace overheated cylinder "E" - 1 - (blue color).
 Replace ATF filter --> Fig. 118.
ATF leakage between engine and transmission
The ATF pump corroded resulting in increased wear and chafing on the torque converter hub, heavy ATF
leakage.
Fig. 18: Checking For ATF Escaping At Oil Leak Inspection Opening
 Make sure that no ATF escapes at oil leak inspection opening - arrow - after removing transmission. In
this case, the final drive/transmission housing double shaft seal would be faulty.
 Replace final drive/transmission housing double shaft seal if necessary --> 39 - FINAL DRIVE,
DIFFERENTIAL .
1:48:09 AM Page 17
Fig. 19: Identifying Brass Sleeve

 Check brass sleeve - arrow - for signs of wear and seizing.

 Check hub - arrow - of torque converter for wear and corrosion.
If corrosion is detected:
 Replace ATF pump and torque converter.

 If there is heavy soiling --> Evaluating wear by evaluating ATF color and impurities , disassemble
and clean transmission.
1:48:09 AM Page 18
Fig. 21: Torque Converter Centering Bushing

 Check whether alignment sleeve - arrow - for torque converter is installed in crankshaft -->
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.8 LITER 4-CYL. 5V TURBO
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 2.0 LITER 4-CYL. 4V TURBO
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.2 V6 4V ENGINE
MECHANICAL, ENGINE CODE(S): BKH
.
Fig. 22: Location of Alignment Sleeves

 Check whether both alignment sleeves - A - are inserted in cylinder block.
1:48:09 AM Page 19
 Check alignment sleeves for deformation and holes in transmission flange for damage.
NOTE:  Disregard - 1 to 9 -.
Speed-dependent noises in driving operation
Fig. 23: Identifying Of Intermediate Pinion, Drive Pinion, And Pinion Gears
Faulty spur gear bearings or spur gears - 1 to 3 -.
 Required action:
 Replace transmission.
TORQUE CONVERTER
Torque converter clutch, checking
NOTE:  Check DTC memory of Transmission Control Module (TCM) J217 before
troubleshooting.
 Check also DTC memory of Engine Control Module (ECM), as DTCs of the
Engine Control Module (ECM) can lead to transmission malfunctions.
 Check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS,
HOUSING before troubleshooting.
1:48:09 AM Page 20
Connector (DLC)
Torque converter clutch can only be checked when driving in On Board Diagnostics (OBD).
CAUTION:  Test and measuring equipment must always be secured to the rear
seat and operated from there by a second person.
 If test and measuring equipment is operated from the passenger seat,
the person seated there could be injured in the event of an accident
involving deployment of the passenger-side airbag.
 With ignition switched off, connect Vehicle Diagnosis, Testing and Information System VAS 5051 to
Data Link Connector (DLC).
 Start engine.
1:48:09 AM Page 21

Display on VAS 5051 :
 Tap Vehicle Self-Diagnosis button.

 In selection - 1 - , click on function "02 - Transmission electronics".

 Wait until the next indication appears on display.

 From list - 1 - select function "08 - Reading measured value block".
1:48:09 AM Page 22

1 - Enter display group, max. input value = 255
 In button field - 2 - , tap 7 button for "display group 007" and confirm entry by tapping Q button.
 Perform a road test.

 Check indication in display fields - 3 - and - 4 -. Specified values:
3 - TC closed
4 - 0 to 20/min
If indications do not resemble description, ratio of transmission RPM to engine speed with closed torque
converter clutch does not match (implausibility).
1:48:09 AM Page 23
 Causes:
 Torque converter clutch circuit malfunctioning, worn.

 Incorrect torque converter.
 Automatic Transmission Pressure Regulating Valve 4 N218 mechanically malfunctioning.
 Problems in ATF lines to Automatic Transmission Pressure Regulating Valve 4 N218.
 Valve for torque converter pressure malfunctioning.

 Torque converter clutch valve faulty.
 Press <-- button to end function "08 - Read measured value block".
 Select "06 - End output" function.
 Switch off ignition and disconnect diagnostic connector.
Fig. 30: Extracting ATF From Torque Converter With Used Oil Collection And Extraction Tool V.A.G
1782
In case of soiling of the ATF via shavings or during a major transmission overhaul, torque converter must be
drained.
 Extract ATF from torque converter with Used Oil Collection and Extraction Tool V.A.G 1782.
1:48:09 AM Page 24

 Check hub - arrow - of torque converter for wear and corrosion.

 Check whether balance plates are properly seated and threads are undamaged.
If signs of wear and corrosion on torque converter, loosened balance plates or damaged threads are detected:
 Replace torque converter.
NOTE:  If the torque converter clutch is burnt or worn, sand-like material and
residues can be found in the ATF filter.
Fig. 32: Torque Converter Bolts

 If the bolts - arrow - for the attachment of the torque converter to the drive plate protrude only 2 mm, the
torque converter can get dented and the torque converter clutch can be damaged. Therefore, only use
original bolts.
1:48:09 AM Page 25
TRANSMISSION, ATTACHING ASSEMBLY STAND
Work procedure
 Torque converter secured with Bracket 30-211 A or removed.
 Attach holding plate VW 309 onto attachment and holding rig 3457.

 Attach and secure Attachment and Holding Rig 3457 at mounts on transmission housing.
NOTE:  Attachment and Holding Rig 3457 should only be installed by hand in
transmission.
 If bolt is installed with pliers, transmission housing can be damaged.
 Insert transmission into Engine and Transmission Holder VAS 6095 using Shop Crane -Load Cap=700-
1200 kg VAS 6100.
turning a filled transmission with oil pan upward on the engine and
transmission holder.
PLANETARY GEAR, DISASSEMBLING AND ASSEMBLING
Planetary gear, disassembling and assembling
NOTE:  General repair notes --> General Repair Notes .

 Lubricate O-rings and gaskets with ATF or Vaseline before installing to
prevent rings from being pinched when inserting.
1:48:09 AM Page 26
 Attach mount and adjustment shims only with Vaseline.
Planetary gear, component overview
NOTE:  Some of the depicted components are part of component groups and are
not available separately as replacement part.
Fig. 34: Planetary Gear, Component Overview

1 - Bolt, 10 Nm
1:48:09 AM Page 27
2 - Sealing washer
 Replace
3 - O-ring
 Replace
4 - ATF supply
 With ATF pump

 Disassembling and assembling --> Clutch "C" , disassembling and assembling
5 - Axial needle bearing
6 - Rectangular rings
 Replace
7 - Rectangular ring
 Replace
8 - O-rings
 Replace
9 - Adjustment shim
 Determine thickness --> Fig. 108
10 - Tower "II"
 Disassembling and assembling --> Tower "II" , disassembling and assembling
11 - Thrust washer
13 - Thrust washer
14 - Intermediate shaft with inner plate carrier
15 - Angle washer
1:48:09 AM Page 28
17 - Thrust washer
18 - Sun shaft
20 - Sun gear "I"
 Magnetic, for transmission with hydraulic control "E17" , Transmission Input Speed (RPM) Sensor G182
is then an inductive sensor
 Not magnetic, for transmission with hydraulic control "E18/2" , Transmission Input Speed (RPM) Sensor
G182 is then a Hall sensor
21 - Planetary gear set "I" and "II"
22 - Angle washer
24 - Thrust washer
25 - Shaft with ring gear "I"
26 - Ribbed cup
27 - Thrust washer
29 - Angle washer
 Height 2.5 mm incl. collar
30 - Circlip
31 - Fitting key
32 - Tower "I"
 Disassembling and assembling --> Tower "I" , disassembling and assembling
33 - Angle washer
 Height 5 mm incl. collar
1:48:09 AM Page 29
35 - Angle washer
36 - Sun gear "III"
Planetary gear, disassembling and assembling
Disassembling
 Transmission attached to assembly stand --> Transmission, attaching assembly stand.
 Remove torque converter.

 Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
CAUTION: Wear eye protection.
Fig. 35: Identifying ATF Drain Plug And ATF Level Inspection Plug
 Remove ATF drain plug - 1 - and allow ATF to drain.

 Rest of ATF remains in the ATF oil pan.
Automatic transmission 01V Front Wheel Drive:
1:48:09 AM Page 30
 Loosen front final drive cover bolts in sequence - 14 to 1 - and then remove completely.
 Allow escaping oil to drain into Used Oil Collecting and Extracting Device V.A.G 1782.
CAUTION:  Slowly and carefully remove cover for front final drive from
transmission housing. The spur gears can otherwise fall out of the
transmission.
 Lift off cover for front final drive.
1:48:10 AM Page 31
 Mark installation position of intermediate pinion - 1 - and pinion gear - 3 -.
CAUTION:  Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in

the same position to maintain running direction.
 For this reason, mark installation position of intermediate pinion and
pinion gear.
 Remove pinion gear together with intermediate pinion, while doing so pull drive pinion - 2 - slightly
toward rear.
 Remove drive pinion - 2 -.
Fig. 38: Identifying Adjustment Shim, Axial Needle Bearing, And Coil Spring
 Remove adjustment shim - 1 - and axial needle bearing - 2 - from input shaft.
 Remove coil spring - 3 - from pinion shaft.
1:48:10 AM Page 32

Automatic transmission 01V All Wheel Drive:
 Remove locking bolt - A - and allow axle oil to drain from transfer case.
Fig. 40: Identifying Transfer Case Housing Bolts

 Loosen transfer case housing bolts - arrows - in a diagonal sequence and then remove them completely.
CAUTION: Carefully and slowly pull transfer case housing off of transmission toward
rear. The Torsen differential could otherwise fall out of the transmission.
1:48:10 AM Page 33
Fig. 41: Removing/Installing Torsen Differential At Input Shaft

 Remove Torsen differential - arrow - from input shaft.

Fig. 42: Identifying Intermediate Flange For Front Final Drive Fasteners
 Remove bolts - arrows - at intermediate flange for front final drive.

 Allow escaping oil to drain into Used Oil Collecting and Extracting Device V.A.G 1782.
CAUTION:  Slowly and carefully remove intermediate flange for front final drive
from transmission housing. The spur gears can otherwise fall out of
the transmission.
1:48:10 AM Page 34
 Lift off intermediate flange for front final drive.
Fig. 43: Identifying Intermediate Pinion, Drive Pinion, And Pinion Gears, and Input Shaft
 Cover entire splines - arrow - on input shaft with insulating tape without wrinkling or overlapping to
avoid damaging shaft seal in front final drive intermediate flange when removing drive pinion - 2 -.


toward rear.
 Remove adjustment shim - 1 - and axial needle bearing - 2 - from input shaft.
 Remove coil spring - 3 - from pinion shaft.
1:48:10 AM Page 35
Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive:

 Remove right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft
using a pry bar.
 Pull out right flange shaft.
1:48:10 AM Page 36
 Loosen final drive cover bolts in sequence - 12 to 1 - and then remove completely.
CAUTION:  Slowly and carefully remove final drive cover from transmission
housing. Otherwise differential can fall out of transmission.
 A differential that has fallen onto the floor must not be installed
again. The transmission must be replaced in this case.
 Remove final drive cover.
CAUTION:  Ensure tapered roller bearing outer race and differential adjusting
screw do not fall out of final drive cover.
 Tapered roller bearing outer race must be installed in the same
location.
 The shim must be the correct size and must not be replaced by a
shim with a different thickness.
Fig. 47: Removing/Installing Differential

 Carefully remove differential - arrow -.
1:48:10 AM Page 37
Fig. 48: Removing/Installing Baffle At Final Drive Cover

 Remove bolts - arrows - and remove baffle.
 Completely cover splines - arrow - on left flange shaft with insulating tape without wrinkling or
overlapping to avoid damaging final drive/transmission housing double shaft seal when removing flange
shaft.
1:48:10 AM Page 38

 Remove left drive flange mounting bracket - arrows -.

 Pull out left drive flange.
NOTE:  When sliding off, left drive flange must be carefully guided by hand to
prevent damage to the double seal in final drive/transmission housing.
Fig. 51: Identifying Oil Pan Bolts

 Loosen ATF oil pan bolts - arrow - in a diagonal sequence and then remove them completely.
 Remove ATF oil pan.
NOTE:  Milky green cover in ATF oil pan means there is damage to the torque
converter clutch.
1:48:10 AM Page 39

 Remove ATF screen bolts - arrows -.

 Pull ATF filter off of valve body.

 Remove circlip - arrow - for wiring harness/harness connector.

 Remove wiring harness/harness connector by pressing inward.
1:48:10 AM Page 40
Fig. 54: Identifying Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM)
Sensor G195 Harness Fastener
 Remove bolt - arrow - and remove Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output
Speed (RPM) Sensor G195.
Fig. 55: Identifying Connector Transmission Input Speed (RPM) Sensor G182 At Valve Body
 In a transmission with hydraulic control "E18/2" , disengage electrical connector to Transmission Input
Speed (RPM) Sensor G182 at valve body - arrow - and disconnect connector.
Fig. 56: Loosening or Tightening Valve Body Bolts In Sequence (As Describe)
 Loosen valve body bolts - 17 to 1 - in sequence and remove them completely.
1:48:10 AM Page 41
CAUTION:  Only the designated bolts must be removed; bolt - 6 - is only on

transmissions with hydraulic control "E17".
 When removing other bolts, the function of the valve body can be
 Note the different lengths of the bolts.
Fig. 57: Carefully Remove Valve Body From Transmission

 Carefully remove valve body from transmission.
CAUTION: Only transmissions with hydraulic control "E17" : Do not rest valve body
on Transmission Input Speed (RPM) Sensor G182 (on bottom side of valve
body - arrow -) - risk of damage.
Fig. 58: Location Of Inlet Bores Sealing Sleeves

 Pull sealing sleeves - arrows - in inlet bores toward clutches "C" , "A" , "B" , "E" and toward torque
converter clutch using extracting handle T10271.
1:48:10 AM Page 42
Fig. 59: Identifying Securing Rings, Coil Springs, and Sealing Sleeves
 Remove 3 securing rings - 1 -.

 Remove coil springs - 2 -.
 Pull out sealing sleeves - 3 - , using extracting handle T10271.
 Rotate transmission on assembly stand.
 ATF pump faces upward.
Fig. 60: Identifying ATF Pump Bolts Tightening Sequence

 Loosen ATF pump bolts - 9 to 1 - in sequence and remove them completely.

 Remove bolts with sealing washers.
1:48:10 AM Page 43
Fig. 61: Removing ATF Pump Using Puller T10286

 Secure puller for ATF supply T10286 to stator shaft and pull ATF supply firmly upward.
If ATF pump cannot be loosened:
Fig. 62: If ATF Pump Cannot Be Loosened Proceed As Shown

 On the bottom side of the transmission, place a screwdriver between sun gear "I" and ribbed cup and pry
component above sun gear upward - arrow -.
1:48:10 AM Page 44
Fig. 63: Identifying Adjustment Shim and Axial Needle Bearing

 Remove adjustment shim - 1 - and axial needle bearing - 2 -.
Fig. 64: Removing/Installing Tower "II" Out/In Of Transmission Housing

 Lift tower "II" - 1 - out of transmission housing.
1:48:10 AM Page 45
Fig. 65: Tower "II" Mounted On Device T10283Tower "II" Mounted On Device T10283
 Twist tower "II" - 1 - and place together with input shaft in mounting device T10283.
Fig. 66: Removing/Installing Sun Shaft with Intermediate Shaft Out/In Of Transmission Housing
 Remove sun shaft - 1 - with intermediate shaft - 2 - with inner plate carrier.
1:48:10 AM Page 46
Fig. 67: Disassemble/Assemble The Following Components (As Shown)

 Disassemble the following components:
1. Sun shaft
2. Thrust washer
3. Axial needle bearing
4. Angle washer
5. Intermediate shaft with inner plate carrier
6. Thrust washer
8. Thrust washer
Fig. 68: Identifying Axial Needle Bearing
1:48:10 AM Page 47
 Remove axial needle bearing - 1 -.
Fig. 69: Identifying Sun Gear "I"

 Remove sun gear "I" - 1 -.
Fig. 70: Identifying Planetary Gear Set "I" And "II"

 Remove planetary gear set "I" and "II" - 1 -.
1:48:10 AM Page 48
Fig. 71: Angle Washer, Axial Needle Bearing and Thrust Washer
 Remove angle washer - 3 - , axial needle bearing - 2 - and thrust washer - 1 -.
Fig. 72: Shaft With Ring Gear "I", Thrust Washer, Axial Needle Bearing and Angle Washer
 Remove shaft with ring gear "I" - 4 - , thrust washer - 3 - , axial needle bearing - 2 - and angle washer - 1
-.
Fig. 73: Ribbed Cup
1:48:10 AM Page 49
 Remove ribbed cup - 1 -.
Fig. 74: Circlip For Tower "I"

 Remove circlip - arrow - for tower "I".
Fig. 75: Installing/Removing Lifting Device T10287

 Turn back knurled nut of lifting device T10287.

 Insert lifting device into tower "I" until stop.
 Tighten knurled nut of lifting device in clockwise direction.
 Check lifting device in tower "I" for proper seating.
1:48:10 AM Page 50
 Lift tower "I" out of transmission housing by hand.
Fig. 76: Identifying Lifting Device T10287 And Mounting Device T10282
 Place tower "I" in mounting device T10282.
Fig. 77: Sun Gear "III" With Lower Angle Washer, Axial Needle Bearing, and Upper Angle Washer
 Remove sun gear "III" - 1 - with lower angle washer - 2 - , axial needle bearing - 3 - and upper angle
washer - 4 - from transmission housing.
NOTE:  Upper angle washer - 4 - possibly adheres to underside of tower "I".
Assembling
1:48:11 AM Page 51
 Lift tower "I" out of mounting device T10282 by hand and lay aside on workbench.
Fig. 79: Tower "I", Overview

 Attach the following components to input shaft of tower "I" - 5 - :
1:48:11 AM Page 52
4 - Upper angle washer - angled edge points up toward tower "I"
2 - Lower angle washer - angled edge points toward axial needle bearing
1 - Sun gear "III" - outer splines of sun gear must engage in splines of clutch "F"
Fig. 80: Securing Sun Gear "III" On Input Shaft Without Play, Using Assembly Sleeve T10290
 Secure sun gear "III" on input shaft without play, using assembly sleeve T10290 , as depicted in
illustration, thread stud bolt - 1 - into bore identified by "A" - arrow A - and hand-tighten.
CAUTION:  Stud bolt must not be threaded in bore identified by "B" under any
circumstances, or splines will be damaged.
 Bore "A" faces toward sun gear "III".
1:48:11 AM Page 53
Fig. 81: Securing Sun Gear "III" On Input Shaft Without Play, Using Assembly Sleeve T10290
 Secure sun gear "III" on input shaft without play, using assembly sleeve T10290 , as depicted in
illustration, thread stud bolt - 1 - into bore identified by "B" - arrow B - and hand-tighten.
CAUTION:  Stud bolt must not be threaded in bore identified by "A" under any
circumstances, or contact surface will be damaged.
 Bore "A" faces toward sun gear "III".
Fig. 82: Checking Fitting Keys Are Inserted Centrally On Both Sides Of Cylinder "D/G"
1:48:11 AM Page 54
 Check whether fitting keys - arrow - are inserted centrally on both sides of cylinder "D/G".
Fig. 83: Location Of Oil Bores On Cylinder "D/G"

 Bring tower "I" into installation position.
 Oil bores - arrows - on cylinder "D/G" face toward underside of transmission and must align with
openings in transmission housing.
Fig. 84: Installing/Removing Lifting Device T10287

 Insert tower "I" completely into transmission housing.
 Tower "I" must be inserted far enough that circlip groove is free.
1:48:11 AM Page 55
 Loosen knurled nut and remove lifting device T10287.
Fig. 85: Circlip For Tower "I"

 Carefully insert circlip - arrow - for tower "I" into transmission housing.
CAUTION: Make sure that circlip is seated evenly all around in groove of
transmission housing, if necessary, drive circlip into groove all around
using drift.
Fig. 86: Loosen Stud Bolt And Remove Assembly Sleeve T10290
 Loosen stud bolt and remove assembly sleeve T10290.
NOTE:  Depicted in the illustration with Automatic Transmission 01V All Wheel
Drive.
1:48:11 AM Page 56
Fig. 87: Ribbed Cup

 Insert ribbed cup - 1 -.
Fig. 88: Shaft With Ring Gear "I", Thrust Washer, Axial Needle Bearing and Angle Washer
 Attach angle washer - 1 - on tower "I".
 Angled edge of angle washer faces down.
 Insert axial needle bearing - 2 -.

 Insert thrust washer - 3 -.
 Insert shaft with ring gear "I" - 4 -.
1:48:11 AM Page 57
Fig. 89: Angle Washer, Axial Needle Bearing and Thrust Washer
 Insert thrust washer - 1 - into ring gear "I".

 Place angled washer - 3 -.
 Angled edge of angle washer faces down.
Fig. 90: Identifying Planetary Gear Set "I" And "II"

 Insert planetary gear set "I" and "II" - 1 -.
1:48:11 AM Page 58
Fig. 91: Identifying Sun Gear "I"

 Insert sun gear "I" - 1 - in planetary gear set "I" and "II".
NOTE:  Magnetic sun gear for transmission with hydraulic control

"E17" (Transmission Input Speed (RPM) Sensor G182 as inductive sensor).
 Non-magnetic sun gear for transmission with hydraulic control
"E18/2" (Transmission Input Speed (RPM) Sensor G182 as Hall sensor).
Fig. 92: Identifying Axial Needle Bearing

1:48:11 AM Page 59
Fig. 93: Disassemble/Assemble The Following Components (As Shown)

 Assemble the following components as one unit:
1. Sun shaft
2. Thrust washer
4. Angle washer - angled edge points downward toward axial needle bearing
5. Intermediate shaft with inner plate carrier
6. Thrust washer
8. Thrust washer
Fig. 94: Removing/Installing Sun Shaft with Intermediate Shaft Out/In Of Transmission Housing
1:48:11 AM Page 60
 Insert sun shaft - 1 - together with intermediate shaft - 2 - with inner plate carrier.
Fig. 95: Tower "II" Mounted On Device T10283Tower "II" Mounted On Device T10283
 Remove "tower II" - 1 - from mounting device T10283 and turn to installation position.
Fig. 96: Removing/Installing Tower "II" Out/In Of Transmission Housing

 Insert tower "II" - 1 - into transmission housing by hand using turning motions.
 Ensure sun gear coupling plate splines "I" engage in outer splines on cylinder "B" by turning input shaft
and sun gear "I".
1:48:11 AM Page 61
Fig. 97: Identifying Dimension

 Check tower "II" for proper installation.

 Measure distance between contact surface for adjustment shim on tower "II" and contact surface for ATF
pump on transmission housing.
 Dimension - a - = at least 6.0 mm.

 Adjustment shim may not be installed.
Fig. 98: Adjustment Shim

 Place previous adjustment shim - 1 - on plate carrier "C".
1:48:11 AM Page 62
Fig. 99: Location Of Rectangular Rings

 Replace 2 rectangular rings on input shaft.

 Before inserting, thinly coat rectangular rings on input shaft with Vaseline. Use only Vaseline, other
lubricating substances cause functional problems in hydraulic transmission control.
 Make sure that rectangular rings are fully seated all around in the input shaft groove.
Fig. 100: ATF Pump, Axial Needle Bearing, and Rectangular Rings And
 Thinly coat back side of axial needle bearing - 2 - with Vaseline. Use only Vaseline, other lubricating
substances cause functional problems in the hydraulic transmission control.
 Append axial needle bearing to ATF pump - 1 -.
 Closed side of axial needle bearing faces toward ATF pump.
1:48:11 AM Page 63
 Replace rectangular rings - 3 - and - 4 - on stator shaft.

 Before inserting, lightly coat rectangular ring with Vaseline. Use only Vaseline, other lubricating
 Make sure that rectangular rings are fully seated all around in stator shaft groove.
Fig. 101: Hooking Ends Of Piston Ring Together

 Engage ends of installed rectangular rings - arrows - , as depicted in illustration.
Fig. 102: ATF Pump O-ring

 Replace O-ring - 1 - on ATF supply.

 Thinly coat O-ring with Vaseline. Use only Vaseline, other lubricating substances cause functional
problems in hydraulic transmission control.
1:48:11 AM Page 64
Fig. 103: Align Coated Plates Of Clutch "C" Using Centering Tool T10288/1
 Align coated plates - 3 - of clutch "C" using centering tool T10288/1 , to do so let pins - 2 - and - 4 -
engage in splines of all coated splines.
 Align lining discs to ATF pump housing by inserting centering pins - 1 - and - 5 - into appropriate holes
on ATF pump.
 Centering pins fit only in one position.
 Hold centering tool in this position and insert wedge T10288/2 from side between waved washer and
piston "F" - arrow -.
 Wedge must secure all plates in current position.
 Remove centering tool T10288/1 , wedge T10288/2 remains inserted.
1:48:11 AM Page 65
Fig. 104: Align Plate Carrier For Clutch "C" Using Centering Tool T10288/3
 Align plate carrier for clutch "C" using centering tool T10288/3 , install guide pins T10288/4 into
 Holes in centering tool and transmission housing only fit in one position.
 Carefully remove centering tool T10288/3 upward, guide pins T10288/4 remain in transmission housing.
 Plate carrier for clutch "C" may no longer be turned.
Fig. 105: Attaching Puller For ATF Pump T10286 At Stator Shaft
 Attach puller for ATF supply T10286 at stator shaft.

 Bring ATF supply to installation position.
 Recess for flange shaft faces toward valve body side.
 Attach ATF supply with corresponding bores onto guide pins T10288/4.
 Carefully insert ATF supply into transmission housing and push forcefully.
 Bring ATF supply to final installation position by alternately tightening two opposing attachment bolts
each.
1:48:11 AM Page 66
Fig. 106: Removing Wedge 10288/2 Using Hook 3438

 Remove wedge 10288/2 using hook 3438.

 Remove Puller for ATF supply T10286.
 Remove guide pins T10288/4.

 Insert ATF pump bolts with new sealing washers into ATF pump housing.
 Tighten ATF pump bolts - 1 to 9 - in sequence.
 Tightening torque: 10 Nm.
NOTE:  Check for correct ATF pump installation: You must be able to rotate the
input shaft. Otherwise, the last clutch plate "C" may have been pinched
during installation and bent. In this case, remove ATF pump again and
check discs for damage.
1:48:11 AM Page 67
Fig. 108: Checking Input Shaft Axial Clearance

 Attach Dial gauge VAS 6080 with Dial gauge holder VW 387 to transmission flange.
 Insert Dial gauge VAS 6080 with dial gauge extension onto input shaft of transmission, as depicted in
illustration.
 Set dial gauge to "0".
 To protect against damage, cover input shaft with insulating tape.
 Move input shaft up and down using pliers, while doing so avoid lateral movement.
 Read input shaft axial clearance on dial gauge.
 Specified value: 0.10 to 0.30 mm.
If specified value is not obtained:
 Remove ATF pump again.
Fig. 109: Identifying Tower "II", Clutch "B" and Adjustment Shim
 Determine correct adjustment shim - 2 - on tower "II" item - 1 - according to the following table.
1:48:12 AM Page 68
 Measured axial clearance too small: Install respectively thinner shim.

 Measured axial clearance too large: Install respectively thicker shim.
Available shims - thickness in mm

1.6 2.0 2.4
1.8 2.2 2.6
 Reinstall ATF pump with new adjustment shim, new sealing washers and new O-ring. Refer to Fig. 100 .
 Check axial clearance of input shaft again --> Fig. 108 .
If specified value is again not obtained:
 Repeat adjustment.
If specified value is obtained:
 Valve body side points upward.
 Press sealing sleeves - 3 - into transmission housing holes to stop.

 Insert coil springs - 2 - and secure with circlips - 1 - by pressing circlips into hole down to shoulder.
1:48:12 AM Page 69
on Transmission Input Speed (RPM) Sensor G182 - arrow - (on bottom side
of valve body) - risk of damage.

Fig. 112: Position Valve Body On Transmission Housing While Inserting Notched Disc Pins Into Selector
Slide Groove
 Position valve body on transmission housing without force while inserting notched disc pins - 1 - into
selector slide groove - 2 -.
 Position valve body bolts.
NOTE:  Note different length of bolts.
1:48:12 AM Page 70
 Bolt - 6 - is only present on transmissions with hydraulic control "E17".

 On a transmission with hydraulic control "E18/2" , ensure electrical wire to Transmission Input Speed
(RPM) Sensor G182 is not pinched between transmission housing and valve body.
 Tighten valve body bolts in 2 stages as follows:
Stage Tightening
I  Hand-tighten bolts - 1 to 17 - in sequence.
II  Tighten bolts - 1 to 17 - in sequence to 8 Nm.
 Replace O-rings for wiring harness/harness connector.
1:48:12 AM Page 71
Fig. 114: Location Of Transmission Harness Connector and Connector O-ring

 Connect wiring harness connector - arrow - to transmission housing.
 Installation position: Retainers - 1 - and - 2 - at collar are horizontal, leveled side - arrow - of connector
must be parallel to ATF oil pan sealing surface.

 Position wiring harness connector securing clip - arrow - and ensure it locks securely.
1:48:12 AM Page 72
 Tighten bolt - arrow - for Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed
(RPM) Sensor G195.
 With a transmission with hydraulic control "E18/2" , connect electrical connector to Transmission Input
 Clip electrical harness connector into valve body mount - arrow -.
 Replace ATF filter.
1:48:12 AM Page 73

 Position ATF filter on valve body and tighten - arrows -.
NOTE:  Clean magnets (6x) in ATF oil pan.

 Ensure full surface contact of the magnets in the ATF oil pan.

 Install ATF oil pan - arrow - with new seal.

 Tighten bolts for ATF oil pan in diagonal sequence in stages.
1:48:12 AM Page 74

 If necessary, replace flange seal for left flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Replace O-ring - arrow B - in mounting bracket for left flange shaft.
NOTE:  Disregard - arrow A -.
DIFFERENTIAL .
overlapping to avoid damaging final drive/transmission housing double shaft seal when installing flange
shaft.
 Insert left flange shaft into transmission.
1:48:12 AM Page 75
NOTE:  When sliding on, left drive flange must be carefully guided by hand to

 Tighten left flange shaft mounting bracket bolts - arrows -.
location.
1:48:12 AM Page 76
Fig. 123: Removing/Installing Baffle At Final Drive Cover

 Clean baffle and tighten it to final drive cover - arrows -.
 Replace O-ring - arrow - in final drive cover.

 If necessary, replace flange seal for right flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .
1:48:12 AM Page 77

 Carefully install differential - arrow -.
 Position final drive cover on transmission housing.

 Tighten final drive cover bolts in 2 stages as follows:
Stage Tightening
II  Tighten bolts - 1 to 12 - in sequence to 23
Nm.
1:48:12 AM Page 78

 Tighten right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft
using a pry bar.
 Attach coil spring - 3 - onto pinion shaft.

 Attach axial needle bearing - 2 - and adjustment shim - 1 - onto input shaft.
 Angled edge of axial needle bearing points toward adjustment shim.
1:48:12 AM Page 79
 Attach drive pinion - 2 - onto input shaft until stop.
CAUTION: Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the

same position to maintain running direction.
 Insert pinion gear - 3 - into transmission housing together with intermediate pinion - 1 - , as marked when
removed, to do so pull back drive pinion - 2 - from input shaft approx. 20 mm.
1:48:12 AM Page 80
 Check whether alignment sleeve - A - is inserted in front final drive cover.

 Install new gasket.
NOTE:  Apply thin coat of axle oil on sealing surface before installing gasket to
avoid slipping of the gasket.
 Tighten front final drive cover bolts in 2 stages as follows:
Stage Tightening
I  Hand-tighten bolts - 1 to 3 - in sequence
1:48:13 AM Page 81
while ensuring housing gap between front

final drive cover and transmission housing
decreases evenly all around.
Nm.
Fig. 131: Cover Splines On Input Shaft (To Prevent Damage To Gasket)
 Completely cover splines on input shaft - arrow A - with insulating tape without creasing or overlapping
the tape to prevent damage to gasket when sliding on drive pinion.
NOTE:  Disregard - arrow B -.
1:48:13 AM Page 82
 Attach coil spring - 3 - onto pinion shaft.

 Attach axial needle bearing - 2 - and adjustment shim - 1 - onto input shaft.
 Angled edge of axial needle bearing points toward adjustment shim.
 Replace shaft seal in drive pinion if necessary --> Shaft seal in drive pinion, replacing.
 Attach drive pinion - 2 - onto input shaft until stop.
CAUTION: Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the

same position to maintain running direction.
 Insert pinion gear - 3 - into transmission housing together with intermediate pinion - 1 - , as marked when
removed, to do so pull back drive pinion - 2 - from input shaft approx. 20 mm.
 If necessary, replace shaft seal for output flange/drive shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .
Fig. 134: Checking Alignment Sleeve Is Inserted In Intermediate Flange For Front Final Drive
1:48:13 AM Page 83
 Check whether alignment sleeve - A - is inserted in intermediate flange for front final drive.
 Carefully place intermediate flange for front final drive.
CAUTION: When installing the intermediate flange to the input shaft carelessly, the
sealing lip of the shaft seal - arrow - can be damaged.
 Tighten front final drive intermediate flange bolts in 2 stages as follows:
Stage Tightening
I  Hand-tighten bolts - arrows - in diagonal
sequence while ensuring housing gap between
front final drive intermediate flange and
transmission housing decreases evenly all
around.
II  Tighten bolts in diagonal sequence to 23 Nm.
 Check whether alignment sleeves - A - are inserted in front final drive intermediate flange.
1:48:13 AM Page 84
 Slide cleaned solenoid in cast-on holding pocket - B - in front final drive intermediate flange.
 Add 200 ml axle oil to Torsen differential.
Fig. 136: Removing/Installing Torsen Differential At Input Shaft

 Attach Torsen differential - arrow - onto input shaft.
Fig. 137: Identifying Transfer Case Housing Bolts

 Attach transfer case housing with installed spur gears and driveshaft input flange to transmission.
 Tighten transfer case housing bolts in 2 stages as follows:
Stage Tightening
I  Hand-tighten bolts - arrows - in diagonal
sequence while ensuring housing gap between
1:48:13 AM Page 85
transfer case housing and transmission

housing decreases evenly all around.
II  Tighten bolts in diagonal sequence to 23 Nm.
 Remove transmission from assembly stand.

 Insert torque converter and secure against falling down with Bracket 30-211 A.
 Check installation dimension of torque converter --> 32 - TORQUE CONVERTER .
CAUTION: The old transmission should be installed and put into operation as quickly
as possible to prevent corrosion on the newly installed components.
 Fill ATF and check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .
 Fill axle oil in front final drive and check oil level --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Top off axle oil in transfer case and check oil level --> 39 - FINAL DRIVE, DIFFERENTIAL .
Torque specifications
Component Nm
ATF supply on transmission housing 10
Valve body at transmission housing 8
ATF filter on valve body 5
ATF oil pan on transmission housing 10
Mounting bracket for left drive flange on 23
transmission
Final drive cover to transmission 23
Right drive flange 25
1:48:13 AM Page 86
Front final drive cover or front final drive 23

intermediate flange to transmission
Transfer case housing to transmission 23
TOWER I , DISASSEMBLING AND ASSEMBLING
Tower "I" , disassembling and assembling

 Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause faults to occur in the
transmission hydraulics.
Tower "I" , component overview
1:48:13 AM Page 87
Fig. 139: Tower "I", Component Overview

1 - Clutch "D/G" with freewheel
2 - Clutch "F"
3 - Angle washer
5 - Thrust washer
6 - Planetary drive "III"
Tower "I" , disassembling
1:48:13 AM Page 88
 Remove lifting device T10287 from tower "I".
Fig. 141: Remove/Install clutch "D/G" From/To Clutch "F"

 Remove clutch "D/G" - 2 - from clutch "F" - 1 -.
1:48:13 AM Page 89

 Remove clutch "F" - 5 - from planetary gear "III" - 1 -.
NOTE:  Thrust washer - 2 - , axial needle bearing - 3 - and angle washer - 4 - remain
on planetary drive "III".
Clutch "F" , component overview
NOTE:  Clutch "F" is depicted in installed position.

 Some of the depicted components are part of component groups and are
not available separately as replacement part .
 Before assembling, check clutch components "F" for wear and damage -->
Clutch "F".
1:48:13 AM Page 90
Fig. 143: Clutch "F", Component Overview

1 - Cylinder "F"
2 - O-ring
 Replace
3 - Piston "F"
4 - O-ring
 Replace
5 - Thrust piece
1:48:13 AM Page 91
6 - Plate spring
7 - Split retaining ring
8 - Waved washer
9 - Outer plate
10 - Coated plate
11 - Circlip
Clutch "F" , disassembling and assembling
Fig. 144: Identifying Circlip and Plate Pack

Disassembling
 Rotate clutch - F -.
 Remove circlip - 1 - and remove plate pack - 2 - from cylinder "F".
Fig. 145: Press Plate Spring Down Under Shop Press Using Installation Bracket T10289
1:48:13 AM Page 92
 Press plate spring down under shop press using installation bracket T10289.
 Remove split retaining ring - 1 -.
 Release shop press.
 Remove thrust piece and plate spring.
 Position cylinder "F" on clutch "D/G" with freewheel.
Fig. 146: Carefully Press Piston "F" With Compressed Air Out Of Cylinder "F"
 Carefully press piston "F" with compressed air out of cylinder "F" as shown in illustration.
Assembling
CAUTION: Before assembling, check clutch components "F" for wear and damage -->
Clutch "F".
1:48:14 AM Page 93
Fig. 147: Clutch "F", Assembling, Overview

 Replace O-rings - 2 - and - 4 - for piston "F" - 3 -.

 Press piston "F" - 3 - into cylinder "F" - 1 - as far as stop.
 Place thrust piece - 5 -.
 Position plate spring - 6 -.
 Install split retaining ring - 1 -.
1:48:14 AM Page 94
 Bent inner side at right angle of retaining ring faces downward.
Fig. 149: Cylinder "F" Component, Overview

 Insert waved washer - 2 - into cylinder "F" - 1 -.

 Install outer plate - 3 - and coated plate - 4 - alternately.
NOTE:  Ensure rounded edges of last outer clutch disc faces toward lining disc - 4
- and not toward circlip - 5 -. This improves circlip contact surface.
 Insert circlip - 5 -.
Adjust clutch "F"
1:48:14 AM Page 95
Fig. 150: Adjusting Clutch "F" "Air Gap"

 Place clutch "F" on pre-tensioning tool T10285.

 Place plate T10292 on outer clutch disc "F".
 Plate must not touch circlip all around.
 Insert pressure unit T10285/1 with centering pin into bore of plate.
 Align clutch "F" on plate of pre-tensioning tool.
 The pressure unit must be centrally positioned under spindle thrust piece.
 Turn spindle of pre-tensioning tool downward.
 The markings at inspection hole of pressure unit must align - arrow -.
 Apply Digital depth gauge VAS 6087 at upper edge of cylinder "F" , as depicted in illustration.
 Apply measuring tongue on outer plate and note measuring value.
 Mark contact point on cylinder "F".
 Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.
 Average over 3 measured values under load.

 Release spindle and remove plate.
1:48:14 AM Page 96
Fig. 151: Reach With Both Hands Into Clutch "F" and Pull Plate Pack Upward Until Stop
 Reach with both hands into clutch "F" and pull plate pack upward until stop.
 When disc pack is pulled up, measure distance between upper edge of cylinder "F" and outer disc (2nd
technician required) at one of the marked points.
 Repeat measurement at 2 other marked points of outer plate.
 Average over 3 measured values when plate pack is pulled up.
 Determine air gap on basis of the following calculus:
Average of measured values under load (value 1 +

value 2 + value 3): 3
Measurement when plate pack is pulled up (value 1
+ value 2 + value 3): 3
= Air gap
 Subtract average of measured values when plate pack is pulled up from average of measured values under
load.
Clutch "F" air gap - Automatic Transmission 01V Front Wheel Drive
Transmission codes Specified value

CJQ, CJU, DDS, DDT, DRF, DUL, DUM 1.50 to 1.82 mm
CJV, CJW, CJX, CJY, CJZ, DEQ, DCS, DES,
DEU, DPS, DRD, DSS, EFR, ETU, ETV, ETW, 1.90 to 2.20 mm
EZV, FAC
EBU, EBY, EZR, EZS, FAB, FEV 1.81 to 2.10 mm
EBV, EBW, EBX, EBZ, ECJ, EDC, EDE, EFP,
EKC, EMA, ERY, ETK, ETL, ETZ, EYF, EZP,
EZW, EZX, EZY, EZZ, FAD, FAE, FATF, FAH, 2.26 to 2.55 mm
FAJ, FAK, FED, FEE, FHV, FNL, FRT, GDE,
GML
1:48:14 AM Page 97
Clutch "F" air gap - Automatic Transmission 01V All Wheel Drive

DKB, DTV 1.50 to 1.82 mm
CJP, CJR, CJS, CJT, DEV, DEW, DEX, DEY,
DPT, DRK, DRN, DST, DTU, EKX, ETX, ETY, 1.90 to 2.20 mm
FAN, FHD
EFQ, FAL, FEP, GBH 1.81 to 2.10 mm
ECB, ECC, ECD, ECG, ECH, EDF, EKD, EMM,
EMP, ETM, ETN, EUA, EYJ, EYK, EZB, FAM,
FAP, FAQ, FAR, FAS, FAU, FAV, FAW, FAX,
2.26 to 2.55 mm
FAZ, FBA, FBB, FEF, FEG, FEJ, FEQ, FHF, FHG,
FHH, FLC, FLV, FNM, FRU, FVE, FXL, GAK,
GBF, GBG, GBJ

 Determine new circlip - 1 - according to the following table.
NOTE:  Disregard - 2 -.
 Air gap too small: Install respectively thinner circlip.
 Air gap too large: Install respectively thicker circlip.
Available circlips - thickness in mm

1.2 1.8 2.4
1.4 2.0 2.6
1.6 2.2 2.8
 Check air gap of circlip again after inserting.
1:48:14 AM Page 98
Clutch "D/G" with freewheel, component overview
 Before assembling, check components of freewheel, clutch "D" or clutch
"G" for wear and damage --> Clutch "D/G" with freewheel.
Fig. 153: Clutch "D/G" With Freewheel, Component Overview

1 - Freewheel inner race
2 - O-rings
 Replace
1:48:14 AM Page 99
 Replace
4 - Freewheel with freewheel housing
5 - Circlip
6 - Thick outer plates
7 - Coated plates
8 - Outer plates
9 - Waved washer
10 - Holding plate
11 - Plate spring
12 - O-ring
 Replace
13 - Piston "D"
14 - O-ring
 Replace
15 - Cylinder "D/G"
16 - O-ring
 Replace
17 - Piston "G"
18 - O-ring
 Replace
19 - Plate spring
20 - Thrust washer
1:48:14 AM Page 100

21 - Circlip
22 - Waved washer
23 - Outer plates
24 - Coated plates
25 - Thick outer plate
26 - Circlip
Clutch "D/G" with freewheel, disassembling and assembling
Disassembling
 Clutch "D" faces upward.

 Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".

 Twist cylinder "D/G".
 Clutch "G" faces upward (plate spring is visible).
1:48:14 AM Page 101


 Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".
Fig. 156: Place Cylinder "D/G" On Thrust Piece 3301/4 Under Shop Press
 Place cylinder "D/G" on thrust piece 3301/4 under shop press.

 Remove circlip - 1 - , thrust washer and plate spring.
1:48:14 AM Page 102

Fig. 157: Carefully Press Piston "G" Out Of Cylinder "D/G" With Compressed Air
 Carefully press piston "G" out of cylinder "D/G" with compressed air.
Fig. 158: Press Freewheel Inner Race Out Of Cylinder "D/G"

 Press freewheel inner race - 2 - out of cylinder "D/G" - 1 - - arrow - , loosen with light taps using a
plastic hammer if necessary.
 Remove cylinder "D/G" from freewheel.
 Twist cylinder "D/G".
 Cylinder "D" faces upward.
1:48:14 AM Page 103

Fig. 159: Carefully Press Piston "D" Out Of Cylinder "D/G" With Compressed Air
 Carefully press piston "D" out of cylinder "D/G" with compressed air.
Fig. 160: Freewheel, Overview

 Disassemble freewheel:
6 - Plate spring
5 - Holding plate
1:48:15 AM Page 104

2 - O-rings
Assembling
CAUTION: Before assembling, check components of freewheel, clutch "D" or clutch

"G" for wear and damage --> Clutch "D/G" with freewheel.
Fig. 161: Cylinder "D/G", and O-rings -2/4- for Piston "D"
 Replace O-rings - 2 - and - 4 - for piston "D" - 3 -.

 Press piston "D" - 3 - into cylinder "D/G" - 1 - as far as stop.
1:48:15 AM Page 105

Fig. 162: Clutch "D/G", Component Overview

 Insert waved washer - 2 - into cylinder "D/G" - 1 -.

 Install thick outer plate - 5 -.
NOTE:  Ensure rounded edges of thick outer clutch disc faces toward lining disc -
4 - and not toward circlip - 6 -. This improves circlip contact surface.
Adjust clutch "D" air gap
1:48:15 AM Page 106

Fig. 163: Inspection Hole Markings Of Pressure Unit Must Align

 Place clutch "D/G" on pre-tensioning tool T10285.
 Place plate T10293 on outer clutch disc "D".
 Align clutch "D/G" on plate of pre-tensioning tool.
 The markings at inspection hole of the pressure unit must align - arrow -.
1:48:15 AM Page 107

Fig. 164: Apply Digital Depth Gauge VAS 6087 At Upper Edge Of Cylinder "D/G"
 Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G" , as depicted in illustration.
 Mark contact point on cylinder "D/G".

 Reach with both hands into clutch "D" and pull plate pack upward until stop.
 When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd
technician required) at one of marked points.

 Determine air gap on basis of the following calculations:

Measurement when lamella pack is pulled up (value
1 + value 2 + value 3): 3
= Air gap
load.
1:48:15 AM Page 108

Clutch "D" air gap - Automatic Transmission 01V Front Wheel Drive

EBV, EBW, EBX, EBZ, ECJ, EDC, EDE, EFP,
EZW, EZX, EZY, EZZ, FAD, FAE, FATF, FAH, 2.29 to 2.59 mm
GML
CJQ, CJU, CJW, CJX, CJY, CJZ, DCS, DDS, DDT,
DEQ, DES, DEU, DPS, DRD, DRF, DUL, DUM, 2.55 to 2.85 mm
DSS, EFR, ETV, ETW, ETU, EZV, FAC
CJV 2.60 to 2.92 mm
Clutch "D" air gap - Automatic Transmission 01V All Wheel Drive

DKB, DPT, DRK, DRN, DST, DTU, DTV, EKX, 2.55 to 2.85 mm
ETX, ETY, FAN, FHD
ECB, ECC, ECD, ECG, ECH, EDF, EKD, EMM,
2.29 to 2.59 mm
GBG, GBH, GBJ
EFQ, FAL, FEP, GBF 1.92 to 2.22 mm

1:48:15 AM Page 109


2.2 3.0 3.8
2.4 3.2 4.0
2.6 3.4 4.2
2.8 3.6

 After having determined correct circlip, remove circlip - 1 - and remove plate pack - 2 - from cylinder
"D/G" again.
1:48:15 AM Page 110

Fig. 167: Freewheel, Overview

 Replace O-rings - 2 - and rectangular rings - 3 - on freewheel inner race - 1 -.
5 - Holding plate
6 - Plate spring
 Before inserting, thinly coat O-rings and rectangular rings with Vaseline. Use only Vaseline, other
lubricating substances cause functional problems in the hydraulic transmission control.
 Make sure that rectangular rings are fully seated all around in freewheel inner race grooves.
1:48:15 AM Page 111

Fig. 168: Checking Rotating and Locking Direction Of Freewheel

 Insert freewheel inner race - 2 - with freewheel housing until stop into freewheel - 1 - using turning
motions in clockwise direction - arrows -.
Fig. 169: Lay Cylinder "D/G" On 2 Wood Blocks For Assembly

 Lay cylinder "D/G" - 1 - on 2 wood blocks in height of approx. 40 mm.
1:48:15 AM Page 112

 Cylinder "D" faces upward.
 Insert dished washer - 2 - and holding plate - 3 - into cylinder "D/G".
 Tabs on holding plate face cylinder "D/G".
 Grasp freewheel - 4 - so that the freewheel inner race can no longer slip out and press inner race splines
into splines of cylinder "D/G".
Fig. 170: Place Cylinder "D/G" On Thrust Piece 3301/4 For Assembly
 Twist cylinder "D/G" - 1 - , while doing so secure freewheel inner race against slipping out.
 Cylinder "G" faces upward.
 Place cylinder "D/G" on thrust piece 3301/4.

 Replace O-rings - 2 - and - 4 - for piston "G" - 3 -.
 Press piston "G" - 3 - into cylinder "D/G" until stop.
 Place dished washer - 5 - and thrust washer - 6 -.
 Teeth of thrust washer must engage into splines of freewheel inner race.
7 - Circlip
1:48:15 AM Page 113

Fig. 171: Place Cylinder "D/G" On Thrust Piece 3301/4 Under Shop Press
 Place cylinder "D/G" on thrust piece 3301/4 under shop press.

 Push thrust washer fully downward and insert circlip - 1 -.
 Make sure that circlip is seated evenly all around in groove of freewheel inner race, if necessary, press
circlip into groove all around using screwdriver.

 Press plate spring down again to check if freewheel is inserted correctly.
 Thrust washer - 6 - --> in previous illustration "A37-10345" must be able to move.
1:48:16 AM Page 114

Fig. 172: Cylinder "D/G", Overview


Adjust clutch "G" air gap
 Clutch "G" faces upward.
1:48:16 AM Page 115

Fig. 173: Place Clutch "D/G" On Pre-Tensioning Tool T10285

 Place clutch "D/G" on pre-tensioning tool T10285.

 Place plate T10292 on outer clutch disc "G".
 Align clutch "D/G" on plate of pre-tensioning tool.
 Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G" , as depicted in illustration.
 Mark contact point on cylinder "D/G".

1:48:16 AM Page 116

Fig. 174: Reach With Both Hands Into Clutch "G" and Pull Plate Pack Upward Until Stop
 Reach with both hands into clutch "G" and pull plate pack upward until stop.
 When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd
 Determine air gap on the basis of the following calculations:

= Air gap
load.
Clutch "G" air gap - Automatic Transmission 01V Front Wheel Drive

CJV, CJW, CJX, CJY, CJZ, DCS, DEQ, DES,
DEU, DPS, DRD, DSS, EFR, ETU, ETV, ETW, 1.52 to 1.82 mm
EZV, FAC
EBW, EBX, EBZ, ECJ, EDC, EDE, EFP, EKC,
1:48:16 AM Page 117

EMA, ERY, ETK, ETL, ETZ, EYF, EZP, EZW,

EZX, EZY, EZZ, FAB, FAE, FATF, FAH, FAJ, 1.79 to 2.08 mm
FAK, FED, FEE, FHV, FNL, FRT, GDE, GML
EBU, EBV, EBY, EZR, EZS, FAD, FEV 1.33 to 1.62 mm
Clutch "G" air gap - Automatic Transmission 01V All Wheel Drive

DPT, DRK, DRN, DST, DTU, ECB, ECC, ECD,
ECG, ECH, EDF, EKD, EKX, EMM, EMP, ETM,
ETN, ETX, ETY, EUA, EYJ, EYK, EZB, FAM, 1.52 to 1.82 mm
FAN, FAP, FAQ, FAR, FAS, FAU, FAV, FAW,
FAX, FAZ, FBA, FBB, FEF, FEG, FEJ, FHD, FHF,
FHG, FHH, FLC, FLV
FEQ, FNM, FRU, FVE, FXL, GAK, GBG, GBH, 1.79 to 2.08 mm
GBJ

1:48:16 AM Page 118

1.8 2.4 3.0

2.0 2.6 3.2
2.2 2.8 3.4
 Twist clutch "D/G".
 Install plates for clutch "D" with newly determined circlip as follows:
Fig. 176: Clutch "D/G", Component Overview


Planetary drive "III" , component overview
1:48:16 AM Page 119

 Before assembling, check components of planetary gear for wear and

damage --> Planetary drive "III".
Fig. 177: Planetary Drive "III", Component Overview

1 - Circlip
2 - Shaft
3 - Ring gear "III"
4 - Angle washer
1:48:16 AM Page 120

6 - Thrust washer
7 - Planetary carrier "III"
Planetary drive "III" , disassembling and assembling
Disassembling

 Remove ring gear "III" with shaft - 5 - from planetary carrier "III" - 1 -.
 Remove angle washer - 4 - , axial needle bearing - 3 - and thrust washer - 2 -.
Assembling
CAUTION: Before assembling, check components of planetary gear "III" for wear and
damage --> Planetary drive "III".
 Attach the following components onto shaft of planetary carrier "III" - 1 - :
2 - Thrust washer
4 - Angle washer - angled edge points toward axial needle bearing
 Position ring gear "III" with shaft - 5 - on planetary carrier "III" - 1 -.
1:48:16 AM Page 121

Tower "I" , assembling

 Place planetary drive "III" - 1 - in mounting device T10282.

 Lay thrust washer - 2 - , axial needle bearing - 3 - and angle washer - 4 - on planetary drive "III" - item 1
-.
 Angled edge of angle washer faces planetary drive "III".
 Attach clutch "F" "item 5" onto disc carrier of planetary gear - III - - 1 - , using short lifting/turning
motions.
 All clutch discs "F" must engage one after another in planetary drive disc carrier "III".
 Check whether all plates are engaged, to do so lift clutch "F" a few millimeters and let fall.
 If this produces a metallic sound, all plates are engaged.

 If only a muted sound is heard, not all plates are engaged.
1:48:16 AM Page 122

Fig. 180: Remove/Install clutch "D/G" From/To Clutch "F"

 Place clutch "D/G" - 2 - onto plate carrier on clutch "F" - 1 - , using short lifting/turning motions.
 All clutch discs "G" must engage in sequence in plate carrier of clutch "F".
 Check whether all plates are engaged, to do so lift clutch "D/G" a few millimeters and let fall.

1:48:17 AM Page 123

Install lifting device T10287 as follows:
 Turn back knurled nut of lifting device.

 Insert lifting device into tower "I" until stop.
 Tighten knurled nut of lifting device in clockwise direction.
TOWER II , DISASSEMBLING AND ASSEMBLING
Tower "II" , disassembling and assembling

Tower "II" , component overview
1:48:17 AM Page 124

Fig. 182: Tower "II", Component Overview

1 - Clutch "E"
2 - O-ring
 Replace
3 - Clutch "A"
4 - Circlip
6 - Clutch "B"
1:48:17 AM Page 125

7 - Adjustment shim
 Determine thickness --> Fig. 108
 Replace
Tower "II" , disassembling
 If not carried out yet, remove adjustment shim - 2 - from clutch "B" - 1 -.
Fig. 184: Identifying Clutch "B" and Clutch "A" Axial Needle Bearing
1:48:17 AM Page 126

 Remove clutch "B" - 3 - and axial needle bearing - 2 - from clutch "A" - 1 -.
Fig. 185: Identifying Circlip and Input Shaft

 Remove circlip - 2 - from input shaft - 1 -.
Fig. 186: Tap On Input Shaft With Clutch "E" Using Plastic Hammer
 Place clutch "A" - 1 - with outer edges on 2 wood blocks, approx. 40 mm high.
 Tap on input shaft - 2 - with clutch "E" using plastic hammer.
 Remove clutch "A" from clutch "E".
Clutch "B" , component overview
1:48:17 AM Page 127

 Before assembling, check components of clutch "B" for wear and damage
--> Clutch "B".
CAUTION: Illustration depicts current construction version of clutch "B" with waved
washer , 2x outer plate and 2x coated plate. Clutch "B" must be replaced
on older versions without waved washer and with 3x lining and outer discs
each.
Fig. 187: Clutch "B" Component Overview

1 - Adjustment shim
1:48:17 AM Page 128

2 - Cylinder "B"
3 - O-ring
 Replace
4 - Piston "B"
5 - O-ring
 Replace
6 - Plate spring
 Bent side at right angle faces dished washer
8 - Waved washer
9 - Outer plate
10 - Coated plate
12 - Circlip
 Determining thickness Available circlips - thickness in mm
Clutch "B" , disassembling and assembling
Disassembling
 Rotate clutch "B".
1:48:17 AM Page 129


 Remove circlip - 1 - and remove disc pack - 2 - from cylinder "B".
1:48:17 AM Page 130

Fig. 190: Cylinder "B" Component Overview

 Remove dished washer - 5 -.

Fig. 191: Carefully Press Piston "B" Out Of Cylinder "B" With Compressed Air
 Carefully press piston "B" out of cylinder "B" with compressed air, to do so plug free oil bore using
finger.
Assembling
1:48:17 AM Page 131

CAUTION: Before assembling, check components of clutch "B" for wear and damage
--> Clutch "B".
Fig. 192: Cylinder "B" Component Overview

 Replace O-rings - 2 - and - 4 - for piston "B" - 3 -.

 Press piston "B" - 3 - into cylinder "B" - 1 - as far as stop.
1:48:18 AM Page 132


Fig. 194: Cylinder "B", Overview

 Insert waved washer - 2 - into cylinder "B" - 1 -.

washer - 2 - , 2x outer plates - 3 - and 2x coated plates - 4 -. Clutch "B"
must be replaced on older versions without waved washer and with 3x
lining and outer discs each.
Adjust clutch "B" air gap
1:48:18 AM Page 133

Fig. 195: Place Clutch "B" On Pre-Tensioning Tool T10285

 Place clutch "B" on pre-tensioning tool T10285.

 Place plate T10294 on outer clutch disc "B".
 Align clutch "B" on plate of pre-tensioning tool.
 The markings at the inspection hole of the pressure unit must align - arrow -.
 Insert dial gauge VAS 6080 into measuring bar VW 382/7 and tighten knurled nut.
 Apply measuring bar at upper edge of cylinder "B" , as depicted in illustration.
 Check whether measuring bar makes proper contact at edge of cylinder "B".
 Position measuring tip on outer plate and note measuring value.
 Mark exact contact point on cylinder "B".

1:48:18 AM Page 134

Fig. 196: Reach With Both Hands Into Clutch "B" and Pull Plate Pack Upward Until Stop
 Reach with both hands into clutch "B" and pull plate pack upward until stop.
 When disc pack is pulled up, measure exact distance between upper edge of cylinder "B" and outer disc
(2nd technician required) at one of the marked points.

= Air gap
load.
Clutch "B" air gap - Automatic Transmission 01V Front Wheel Drive

CJQ, CJU, CJV, CJW, CJX, CJY, CJZ, DCS, DDS,
DDT, DEQ, DES, DEU, DPS, DRD, DRF, DSS, 0.99 to 1.28 mm
DUL, DUM, EFR, ETU, ETV, ETW, EZV, FAC
EBU, EBV, EBW, EBX, EBY, EBZ, ECJ, EDC,
EDE, EFP, EKC, EMA, ERY, ETK, ETL, ETZ,
EYF, EZP, EZR, EZS, EZW, EZX, EZY, EZZ, 1.37 to 1.66 mm
FAB, FAD, FAE, FATF, FAH, FAJ, FAK, FED,
FEE, FEV, FHV, FNL, FRT, GDE, GML
Clutch "B" air gap - Automatic Transmission 01V All Wheel Drive
1:48:18 AM Page 135


DKB, DPT, DRK, DRN, DST, DTU, DTV, EKX, 0.99 to 1.28 mm
ETX, ETY, FAN, FHD
ECB, ECC, ECD, ECG, ECH, EDF, EFQ, EKD,
EMM, EMP, ETM, ETN, EUA, EYJ, EYK, EZB,
FAL, FAM, FAP, FAQ, FAR, FAS, FAU, FAV,
1.37 to 1.66 mm
FAW, FAX, FAZ, FBA, FBB, FEF, FEG, FEJ, FEP,
FEQ, FHF, FHG, FHH, FLC, FLV, FNM, FRU,
FVE, FXL, GAK, GBF, GBG, GBH, GBJ


0.8 1.4 2.0
1.0 1.6
1.2 1.8
Clutch "A" , component overview
1:48:18 AM Page 136


 Before assembling, check clutch components "A" for wear and damage -->
Clutch "A".
Fig. 198: Clutch "A", Component Overview

1 - Circlip
 Replace
 Do not over-stretch circlip when installing.
2 - Adjustment shim
 Determining thickness --> Fig. 108
1:48:18 AM Page 137

3 - O-ring
 Replace
4 - Ring
5 - Cylinder "A"
6 - O-ring
 Replace
7 - Green O-ring
 Replace
8 - Piston "A"
9 - O-ring
 Replace
10 - Plate spring
 Bent side at right angle faces dished washer
12 - Waved washer
 Equipment depends on version
13 - Outer plate
14 - Coated plate
16 - Circlip
 Determining thickness --> Available circlips - thickness in mm
Clutch "A" , disassembling and assembling
Disassembling
 Rotate clutch "A".
1:48:18 AM Page 138


 Remove circlip - 1 - and remove plate pack - 2 - from cylinder "A".
 Remove dished washer.
1:48:18 AM Page 139

Fig. 201: Cylinder "A", Ring and O-Ring

 Press ring - 2 - with O-ring - 3 - out of cylinder "A" - 1 -.
Fig. 202: Carefully Press Piston "A" Out Of Cylinder "A" With Compressed Air
 Carefully press piston "A" out of cylinder "A" with compressed air, to do so plug two other oil bores
using fingers.
Assembling
CAUTION: Before assembling, check clutch components "A" for wear and damage -->
Clutch "A".
1:48:18 AM Page 140

Fig. 203: Clutch "A", Components Overview

 Replace O-rings - 2 - (green), - 3 - (black) and - 5 - (black) for piston "A" - 4 -.

 Press piston "A" - 4 - into cylinder "A" - 1 - as far as stop.
1:48:19 AM Page 141

Fig. 205: Cylinder "A", Overview

 Insert waved washer - 2 - into cylinder "A" - 1 -.

1:48:19 AM Page 142

Fig. 206: Place Clutch "A" On Pre-Tensioning Tool T10285

Adjust clutch "A" air gap
 Place clutch "A" on pre-tensioning tool T10285.

 Place plate T10293 on outer clutch disc "A".
 Align clutch "A" on plate of pre-tensioning tool.
 Apply Digital depth gauge VAS 6087 at upper edge of cylinder "A" , as depicted in illustration.
 Mark contact point on cylinder "A".

1:48:19 AM Page 143

Fig. 207: Reach With Both Hands Into Clutch "A" and Pull Plate Pack Upward Until Stop
 Reach with both hands into clutch "A" and pull plate pack upward until stop.
 When disc pack is pulled up, measure distance between upper edge of cylinder "A" and outer disc (2nd
 Average over 3 measured values when pate pack is pulled up.
 Determine air gap on basis of the following calculations:

= Air gap
load.
Clutch "A" air gap - Automatic Transmission 01V Front Wheel Drive

CJV, CJW, CJX, CJY, CJZ, DCS, DDT, DEQ, 1.73 to 2.03 mm
DES, DEU, DPS, DRD, DSS, EFR, ETU, ETV,
ETW, EZV, FAC
EBV, EBW, EBX, EBZ, ECJ, EDC, EDE, EFP, 2.06 to 2.35 mm
EZW, EZX, EZY, EZZ, FAD, FAE, FATF, FAH,
GML
1:48:19 AM Page 144

Clutch "A" air gap - Automatic Transmission 01V All Wheel Drive

CJP, CJR, CJS, CJT, DEV, DEW, DEX, DEY, 1.73 to 2.03 mm
DPT, DRK, DRN, DST, DTU, EKX, ETX, ETY,
FAN, FHD
ECB, ECC, ECD, ECG, ECH, EDF, EKD, EMM, 2.06 to 2.35 mm
GBG, GBH, GBJ


1.0 1.6 2.2
1.2 1.8 2.4
1.4 2.0 2.6
1:48:19 AM Page 145

Fig. 209: Cylinder "A", Ring and O-Ring

 Replace O-ring - 3 - on ring - 2 -.

 Press ring into cylinder "A" - 1 - until stop.
Clutch "E" , component overview
 Before assembling, check components of clutch "E" for wear and damage
--> Clutch "E".
1:48:19 AM Page 146

Fig. 210: Clutch "E", Component Overview

 Replace
2 - O-ring
 Replace
3 - Cylinder "E"
4 - O-ring
 Replace
1:48:19 AM Page 147

5 - Piston "E"
6 - O-ring
 Replace
7 - Plate spring
8 - O-ring
 Replace
9 - Diaphragm plate
10 - Circlip
 Replace
 Do not over-stretch circlip when installing.
11 - Waved washer
12 - Outer plates
13 - Coated plates
15 - Circlip
Clutch "E" , disassembling and assembling
Disassembling
1:48:19 AM Page 148

Fig. 211: Place Clutch "E" In Mounting Device T10283

 Place clutch "E" - 1 - in mounting device T10283.

 Remove circlip - 1 - and remove plate pack - 2 - from cylinder "E".
1:48:20 AM Page 149

Fig. 213: Press Diaphragm Plate Down Under Shop Press Using Installation Bracket T10276
 Press diaphragm plate down under shop press using installation bracket T10276.
 Remove circlip - 1 -.

 Remove diaphragm plate - 7 -.
1:48:20 AM Page 150


 Twist cylinder "E".
Fig. 215: Carefully Press Piston "E" Out Of Cylinder "E" With Compressed Air
 Carefully press piston "E" out of cylinder "E" with compressed air.
Assembling
CAUTION: Before assembling, check components of clutch "E" for wear and damage
--> Clutch "E".
1:48:20 AM Page 151


 Replace O-rings - 2 - and - 4 - for piston "E" - 3 -.

 Press piston "E" - 3 - into cylinder "E" - 1 - as far as stop.
 Insert dished washer - 5 -.
 Replace O-ring - 6 - on diaphragm plate - 7 -.
 Insert diaphragm plate - 7 - into cylinder "E" - 1 -.
8 - Circlip
1:48:20 AM Page 152

Fig. 217: Press Diaphragm Plate Down Under Shop Press Using Installation Bracket T10276
 Press diaphragm plate down under shop press using installation bracket T10276.
 Insert new circlip - 1 -.
CAUTION: Do not over-stretch circlip. After installing, check proper seating of circlip.
Fig. 218: Cylinder "E", Overview

 Insert waved washer - 2 - into cylinder "E" - 1 -.

 Install outer plates - 3 - and coated plates - 4 - alternately.
 Install thick outer plates - 5 -.
1:48:20 AM Page 153

Fig. 219: Adjust Clutch "E" Air Gap Using Pre-Tensioning Tool T10285
Adjust clutch "E" air gap
 Secure pre-tensioning tool T10285 with wide base in vise.

 Install clutch "E" in pre-tensioning tool.
 Input shaft projects through bore in base plate.
 Place plate T10291 on outer clutch disc "E".
 Align clutch "E" on plate of pre-tensioning tool.
 Insert dial gauge VAS 6080 into measuring bar VW 382/7 and tighten knurled nut.
 Apply measuring bar at upper edge of cylinder "E" , as depicted in illustration.
 Check whether measuring bar makes proper contact at edge of cylinder "E".
 Position measuring tip on outer plate and note measuring value.
1:48:20 AM Page 154

 Mark exact contact point on cylinder "E".

Fig. 220: Reach With Both Hands Into Clutch "E" and Pull Plate Pack Upward Until Stop
 Reach with both hands into clutch "E" and pull plate pack upward until stop.
 When disc pack is pulled up, measure distance between upper edge of cylinder "E" and outer disc (2nd

= Air gap
load.
Clutch "E" air gap - Automatic Transmission 01V Front Wheel Drive

CJV, CJW, CJX, CJY, CJZ, DCS, DEQ, DES,
DEU, DPS, DRD, DSS, EBV, EBW, EBX, EBZ,
ECJ, EDC, EDE, EFP, EFR, EKC, EMA, ERY, 1.78 to 2.08 mm
ETK, ETL, ETU, ETV, ETW, ETZ, EYF, EZP,
1:48:20 AM Page 155

EZV, EZW, EZX, EZY, EZZ, FAC, FAD, FAE,

FATF, FAH, FAJ, FAK, FED, FEE, FHV, FNL,
FRT, GDE, GML
CJQ, CJU, DDS, DDT, DRF, DUL, DUM, EBU,
1.41 to 1.71 mm
EBY, EZR, EZS, FAB, FEV
Clutch "E" air gap - Automatic Transmission 01V All Wheel Drive

DPT, DRK, DRN, DST, DTU, ECB, ECC, ECD,
ECG, ECH, EDF, EKD, EKX, EMM, EMP, ETM,
ETN, ETX, ETY, EUA, EYJ, EYK, EZB, FAM,
1.78 to 2.08 mm
FAN, FAP, FAQ, FAR, FAS, FAU, FAV, FAW,
FAX, FAZ, FBA, FBB, FEF, FEG, FEJ, FEQ, FHD,
FHF, FHG, FHH, FLC, FLV, FNM, FRU, FVE,
FXL, GAK, GBG, GBH, GBJ
DKB, DTV, EFQ, FAL, FEP, GBF 1.41 to 1.71 mm


1.2 1.8 2.4
1.4 2.0 2.6
1:48:21 AM Page 156

1.6 2.2
Tower "II" , assembling
Fig. 222: Tower "II", Assembling

 Replace rectangular rings - 3 - and O-ring - 2 - on input shaft at clutch "E" - 1 -.

 Before inserting, thinly coat rectangular rings - 3 - and O-ring - 2 - with Vaseline. Use only Vaseline,
other lubricating substances cause functional problems in the hydraulic transmission control.
 Make sure that rectangular rings - 3 - are fully seated all around in the input shaft groove.
1:48:21 AM Page 157

Fig. 223: Identifying Clutch "A" and Clutch "E"

 Press clutch "A" - 2 - onto clutch "E" - 1 - until stop.
Fig. 224: Identifying Circlip and Input Shaft

 Install circlip - 2 - on input shaft - 1 -.
1:48:21 AM Page 158

Fig. 225: Identifying Clutch "B" and Clutch "A" Axial Needle Bearing
 Place axial needle bearing - 2 - onto clutch "A" - 1 -.

 Attach clutch "B" - 3 - onto disc carrier of clutch "A" , using short lifting/turning motions.
 All clutch discs "B" must engage in sequence in plate carrier of clutch "A".
 Check whether all plates are engaged, to do so lift clutch "B" a few millimeters and let fall.

 Place adjustment shim - 2 - onto clutch "B" - 1 -.
1:48:21 AM Page 159

CLUTCH C , DISASSEMBLING AND ASSEMBLING
Clutch "C" , disassembling and assembling

Clutch "C" , component overview
 Before assembling, check components of clutch "C" for wear and damage
--> Clutch "C".
1:48:21 AM Page 160

Fig. 227: Clutch "C", Component Overview

1 - ATF pump
 Disassembling --> ATF pump, component overview
2 - O-ring
 Replace
3 - Piston "C"
4 - O-ring
 Replace
1:48:21 AM Page 161

5 - Plate spring
7 - Waved washer
8 - Outer plates
9 - Coated plates
11 - Circlip
Clutch "C" , disassembling and assembling
Disassembling
 Twist ATF pump.

 Remove circlip - 1 - and remove plate pack - 2 - from cylinder "C".
1:48:21 AM Page 162

Fig. 229: Pressing Plate Spring Down Under Shop Press Using Installation Bracket T10289
Fig. 230: Identifying Dished Washer

1:48:22 AM Page 163

Fig. 231: Carefully Press Piston "C" Out Of ATF Pump With Compressed Air
 Carefully press piston "C" out of ATF pump with compressed air.
Assembling
CAUTION: Before assembling, check components of clutch "C" for wear and damage
--> Clutch "C".

 Replace O-rings - 2 - and - 4 - for piston "C" - 3 -.

 Press piston "C" - 3 - into ATF pump - 1 - until stop.
1:48:22 AM Page 164

Fig. 234: Cylinder Component, Overview

 Insert waved washer - 2 - into cylinder "B" - 1 -.

1:48:22 AM Page 165

Adjust clutch "C" air gap
Fig. 235: Adjust Clutch "C" Air Gap Using Pre-Tensioning Tool T10285
 Secure pre-tensioning tool T10285 with wide base in vise.

 Place ATF pump on pre-tensioning tool.
 Stator shaft projects through bore in base plate.
 Place plate T10295 on outer clutch disc "C".
 Align ATF pump on plate of pre-tensioning tool.
1:48:22 AM Page 166

 Apply Digital depth gauge VAS 6087 at upper edge of outer plate carrier "C" , as depicted in illustration.
 Mark contact point on outer plate carrier "C".

Fig. 236: Reach With Both Hands Into Clutch "C" and Pull Plate Pack Upward Until Stop
 Reach with both hands into clutch "C" and pull plate pack upward until stop.
 When disc pack is pulled up, measure distance between upper edge of outer disc carrier "C" and outer
disc (2nd technician required) at one of the marked points.

= Air gap
load.
Clutch "C" air gap - Automatic Transmission 01V Front Wheel Drive
1:48:22 AM Page 167


CJW, CJX, CJY, CJZ, DEQ, DEU, DPS, DRD,
DSS, ECJ, EDE, EFR, ERY, ETK, ETL, ETU,
ETV, ETW, ETZ, EYF, EZV, EZW, FAC, FAD, 2.00 to 2.30 mm
FATF, FAH, FAK, FED, FEE, FNL, FRT, GDE,
GML
CJQ, CJU, CJV, DCS, DDS, DDT, DES, DRF, 1.63 to 1.93 mm
DUL, DUM
EBU, EBV, EBW, EBX, EBY, EBZ, EDC, EFP,
EKC, EMA, EZP, EZR, EZS, EZX, EZY, EZZ, 1.25 to 1.54 mm
FAB, FAE, FAJ, FEV, FHV
Clutch "C" air gap - Automatic Transmission 01V All Wheel Drive

CJR, CJS, CJT, DEW, DEX, DEY, DPT, DRK,
DRN, DST, DTU, ECH, EDF, EKX, EMM, EMP,
ETM, ETN, ETX, ETY, EUA, EYJ, EYK, EZB,
2.00 to 2.30 mm
FAN, FAP, FAQ, FAU, FAW, FAX, FAZ, FBB,
FEF, FEG, FEJ, FEQ, FHD, FHG, FLC, FLV,
FNM, FRU, FVE, FXL, GAK, GBH, GBJ
CJP, DEV, DKB, DTV 1.63 to 1.93 mm
ECB, ECC, ECD, ECG, EFQ, EKD, FAL, FAM,
FAR, FAS, FAV, FBA, FEP, FHF, FHH, GBF, 1.25 to 1.54 mm
GBG,

1:48:22 AM Page 168


1.2 1.8 2.4
1.4 2.0 2.6
1.6 2.2 2.8

ATF PUMP, DISASSEMBLING AND ASSEMBLING
ATF pump, disassembling and assembling

ATF pump, component overview
 Before assembling, check components of ATF pump for wear and damage
--> ATF supply.
 Before assembling, check components of clutch "C" for wear and damage
--> Clutch "C".
1:48:22 AM Page 169

Fig. 238: ATF Pump, Component Overview

1 - Shaft seal
 Replace
2 - Locking washer
3 - O-ring
 Replace
4 - ATF pump housing
5 - Ring gear
1:48:23 AM Page 170

6 - ATF pump wheel
7 - Positioning sleeve
8 - Intermediate panel
9 - O-ring
 Replace
11 - Outer lamella carrier "C"
12 - Recessed bolt
 Tightening sequence Tighten ATF pump screws as follows: under ATF supply housing with stator
shaft, removing and installing
13 - Bolt
14 - Stator shaft
 Removing and installing --> Stator shaft, removing and installing
15 - Recessed bolt
 Replace
17 - Rectangular ring
 Replace
ATF pump (with assembled transmission), completely removing and installing
Removing
1:48:23 AM Page 171

 Transmission attached to assembly stand --> Transmission, attaching assembly stand.
Fig. 239: Identifying ATF Drain Plug And ATF Level Inspection Plug
 Remove ATF drain plug - 1 - and allow ATF to drain.

 Rest of ATF remains in the ATF oil pan.
 Remove torque converter.
1:48:23 AM Page 172


 Remove right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft
using a pry bar.
 Pull out right flange shaft.
 Loosen final drive cover bolts in sequence - 12 to 1 - and then remove completely.
1:48:23 AM Page 173

CAUTION:  Slowly and carefully remove final drive cover from transmission
housing. Otherwise differential can fall out of transmission.
 A differential that has fallen onto the floor must not be installed
again. The transmission must be replaced in this case.
 Remove final drive cover.
location.

1:48:23 AM Page 174

overlapping to avoid damaging final drive/transmission housing double shaft seal when removing left
flange shaft.

 Remove left drive flange mounting bracket - arrows -.

 Pull out left drive flange.
NOTE:  When sliding off, left drive flange must be carefully guided by hand to
1:48:23 AM Page 175


 Loosen ATF oil pan bolts - arrow - in a diagonal sequence and then remove them completely.
 Remove ATF oil pan.

 Remove ATF screen bolts - arrows -.

1:48:23 AM Page 176



1:48:24 AM Page 177

CAUTION:  Only the designated bolts must be removed; bolt - 6 - is only on


 Carefully remove valve body from transmission.
1:48:24 AM Page 178

Fig. 252: Location Of Inlet Bores Sealing Sleeves

 Pull sealing sleeves - arrows - in inlet bores toward clutches "C" , "A" , "B" , "E" and toward torque
converter clutch using extracting handle T10271.
 Remove 3 securing rings - 1 -.

 Remove coil springs - 2 -.
 Pull out sealing sleeves - 3 - , using extracting handle T10271.
1:48:24 AM Page 179

 ATF pump faces upward.

 Loosen ATF pump bolts in - 9 to 1 - sequence and remove them completely.

 Remove bolts with sealing washers.
Fig. 255: Removing ATF Pump Using Puller T10286

 Secure puller for ATF supply T10286 to stator shaft and pull ATF supply firmly upward.
If ATF pump cannot be loosened:
1:48:24 AM Page 180

Fig. 256: If ATF Pump Cannot Be Loosened Proceed As Shown

 On the bottom side of the transmission, place a screwdriver between sun gear "I" and ribbed cup and pry
component above sun gear upward - arrow -.
Installing
 Check if tower "II" is still inserted correctly.

 Measure distance between contact surface for adjustment shim on tower "II" and contact surface for ATF
pump on transmission housing.
1:48:24 AM Page 181

Fig. 257: Identifying Dimension

 Dimension - a - = at least 6.0 mm.

 Adjustment shim may not be installed.
If dimension - a - is exceeded, the tower "II" would be pulled out of disc contact during removal.
 Remove tower "II" and then reinstall Lift tower under Planetary gear, disassembling and assembling.
Fig. 258: Adjustment Shim

 Place previous adjustment shim - 1 - on plate carrier "C".
1:48:24 AM Page 182

Fig. 259: Location Of Rectangular Rings

 Replace 2 rectangular rings on input shaft.

 Before inserting, thinly coat rectangular rings on input shaft with Vaseline. Use only Vaseline, other
lubricating substances cause functional problems in the hydraulic transmission control.
 Make sure that rectangular rings are fully seated all around in the input shaft groove.
Fig. 260: ATF Pump, Axial Needle Bearing, and Rectangular Rings And
 Thinly coat back side of axial needle bearing - 2 - with Vaseline. Use only Vaseline, other lubricating
 Append axial needle bearing to ATF pump - 1 -.
 Closed side of axial needle bearing faces toward ATF pump.
1:48:25 AM Page 183

 Replace rectangular rings - 3 - and - 4 - on stator shaft.

 Before inserting, lightly coat rectangular ring with Vaseline. Use only Vaseline, other lubricating
 Make sure that rectangular rings are fully seated all around in the stator shaft groove.
Fig. 261: Hooking Ends Of Piston Ring Together

 Engage ends of installed rectangular rings - arrows - , as depicted in illustration.
Fig. 262: ATF Pump O-ring

 Replace O-ring - 1 - on ATF supply.

 Thinly coat O-ring with Vaseline. Use only Vaseline, other lubricating substances cause functional
problems in the hydraulic transmission control.
1:48:25 AM Page 184

Fig. 263: Align Coated Plates Of Clutch "C" Using Centering Tool T10288/1
 Align coated plates - 3 - of clutch "C" using centering tool T10288/1 , to do so let pins - 2 - and - 4 -
engage in splines of all coated plate.
 Align lining discs to ATF pump housing by inserting centering pins - 1 - and - 5 - into appropriate holes
on ATF pump.
 Centering pins fit only in one position.
 Hold centering tool in this position and insert wedge T10288/2 from side between waved washer and
piston "F" - arrow -.
 Wedge must secure all plates in current position.
 Remove centering tool T10288/1 , wedge T10288/2 remains inserted.
1:48:25 AM Page 185

Fig. 264: Align Plate Carrier For Clutch "C" Using Centering Tool T10288/3
 Align plate carrier for clutch "C" using centering tool T10288/3 , install guide pins T10288/4 into
 Bores of centering tool and transmission housing only fit in one position.
 Carefully remove centering tool T10288/3 upward, guide pins T10288/4 remain in transmission housing.
 Plate carrier for clutch "C" may no longer be turned.
Fig. 265: Attaching Puller For ATF Pump T10286 At Stator Shaft
 Attach puller for ATF supply T10286 at stator shaft.

 Bring ATF supply to installation position.
 Recess for flange shaft faces toward valve body side.
 Attach ATF supply with corresponding bores onto guide pins T10288/4.
 Carefully insert ATF supply into transmission housing and push forcefully.
 Bring ATF supply to final installation position by alternately tightening two opposing attachment bolts
each.
1:48:25 AM Page 186

Fig. 266: Removing Wedge 10288/2 Using Hook 3438

 Remove wedge 10288/2 using hook 3438.

 Remove Puller for ATF supply T10286.
 Remove guide pins T10288/4.

 Insert ATF pump bolts with new sealing washers into ATF pump housing.
 Tighten ATF pump bolts - 1 to 9 - in sequence.
NOTE:  Check for correct ATF pump installation: You must be able to rotate the
input shaft. Otherwise, the last clutch plate "C" may have been pinched
during installation and bent. In this case, remove ATF pump again and
check discs for damage.
1:48:25 AM Page 187

Fig. 268: Checking Input Shaft Axial Clearance

 Attach Dial gauge VAS 6080 with Dial gauge holder VW 387 to transmission flange.
 Insert Dial gauge VAS 6080 with dial gauge extension onto input shaft of transmission, as depicted in
illustration.
 Set dial gauge to "0".
 To protect against damage, cover input shaft with insulating tape.
 Move input shaft up and down using pliers, while doing so avoid lateral movement.
 Read input shaft axial clearance on dial gauge.
 Specified value: 0.10 to 0.30 mm.
 Remove ATF pump again.
 Determine correct adjustment shim - 2 - on tower "II" item - 1 - according to the following table.
1:48:25 AM Page 188

 Measured axial clearance too small: Install respectively thinner shim.

 Measured axial clearance too large: Install respectively thicker shim.
Available shims - thickness in mm

1.6 2.0 2.4
1.8 2.2 2.6
 Reinstall ATF pump with new adjustment shim, new sealing washers and new O-ring. Refer to Fig. 100 .
 Check axial clearance of input shaft again --> Fig. 108 .
If specified value is again not obtained:
 Repeat adjustment.
 Valve body side points upward.
 Press sealing sleeves - 3 - into transmission housing holes to stop.

 Insert coil springs - 2 - and secure with circlips - 1 - by pressing circlips into hole down to shoulder.
1:48:26 AM Page 189


Slide Groove
1:48:26 AM Page 190


Stage Tightening
1:48:26 AM Page 191




1:48:26 AM Page 192

(RPM) Sensor G195.
 Replace ATF filter.
1:48:26 AM Page 193



NOTE:  Clean magnets (6x) in ATF oil pan.

 Ensure full surface contact of the magnets in the ATF oil pan.
 Install ATF oil pan - arrow - with new seal.

 Tighten bolts for ATF oil pan in diagonal sequence in stages.
1:48:26 AM Page 194


 If necessary, replace flange seal for left flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Replace O-ring - arrow B - in mounting bracket for left flange shaft.
NOTE:  Disregard - arrow A -.
DIFFERENTIAL .
overlapping to avoid damaging final drive/transmission housing double shaft seal when installing flange
shaft.
 Insert left flange shaft into transmission.
1:48:26 AM Page 195

NOTE:  When sliding on, left drive flange must be carefully guided by hand to

 Tighten left flange shaft mounting bracket bolts - arrows -.
location.
1:48:27 AM Page 196

 Replace O-ring - arrow - in final drive cover.

 If necessary, replace flange seal for right flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .

1:48:27 AM Page 197

 Position final drive cover on transmission housing.

 Tighten final drive cover bolts in 2 stages as follows:
Stage Tightening
Nm.

1:48:27 AM Page 198

 Tighten right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft
using a pry bar.
 Remove transmission from assembly stand.

 Insert torque converter and secure against falling down with Bracket 30-211 A.
 Check installation dimension of torque converter --> 32 - TORQUE CONVERTER .
 Fill ATF and check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .
 Fill axle oil in front final drive and check oil level --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Top off axle oil in transfer case and check oil level --> 39 - FINAL DRIVE, DIFFERENTIAL .
Component Nm
ATF supply on transmission housing 10
ATF filter on valve body 5
ATF oil pan on transmission housing 10
Mounting bracket for left drive flange on 23
transmission
Final drive cover to transmission 23
Right drive flange 25
ATF pump and ATF supply housing, removing and installing
Removing
1:48:27 AM Page 199

 ATF supply removed.
 Twist ATF pump.

1:48:27 AM Page 200


1:48:27 AM Page 201

Fig. 292: ATF Pump Housing Fasteners

 Remove bolts - 3 to 10 -.
 Remove bolts - 1 - and - 2 - approx. 5 rotations.
Fig. 293: Loosen ATF Pump By Lightly Tapping On Two Bolts Alternately Using A Plastic Hammer
 Attach TORX socket with extension - 1 - onto head bolt, as depicted in illustration.
 Loosen ATF pump by lightly tapping on two bolts alternately using a plastic hammer - arrow -.
 Remove remaining 2 bolts.
 Remove ATF supply housing.
1:48:28 AM Page 202

Fig. 294: ATF Pump Component, Overview

 Remove intermediate plate - 5 - and positioning sleeve - 6 -.

 Remove ATF pump wheels - 3 - and - 4 - from ATF pump housing - 2 -.
1 - O-ring
Installing
CAUTION: Before assembling, check components of ATF pump for wear and damage
--> ATF supply.
 Replace O-ring - 1 - on ATF pump housing.

 Install ATF pump wheels - 3 - and - 4 - in ATF pump housing - 2 -.
 Markings (points) on ATF pump wheels point toward intermediate panel - 5 -.
 Place intermediate panel and insert positioning sleeve - 6 -.
1:48:28 AM Page 203

 Positioning sleeve engages in rectangular bore on intermediate panel.
Fig. 295: Identifying Guide Pins T10288/4 and ATF Pump Housing
 Turn in guide pins T10288/4 in 2 bores of ATF pump housing that are opposite to each other.
 Attach ATF pump housing onto ATF pump.
Fig. 296: ATF Pump Housing Fasteners

 Tighten ATF pump bolts in 2 stages as follows:
Stage Tightening
I  Tighten bolts - 1 to 10 - in sequence to 5 Nm.
Nm.
1:48:28 AM Page 204



1:48:28 AM Page 205


 Insert waved washer - 2 - into cylinder "C" - 1 -.

NOTE:  If plate pack of clutch "C" was replaced, air gap must be adjusted again
Adjust clutch under Clutch "C" , disassembling and assembling.
ATF supply housing with stator shaft, removing and installing
Removing
 ATF supply removed.
 Twist ATF pump.
1:48:28 AM Page 206


1:48:29 AM Page 207


1:48:29 AM Page 208

Fig. 304: Identifying ATF Pump Housing Onto ATF Pump Fasteners
Fig. 305: Identifying Outer Disc Carrier "C" and ATF Supply Housing
 Remove outer plate carrier "C" - 2 - from ATF pump housing - 1 -.
1:48:29 AM Page 209

 Remove bolts - 4 - and - 5 - approx. 5 rotations.
Fig. 307: Loosen ATF Pump By Lightly Tapping On Two Bolts Alternately Using A Plastic Hammer
 Attach TORX socket with extension - 1 - onto head bolt, as depicted in illustration.
 Loosen ATF pump by lightly tapping on two bolts alternately using a plastic hammer - arrow -.
 Remove remaining 2 bolts.
 Remove ATF supply housing.
1:48:29 AM Page 210


 Remove intermediate plate - 5 - and positioning sleeve - 6 -.

 Remove ATF pump wheels - 3 - and - 4 - from ATF pump housing - 2 -.
1 - O-ring
Installing
 Replace O-ring - 1 - on ATF pump housing.

 Install ATF pump wheels - 3 - and - 4 - in ATF pump housing - 2 -.
 Markings (points) on ATF pump wheels point toward intermediate panel - 5 -.
 Place intermediate panel and insert positioning sleeve - 6 -.
 Positioning sleeve engages in rectangular bore on intermediate panel.
1:48:29 AM Page 211

Fig. 309: Identifying Guide Pins T10288/4 and ATF Pump Housing
 Turn in guide pins T10288/4 in 2 bores of ATF pump housing that are opposite to each other.
 Attach ATF pump housing onto ATF pump.

 Tighten ATF pump screws as follows:
Stage Tightening
I  Tighten bolts - 4 to 13 - in sequence to 5 Nm.
1:48:29 AM Page 212

Fig. 311: Identifying Outer Disc Carrier "C" and ATF Supply Housing
 Hand-tighten outer disc carrier "C" - 2 - to ATF supply housing - 1 -.
 Outer disc carrier "C" must be able to slide onto ATF supply housing.


5 - Plate spring
1:48:30 AM Page 213

 Tighten outer disc carrier bolts "C" and ATF pump with inserted piston "C" in 2 additional stages as
follows:
Stage Tightening
III  Tighten bolts - 4 to 13 - in sequence to 10
Nm.
 Position plate spring.

1:48:30 AM Page 214


 Insert waved washer - 2 - into cylinder "C" - 1 -.

NOTE:  If plate pack of clutch "C" was replaced, air gap must be adjusted again
Adjust clutch under Clutch "C" , disassembling and assembling.
Stator shaft, removing and installing
Removing
 ATF pump removed from ATF supply housing --> ATF pump and ATF supply housing, removing
and installing.
1:48:30 AM Page 215

Fig. 316: ATF Supply Housing Fasteners

 Remove bolts - arrows -.
Fig. 317: Press Stator Shaft Under Shop Press With A Suitable Drift
 Warm ATF supply housing area around stator shaft to approx. 70° C with a hot air gun.
 Press stator shaft under shop press with a suitable drift - 1 -.
Installing
CAUTION: Check ATF supply components for wear and damage --> ATF supply.
1:48:30 AM Page 216

Fig. 318: Install Guide Pin M6 T10288/4 And Position Stator Shaft
 Install guide pin M6 T10288/4 and position stator shaft.

 Warm ATF supply housing area around stator shaft to approx. 70° C with a hot air gun.
 Press stator shaft in under shop press using a suitable drift.
Fig. 319: ATF Supply Housing Fasteners

 Tighten bolts - arrows -.
ATF pump shaft seal, replacing
Work procedure
 ATF pump removed from ATF supply housing --> ATF pump and ATF supply housing, removing
and installing.
NOTE:  Attach screwdriver only at shaft seal but not at locking washer lying
1:48:30 AM Page 217

underneath.
Fig. 320: Pry Off Shaft Seal Using Screwdriver

 Pry off shaft seal using screwdriver - arrow -.

 Check locking washer lying underneath for damage.
Fig. 321: Drive In New Shaft Seal To Stop Using Thrust Piece 3295
 Drive in new shaft seal to stop using thrust piece 3295.
INSTALLED TRANSMISSION, SERVICING
Installed transmission, servicing
NOTE:
1:48:31 AM Page 218

 General repair notes --> General Repair Notes .

 Observe the rules of cleanliness for working on automatic transmissions --
> Rules of cleanliness for working on automatic transmissions.
Removing
 Remove ATF oil pan --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC

CONTROLS .

 Remove ATF filter bolts - arrows -.



1:48:31 AM Page 219

1:48:31 AM Page 220

CAUTION:  Only the designated screws must be removed; bolt - 6 - is only on


 Remove valve body from transmission while guiding wiring connector back.
1:48:31 AM Page 221

on Transmission Input Speed (RPM) Sensor G182 (on bottom side of valve
body - arrow -) - risk of damage.
Installing
Install in reverse order of removal, note the following:
NOTE:  Replace dirty or faulty valve body.
Slide Groove
1:48:31 AM Page 222


Stage Tightening
1:48:31 AM Page 223



1:48:32 AM Page 224

(RPM) Sensor G195.
1:48:32 AM Page 225


 Install ATF oil pan --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC

CONTROLS .
 Fill ATF --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .
Torque specification
Component Nm
Inner oil line, removing and installing
NOTE:  Faulty O-rings on inner oil line allow ATF to leak into the final drive. This
will lead to overfilling and oil will drip from the final drive breather hole.
Removing
 Remove valve body --> Valve body, removing and installing.
1:48:32 AM Page 226

Fig. 335: Pry Internal Oil Line Off Transmission Housing Using A Screwdriver
 Press inner oil line evenly off of transmission housing with a screwdriver.
NOTE:  Inner oil line cannot be removed without causing damage.
Installing
NOTE:  Replace O-rings.

 Oil line may be installed with Oil Line Installer 3381. Otherwise the risk
exists that the oil line may leak by bending.
 Insert oil line in Oil Line Installer 3381.

 Using light blows with a plastic hammer, drive oil line on Oil Line Installer 3381 into transmission
housing as far as stop on tool.
1:48:32 AM Page 227

 Open side of oil line installer 3381 faces toward outer wall of transmission.
 Do not distort oil line. Drive both line ends in equally.
 Install valve body --> Valve body, removing and installing.

 Check oil level in front final drive --> 39 - FINAL DRIVE, DIFFERENTIAL .
Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195 , removing and
installing
Removing
 Drain ATF --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .

 Remove ATF oil pan --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC
CONTROLS .

 Disconnect electrical connector - arrow - at Transmission Vehicle Speed Sensor (VSS)

G38/Transmission Output Speed (RPM) Sensor G195.
1:48:32 AM Page 228

 Remove bolt and remove Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed
(RPM) Sensor G195 - 2 - with spacer sleeve - 1 -.
Installing
Installation in reverse order of removal, note the following:
 Position Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor
G195 - 2 - with spacer sleeve - 1 - on transmission and tighten bolt.
 Spacer sleeve height: 8 mm.
 Install ATF oil pan --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC

CONTROLS .
Component Nm
Transmission Vehicle Speed Sensor (VSS) 6
G38/Transmission Output Speed (RPM) Sensor
G195
Transmission Input Speed (RPM) Sensor G182 (transmission with hydraulic control "E17"), removing and installing
NOTE:  On a transmission with hydraulic control "E17" , Transmission Input

Speed (RPM) Sensor G182 is an inductive sensor (secured on underside of
valve body).
 The allocation of the hydraulic control can be found in Technical Data -->
00 - GENERAL, TECHNICAL DATA .
Removing

 Rotate valve body.
1:48:33 AM Page 229

Fig. 339: Removing/Installing Sensor And Solenoid Valve Harness Connectors At Valve Body
 Disconnect electrical harness connector at Transmission Input Speed (RPM) Sensor G182 - 1 -.
NOTE:  Ignore - arrows - and item - 2 -.
Fig. 340: Identifying Sensor For Transmission RPM And Spacer

 Remove bolts and remove Transmission Input Speed (RPM) Sensor G182 - 1 -.
Installing
Installation is in reverse order or removal, note the following:
 Position Transmission Input Speed (RPM) Sensor G182 - 1 - with spacer sleeves - 2 - on valve body and
tighten bolts.
 Spacer sleeve height: 20 mm.
1:48:33 AM Page 230

 Installation position: Transmission Input Speed (RPM) Sensor G182 contacts face toward center of valve
body.

Component Nm
Transmission Input Speed (RPM) Sensor G182 to 7
valve body
Transmission Input Speed (RPM) Sensor G182 (transmission with hydraulic control "E18/2"), removing and installing
NOTE:  On a transmission with hydraulic control "E18/2" , Transmission Input

Speed (RPM) Sensor G182 is a Hall sensor (secured behind valve body on
transmission housing).
 The allocation of the hydraulic control can be found in Technical Data -->
00 - GENERAL, TECHNICAL DATA .
Removing
1:48:33 AM Page 231

 Remove bolt - B -.
 Remove Transmission Input Speed (RPM) Sensor G182 - A - from transmission.
Installing
Installation is in reverse order of removal, note the following:
 Electrical connector - C - for Transmission Input Speed (RPM) Sensor G182 is clipped into valve body
mount after installing valve body.
Component Nm
Transmission Input Speed (RPM) Sensor G182 to 9
transmission
Removing
1:48:33 AM Page 232

 Pry retaining tabs on electrical connectors on solenoid valves out with a small screwdriver and disconnect
electrical connectors - A - one after the other.
 Disengage wiring harness at valve body side retaining tabs - B -.
1:48:33 AM Page 233


 Disconnect electrical connector - arrow - at Transmission Vehicle Speed Sensor (VSS)

G38/Transmission Output Speed (RPM) Sensor G195.
NOTE:  Shown with valve body installed in illustration.
 Rotate valve body.
Transmission with hydraulic control "E17" :
Fig. 344: Removing/Installing Sensor And Solenoid Valve Harness Connectors At Valve Body
 Remove retaining clip - arrow A - and unclip wiring harness from retaining clip - arrow B -.
 Disconnect electrical connector - 2 - at Solenoid Valve 4 N91.
Transmission with hydraulic control "E18/2" :
1:48:34 AM Page 234

 Remove retaining clip - arrow A - and unclip wiring harness from retaining clip - arrow B -.
Installing
 Connect wiring harness electrical connectors to corresponding solenoid valves and sensors.
 Clip wiring harness into intended retaining clips. If deviated, the wiring harness could be pinched when
installing the valve body.
EVALUATING WEAR ON TRANSMISSION COMPONENTS
Evaluating wear by evaluating ATF color and impurities
ATF color
 Yellow color: New ATF.

 Brown color: Used ATF (from approx. 60,000 km).
 Black, ATF smells burned: Malfunction in transmission, e.g. torque converter clutch overheated, clutch
lining burned.
Shavings in ATF
 Metal shavings smaller than 0.1 mm diameter up to a maximum of 1 cm 3 at solenoid in ATF oil pan or in
ATF are normal.
 Metal shavings larger than 2.0 mm diameter at solenoid in ATF oil pan or in ATF indicate a mechanical
malfunction or strong wear in transmission.
1:48:34 AM Page 235

Measures for contaminated ATF area
If ATF area is heavily soiled (ATF black or shavings Shavings in ATF):
 Completely disassemble and clean transmission.

 Flush ATF oil passages and blow through with pressurized air.
 Disassemble and check all clutches.
 Replace torque converter (cannot be cleaned).
 Replace valve body (cannot be cleaned).

 Replace ATF filter.
 Clean ATF lines and ATF cooler.
Clutch "F"
1:48:34 AM Page 236

Fig. 346: Clutch "F", Component Overview

1 - Cylinder "F"
 Check for scoring from lining discs on inner circumference --> Check cylinder "F" inner
circumference for scoring from lining discs
 Check for scoring from lining discs on outer circumference --> Check cylinder "F" outer
 Checking splines
 Checking needle bearing and metal sleeve for wear --> Checking needle bearing and metal sleeve in
cylinder "F" for wear
3 - Piston "F"
 Checking for wear
6 - Plate spring
 Replace in case of signs of wear or if dished washer tips are bent

 Replace broken plate spring
 Replace if deformed
10 - Outer plates
 Checking for wear Checking coated and outer plate for wear
11 - Coated plate
 Checking for wear Checking coated and outer plate for wear
Check cylinder "F" inner circumference for scoring from lining discs
1:48:34 AM Page 237

Fig. 347: Check Cylinder Inner Circumference For Scoring From Lining Discs
 Check cylinder "F" at inner circumference for signs of wear caused by coated plates.
 Coated plates must not get caught in scoring - arrows -.
If scoring - arrows - caused by coated plates are greater than 0.5 mm:
 Replace cylinder "F" and clutch freewheel inner race "D/G"
Check cylinder "F" outer circumference for scoring from lining discs
Fig. 348: Check Cylinder Outer Circumference For Scoring From Lining Discs
 Check cylinder "F" at outer circumference for signs of wear caused by coated plates.
 Replace cylinder "F".
1:48:34 AM Page 238

NOTE:  This damage is always caused by a malfunctioning valve body.
Checking needle bearing and metal sleeve in cylinder "F" for wear
Fig. 349: Checking Needle Bearing And Metal Sleeve In Cylinder "F" For Wear
 Perform a visual check of needle bearing - arrow 1 -.
 Needle bearing must be like new.
 Replace cylinder "F" if necessary.

 Check contact surface of metal sleeve for wear - arrow 2 - in cylinder "F".
 Contact surface must not be heavily scored and/or show blue discoloration.
In case of deep grooves and/or blue color:
If no blue discoloration and only small grooves are detected, proceed as follows:
 Sandpaper (600 grit, oiled) contact surface 1 to 2 times.

 Carefully wipe off with a clean rag and check contact surface. Contact surface must now be like new.
If scores cannot be removed in this manner:
Checking coated and outer plate for wear
1:48:35 AM Page 239

Fig. 350: Checking Coated And Outer Plate For Wear And Overheating
Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows:
A - Spots of discoloration of outer plate caused by overheating in distance of more than 20 mm: Outer and
coated plate OK, can be reused.
B - Spots of discoloration of outer plate caused by overheating in distance of less than 20 mm: Outer and coated
plates worn, must be replaced.
C - Tarnish blue/brown at outer and/or inner area of outer plate: Outer and coated plates overheated and worn,
must be replaced.
Clutch "D/G" with freewheel
1:48:35 AM Page 240

Fig. 351: Clutch "D/G" With Freewheel, Component Overview

 Checking rotating and locking direction of freewheel Checking rotating and locking direction of
freewheel
 Checking brass sleeves for wear Checking upper and lower brass sleeves in freewheel inner race for
wear
 Checking for wear Checking rectangular rings for wear
1:48:35 AM Page 241

 Checking rotating and locking direction of freewheel Checking rotating and locking direction of
freewheel
7 - Coated plates
 Checking for wear Checking coated and outer plates for wear
8 - Outer plates
11 - Plate spring

 Check for cracks
13 - Piston "D"
 Check for cracks

 Perform sound test by striking with a screwdriver: Clear sound - pistons OK, thudding sound - cracks in
pistons
15 - Cylinder "D/G"
 Check for scoring from lining discs on inner and outer circumference --> Check cylinder "D/G" for
scoring from lining discs
 Checking for cracks in area of groove for circlip
19 - Plate spring
23 - Coated plates
24 - Outer plates
Checking rotating and locking direction of freewheel
1:48:35 AM Page 242

Fig. 352: Checking Rotating and Locking Direction Of Freewheel

 Freewheel inner race - 2 - must be able to turn in a clockwise direction and must lock in a counter-
clockwise direction when turned.
If there is no locking effect:
 Replace freewheel with freewheel housing - 1 -.
Checking upper and lower brass sleeves in freewheel inner race for wear
1:48:35 AM Page 243

Fig. 353: Checking Upper And Lower Brass Sleeves In Freewheel Inner Race For Wear
 Check contact surfaces of brass sleeves - arrows - at inside of freewheel inner race for wear.
 Contact surfaces must not be heavily scored and/or show blue discoloration.
 Replace freewheel inner race.

 Carefully wipe off with a clean rag and check contact surfaces.
 Contact surfaces must now be like new.
Checking rectangular rings for wear
1:48:36 AM Page 244

Fig. 354: Checking Rectangular Rings For Wear

NOTE:  Always replace rectangular rings. However, conclusions can be drawn

from the signs of wear of the rectangular rings regarding the quality of
contact surface for rectangular rings. Evaluating the rectangular rings for
wear is therefore essential.
If rectangular rings show strong axial wear of more than 0.3 mm - arrow 1 - (slight wear of outer edges is
normal):
If rectangular rings show strong radial wear of more than 0.3 mm - arrow 2 - (for comparison, measure
thickness of new rectangular ring):
Checking coated and outer plates for wear
1:48:36 AM Page 245

coated plates OK, can be reused.
must be replaced.
Check cylinder "D/G" for scoring from lining discs
1:48:36 AM Page 246

Fig. 356: Check Cylinder "D/G" For Scoring From Lining Discs
 Check cylinder "D/G" at inner and outer circumference for signs of wear caused by lining discs.
 Coated plates must not get caught in scoring.
 Replace cylinder "D/G".
Planetary drive "III"
1:48:36 AM Page 247


2 - Shaft
 Checking contact surface and brass sleeve of shaft for wear Checking contact surface and brass sleeve
of shaft for wear
3 - Ring gear "III"
 Checking splines of planetary drive, replace planetary drive if splines are damaged
4 - Angle washer
1:48:36 AM Page 248

6 - Thrust washer
7 - Planetary carrier "III"
 Checking contact surfaces of shaft for wear --> Checking contact surfaces of shaft planetary carrier
"III" for wear
 Checking splines of planetary drive, replace planetary drive if splines are damaged
 Checking axial and radial play of planetary gears Checking axial and radial play of planetary gears
Checking contact surface and brass sleeve of shaft for wear
Fig. 358: Checking Contact Surface And Brass Sleeve Of Shaft For Wear
 Check contact surfaces of brass sleeve - arrow 2 - at inside of shaft and contact surface at outer
circumference - arrow 1 - for wear.
 Replace shaft.

 Carefully wipe off with a clean rag and check contact surface.
1:48:37 AM Page 249

 Replace shaft.
Checking contact surfaces of shaft planetary carrier "III" for wear
Fig. 359: Checking Contact Surfaces Of Shaft Planetary Carrier "III" For Wear
 Check contact surfaces - arrows - of shaft for wear.
 Replace planetary drive.

1:48:37 AM Page 250

 Replace planetary drive.
Checking axial and radial play of planetary gears
Fig. 360: Checking Axial And Radial Play Of Planetary Gears

 Check axial play of planetary gears - arrow A -.
 Axial play wear limit: 0.4 mm.
 Check planetary gears for radial play - arrow B -.
 Planetary gears must not show radial play.
 Check planetary gear axles.
 Axle peening must be intact.

 Area around axles must not be blue.
 Replace planetary carrier "III" if necessary.
Clutch "B"
washer , 2x outer plates and 2x coated plates. Always replace clutch "B"
without waved washer, 3x coated plates and 3x outer plates on older
construction versions.
1:48:37 AM Page 251

Fig. 361: Clutch "B" Component Overview

2 - Cylinder "B"
 Checking contact surface for rectangular rings for wear --> Checking contact surface for rectangular
rings in cylinder "B" for wear
4 - Piston "B"
 Checking freedom of movement of valve ball --> Checking freedom of movement of valve ball in
piston "B"
6 - Plate spring
1:48:37 AM Page 252

8 - Waved washer
9 - Outer plates
10 - Coated plates
Checking contact surface for rectangular rings in cylinder "B" for wear
Fig. 362: Checking Contact Surface For Rectangular Rings In Cylinder For Wear
 Check contact surface - arrow - in cylinder "B" for wear.
 Replace cylinder "B".

 Check rectangular rings.

 Contact surface must now be like new.
1:48:38 AM Page 253

Checking freedom of movement of valve ball in piston "B"
Fig. 363: Checking Freedom Of Movement Of Valve Ball In Piston "B"

 Lightly coat bore for valve ball - arrow - at front side with oil.
 Charge valve ball from rear with compressed air.
 Only little ball stroke (hardly visible).

 Ball is not spring-loaded (moves back slowly).
If valve ball is stuck:
 Loosen ball with a nail or tip of a ball point pen.
If valve ball is still stuck or leaks:
 Replace piston "B".
NOTE:  A valve ball that does not seal properly or is stuck will cause slipping in
reverse gear.
1:48:38 AM Page 254

C - Tarnish blue/brown at outer and/or inner area of outer plates: Outer and coated plates overheated and worn,
must be replaced.
Clutch "A"
1:48:38 AM Page 255

Fig. 365: Clutch "A", Component Overview

5 - Cylinder "A"
 Check for scoring from lining discs on inner circumference --> Check cylinder "A" inner
 Check for scoring from lining discs on outer circumference --> Check cylinder "A" outer
 Checking contact surface for rectangular ring in cylinder "A" for wear --> Checking contact surface for
rectangular ring in cylinder "A" for wear
10 - Plate spring
1:48:38 AM Page 256

12 - Outer plates
13 - Coated plates
Check cylinder "A" inner circumference for scoring from lining discs
Fig. 366: Check Cylinder Inner Circumference For Scoring From Lining Discs
 Check cylinder "A" at inner circumference for signs of wear caused by coated plates.
 Replace cylinder "A".
Check cylinder "A" outer circumference for scoring from lining discs
1:48:38 AM Page 257

Fig. 367: Check Cylinder Outer Circumference For Scoring From Lining Discs
 Check cylinder "A" at outer circumference for signs of wear caused by coated plates.
Checking contact surface for rectangular ring in cylinder "A" for wear
Fig. 368: Checking Contact Surface For Rectangular Rings In Cylinder For Wear
 Check contact surface - arrow - in cylinder "A" for wear.
1:48:39 AM Page 258

 Check rectangular rings.

C - Tarnish blue/brown at outer and/or inner area of outer plate: Outer and coated plates seated and worn, must
be replaced.
Clutch "E"
1:48:39 AM Page 259


 Checking for wear Checking rectangular rings for wear
3 - Cylinder "E"
 Checking contact surfaces of shaft and brass sleeve for wear --> Checking contact surfaces of shaft
cylinder "E" and brass sleeve for wear
 Checking welding seam between shaft and cylinder Checking welding seam between shaft and
cylinder
7 - Plate spring
1:48:39 AM Page 260

12 - Outer plates
13 - Coated plates
Checking rectangular rings for wear


If rectangular rings show strong axial wear - arrow 1 - (slight wear of outer edges is normal):
 Replace cylinder "E".
 Replace stator shaft.
1:48:39 AM Page 261

NOTE:  If rectangular rings are worn, converter clutch is possibly worn out
because contact pressure is too low.
Checking contact surfaces of shaft cylinder "E" and brass sleeve for wear
Fig. 372: Checking Contact Surfaces Of Shaft Cylinder "E" And Brass Sleeve For Wear
 Check contact surfaces of brass sleeve - arrow 2 - at inside of shaft and contact surfaces at outer
circumference - arrows 1 - for wear.

1:48:40 AM Page 262

Checking welding seam between shaft and cylinder
Fig. 373: Checking Welding Seam Between Shaft And Cylinder

 Check seal of welding seam between shaft and cylinder "E" , place shaft under friction press with plastic
piece - 1 - in between and charge shaft with very little force.
If shaft is loose or a crack is visible in the area marked with - arrows - :
NOTE:  If cylinder "E" is not properly sealed, there will be shifting from 4th to 5th
gear.
1:48:40 AM Page 263

must be replaced.
Clutch "C"
Fig. 375: Clutch "C", Component Overview

1:48:40 AM Page 264

1 - ATF pump with outer plate carrier "C"
 Check inner splines for scoring from lining discs --> Check inner splines on ATF pump with outer
disc carrier "C" for scoring from lining discs
5 - Plate spring
8 - Coated plates
9 - Outer plates
Check inner splines on ATF pump with outer disc carrier "C" for scoring from lining discs
Fig. 376: Check Inner Splines On ATF Pump With Outer Disc Carrier "C" For Scoring From Lining
Discs
 Check inner splines for signs of wear caused by coated plates.
 Replace outer plate carrier "C".
1:48:40 AM Page 265

must be replaced.
ATF supply
CAUTION: Only the same versions of ATF pump and ATF supply may be used - they
are recognized by aligning oil bores. If versions are mixed, ATF pump can
not build up pressure.
1:48:40 AM Page 266

Fig. 378: ATF Pump, Component Overview

2 - Locking washer
 Checking for deformation
 Checking contact surfaces for grooves and signs of wear Checking components of ATF pump for
grooves and signs of wear
 Checking brass sleeve for wear Checking brass sleeve of ATF pump housing for wear
5 - Ring gear
1:48:41 AM Page 267

6 - ATF pump wheel
 Check yoke in ATF pump wheel Check yoke in ATF pump wheel
10 - ATF supply
 Checking volume controlling valve of ATF pump for freedom of movement Checking volume
controlling valve in ATF pump
14 - Stator shaft
 Checking brass sleeves for wear Checking brass sleeves of stator shaft for wear
 Checking splines for wear
16 - Rectangular rings for clutch "B"
 Checking for wear --> Checking rectangular rings item - 16 - for wear
17 - Rectangular ring for clutch "A"
 Checking for wear --> Checking rectangular ring item - 17 - for wear
 Perform visual check for damage: Axial needle bearing and their contact surfaces must be like new,
replace if necessary
Checking brass sleeve of ATF pump housing for wear
1:48:41 AM Page 268

Fig. 379: Identifying Brass Sleeve

 Check contact surface of brass sleeve - arrow - for wear.
 Replace ATF pump.

 Replace ATF pump.
1:48:41 AM Page 269

 Check torque converter hub - arrow - for wear.
If wear on torque converter can be recognized:
 Replace torque converter.
Checking components of ATF pump for grooves and signs of wear

 Check contact surfaces of the following components for grooves and signs of wear:
3 - Ring gear
4 - ATF pump wheel
1:48:41 AM Page 270

 Surfaces of contact surfaces must be matt or shiny but without any sign of groove.
NOTE:  A malfunctioning ATF pump will cause delays in drive and shifting
procedures.
Check yoke in ATF pump wheel
Fig. 382: Identifying ATF Pump Wheel Coupling Plate

 Check whether coupling plates - arrows - on ATF pump wheel show pressure marks or are broken off,
replace ATF pump if necessary.
Causes:
A - Torque converter not completely inserted during transmission or engine installation
B - Centering sleeve for torque converter not inserted in crankshaft
CAUTION: Always check for broken coupling plates and remove.
Checking volume controlling valve in ATF pump
1:48:42 AM Page 271

Fig. 383: Checking Volume Controlling Valve In ATF Pump

Check volume controlling valve as follows:
 Move valve piston against spring pressure.
 Valve piston must move freely in both directions of movement - arrow -.

 Valve must not have grooves.
 No shavings must be jammed in opening - 1 -.
NOTE:  If valve piston is stuck or opening - 1 - is plugged, there will possibly be no

actuation.
Checking brass sleeves of stator shaft for wear
1:48:42 AM Page 272

Fig. 384: Checking Brass Sleeves Of Stator Shaft For Wear

 Check contact surfaces of brass sleeves - arrows - at inside of stator shaft for wear.

Checking rectangular rings item - 16 - for wear
1:48:42 AM Page 273



If rectangular rings show strong axial wear of more than 0.3 mm - arrow 1 - (slight wear of outer edges is
normal):
Checking rectangular ring item - 17 - for wear
1:48:42 AM Page 274


NOTE:  Always replace rectangular ring. However, conclusions can be drawn from
the signs of wear of the rectangular ring regarding the quality of contact
surface for rectangular rings. Evaluating the rectangular ring for wear is
therefore essential.
If rectangular ring shows strong axial wear of more than 0.3 mm - arrow 1 - (slight wear of outer edges is
normal):
If rectangular ring shows strong radial wear of more than 0.3 mm - arrow 2 - (for comparison, measure

FRONT FINAL DRIVE AND TRANSFER CASE, SERVICING
Front final drive and transfer case, servicing

Transfer case with Torsen differential, removing and installing
1:48:43 AM Page 275

Transfer case with Torsen differential, removing and installing --> 39 - FINAL DRIVE, DIFFERENTIAL .
Front final drive and transfer case, component overview
NOTE:  Components shown in illustration can be removed with transmission

installed.
Fig. 387: Front Final Drive And Transfer Case, Component Overview
1 - Internal hex bolt, 25 Nm
2 - Driveshaft output flange
3 - Shaft seal
1:48:43 AM Page 276

 Replace --> 39 - FINAL DRIVE, DIFFERENTIAL
4 - Bolt, 23 Nm
 Qty. 4
5 - Housing cover
6 - O-ring
 Coat with axle oil
7 - Circlip
 For spur gear 1

 Pressing off Pressing off grooved ball bearing for spur gear 1
 Pressing on Pressing on grooved ball bearing for spur gear 1
9 - Spur gear 1
 For rear ring and pinion set
10 - Circlip
11 - Needle bearing
 For spur gear 1

 Remove only to replace
 To replace transfer case housing, warm to approx. 100° C and drive needle bearing with drift towards rear
(Attention! Wear protective gloves)
 Drive in with Sleeve 30-21 to stop
12 - Bolt, 23 Nm
 Loosen or tighten diagonally
13 - Transfer case housing
 Can be replaced if damaged
14 - Clamping nut
15 - Needle bearing
1:48:43 AM Page 277

 Remove only to replace

 Replace --> Needle bearing for spur gear 2, replacing
16 - Circlip
17 - Spur gear 2
 For rear ring and pinion set
 For spur gear 2

 Pressing off Pressing off grooved ball bearing for spur gear 2
 Pressing on Pressing on grooved ball bearing for spur gear 2
19 - Circlip
20 - Fastening plate
21 - Guide plate
22 - Bolt, 8 Nm
23 - Circlip
24 - Gasket
 Replace complete unit if damaged

 Removing and installing --> 39 - FINAL DRIVE, DIFFERENTIAL
26 - Shaft seal
 Replace --> Shaft seal in front final drive intermediate flange, replacing
27 - Magnet
 Replacing --> 39 - FINAL DRIVE, DIFFERENTIAL
28 - Alignment bushing
 Qty. 2
1:48:43 AM Page 278

29 - Bleeder
 For transfer case

 With attached cover
 Installation position: Without cover, breather must project 10 to 11 mm out of housing
30 - Bolt, 23 Nm
 Loosen and tighten diagonally
 Removing and installing --> 39 - FINAL DRIVE, DIFFERENTIAL
32 - Gasket
33 - Alignment bushing
34 - Drive pinion

 Removing and installing --> Shaft seal in drive pinion, replacing

 Installation position: gear identification faces toward differential
36 - Pinion gear

 Installation position: gear identification faces toward differential
37 - Shaft seal
 Replace --> Shaft seal in drive pinion, replacing
Pressing off grooved ball bearing for spur gear 1
1:48:43 AM Page 279

A - Separating device 22 to 115 mm Kukko 17/2
Pressing on grooved ball bearing for spur gear 1

Pressing off grooved ball bearing for spur gear 2
1:48:44 AM Page 280

A - Separating device 22 to 115 mm Kukko 17/2
Pressing on grooved ball bearing for spur gear 2

Driveshaft output flange shaft seal, replacing
Replace driveshaft output flange shaft seal --> 39 - FINAL DRIVE, DIFFERENTIAL .
Shaft seal in front final drive intermediate flange, replacing
Flange
NOTE:  On the left side of the final drive intermediate flange there is an oil leak
inspection opening - arrow - for shaft seal in drive pinion and shaft seal in
front final drive intermediate flange.
1:48:44 AM Page 281

Work procedure
 Remove transfer case --> 39 - FINAL DRIVE, DIFFERENTIAL .

 Remove front final drive intermediate flange --> 39 - FINAL DRIVE, DIFFERENTIAL .

 Drive shaft seal - arrow - out in toward transfer case using a drift.
 Check shaft seal seating in front final drive intermediate flange for damage, rework if necessary.

 Slide shaft seal onto Thrust Piece 3404.
 The larger, projecting outer race - arrow - on shaft seal faces toward thrust piece.
1:48:44 AM Page 282

 Drive shaft seal in with Thrust Piece 3404 as far as thrust piece stop.
 Install front final drive intermediate flange --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Install transfer case --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Check and correct ATF level in planetary gearing --> 37 - AUTOMATIC TRANSMISSION -
CONTROLS, HOUSING .
Shaft seal in drive pinion, replacing
Flange
NOTE:  On the left side of the intermediate shaft, there is an oil leak inspection
opening - arrow - for shaft seal in drive pinion and shaft seal in
intermediate flange.
Work procedure
1:48:44 AM Page 283

 Remove front final drive intermediate flange --> 39 - FINAL DRIVE, DIFFERENTIAL .


toward rear.
 Drive out shaft seal with a drift.
1:48:45 AM Page 284

 Slide shaft seal onto Thrust Piece 3403.

 Drive shaft seal in with Thrust Piece 3403 as far as thrust piece stop.
NOTE:  Ignore - A - and - B -.

 Completely cover splines on input shaft - arrow - with insulating tape without creasing or overlapping
the tape to prevent damage to gasket when sliding on drive pinion.
 Install front final drive intermediate flange --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Check and correct ATF level in planetary gearing --> 37 - AUTOMATIC TRANSMISSION -
CONTROLS, HOUSING .
Work procedure
1:48:45 AM Page 285


NOTE:  The upper part of the illustration illustrates how the pulling hooks of the
extractor - B - must be installed in the needle bearing - 1 -.
A - Counter support Kukko 22/1
B - Internal puller Kukko 21/4
 Slide centering sleeve - 2 - on Internal Puller Kukko 21/4 - B - approx. 4 mm in direction of - arrow - in
order to be able to open the pulling hooks far enough.
 Install Counter-support Kukko 22/1 - A - on internal puller - B - as show in the illustration.
 Support counter-support with Thrust Plate VW 402 and tension at counter-support nut - 3 -.
 Quickly warm outside of transfer case housing with a hot air gun in area around needle bearing seat to
approx. 100° C.
 Quickly remove needle bearing.
 Check needle bearing seating in transfer case housing for damage, rework if necessary.
1:48:45 AM Page 286

 Evenly warm outside of transfer case housing with a hot air gun in area around needle bearing seat to
approx. 100° C.
Fig. 401: Sleeve 2080 A Positioned On New Needle Bearing

 Position Sleeve 2080 A on new needle bearing - 1 -.

 Drive needle bearing into transfer case housing as far as stop using Punch VW 408 A.
1:48:45 AM Page 287

TORQUE CONVERTER
Torque converter
CAUTION: Check installation dimension of torque converter before installing

transmission --> Torque converter, installing

 Lightly coat sealing ring with ATF. Other lubricating substances lead to
functional problems in the hydraulic transmission control.
1:41:37 AM
1:41:40 Page 1
Fig. 8: Identifying Torque Converter, Seal & Contact Ring

1 - Torque converter
 Secure on removed transmission to keep it from falling out.

 Identification --> Torque converter, identification
 Installing --> Torque converter, installing
2 - Seal
 Always replace --> Torque converter oil seal, replacing
3 - Contact ring
 Behind sealing ring
1:41:37 AM Page 2

Different types of torque converters exist. Identification is performed via code letters (arrow).
Allocation of torque converter/transmission --> Code letters, allocation, ratios, equipment.

 Checking converter hub for wear grooves (arrow).
NOTE:  The torque converter is welded in and must be completely replaced if

damaged or in case of malfunctions.
1:41:37 AM Page 3


 Oil siphoning probe VAG1358 A/1
In case of soiling of the ATF via shavings, torque converter must be drained:
Fig. 12: Extracting ATF From Torque Converter

 Drain ATF from torque converter using oil siphoning unit VAG1358A and Oil siphoning probe
VAG1358 A/1.
1:41:37 AM Page 4

Fig. 14: 3295 Thrust Piece

Removing
 Removing transmission --> Transmission, removing and installing.

 Secure transmission to assembly stand --> Transmission, attaching to assembly stand.
1:41:37 AM Page 5
 Insert extractor lever VW681 directly behind the sealing lip of the sealing ring, so that the contact ring
which is behind it is not damaged.
Installing
 Insert contact ring.

 Coat outer circumference and sealing lips of sealing ring with ATF.
Fig. 16: Driving In Torque Converter Oil Seal Until Stop Of Thrust Piece 3295
 Using thrust piece 3295 , drive in sealing ring for torque converter up to thrust piece stop.
 Depth gauge
1:41:37 AM Page 6
 Slide in converter hub through the sealing ring up to the first stop.
 Rotate torque converter inward with light pressure, until the groove of the torque converter hub engages
in the coupling plate of the pump wheel and the torque converter slides inward noticeably.


Pay particular attention to the following when installing the transmission.
CAUTION: Keep checking to make sure the torque converter behind the drive plate
can be turned before and during tightening the bolts at the
engine/transmission flange.
If the torque converter cannot be turned, it must be assumed that it has

not been inserted properly and that the coupling plate of the torque
bolts.
1:41:37 AM Page 7
TRANSMISSION 5 Spd. Automatic Transmission 01V On Board Diagnostic (OBD)
TRANSMISSION
5 Spd. Automatic Transmission 01V On Board Diagnostic (OBD)
01 ON BOARD DIAGNOSTIC (OBD)

ON BOARD DIAGNOSTIC (OBD) SYSTEM, OPERATION
On Board Diagnostic (OBD) system, operation
The automatic transmission controls are electronic/hydraulic.
The Transmission Control Module (TCM) -J217- receives information from components which influence the
shifts. Based on this information, the control module activates the applicable solenoid valves in the valve body.
The solenoids route the fluid pressure generated by the ATF pump to the clutches or brakes to be closed.
Transmission Control Module (TCM) DTC recognition
The term "On Board Diagnostic system" refers to the electrical/electronic part of the controls.
The control module is equipped with a DTC memory so that in the event of the failure of an electrical/electronic
component, or in the event of an open circuit, the cause of the fault can be determined quickly.
DTCs are recognized by means of electrical signals. If malfunctions occur in the sensors or components being
monitored, they are stored in the DTC memory indicating the type and location of the DTC.
If a DTC is present, it is initially saved as a statistical DTC. If the DTC is no longer present, it first of all
becomes a sporadic DTC (SP).
DTCs that are saved in the DTC memory as sporadically present are displayed as "sporadically occurring
DTCs" during a DTC scan. "SP" appears on the right side of the display. With the printer switched on,
"sporadically occurring DTCs" are printed out following the DTC scan.
DTCs that are saved in the DTC memory as sporadically occurring DTCs are automatically deleted after 40
engine cold starts (and subsequent transmission warm up).
The potential of the On Board Diagnostic system can only be fully realized by using the Vehicle Diagnosis,
Measurement and Information System VAS 5051.
Functions which the VAS 5051 Vehicle Diagnosis, Measurement and Information system can detect. Refer to
List of Selectable Functions, Table of Selectable Functions.
Safety functions of the Transmission Control Module (TCM)
In the event of a failure of individual or multiple components or sensors, the Transmission Control Module -
J217- activates replacement functions or limp-home programs. This ensures non-destructive operation of the
automatic transmission with the concomitant effect on the function and quality of the shifts.
1:50:12 AM
1:50:29 Page 1
If critical DTCs occur and with the Transmission Control Module (TCM) J217 activated, the gear currently
engaged is initially held. As soon as the situation with respect to the transmission and vehicle safety permits, the
Transmission Control Module -J217- activates "Mechanical Limp Home with Active Control Module".
Mechanical Limp Home with Active Control Module
 Transmission shifts out of all forward gears into the hydraulic 4th gear. Converter clutch is open. All
solenoids have no power.
 Maximum shift pressure on the powertrain elements.
 Reverse gear can be engaged. Shift lock (in "P" and "N") is active.
Fig. 1: Mechanical Limp Home with Active Control Module

 All segments of the gear selector display are fully illuminated.
In the event of a Transmission Control Module (TCM) -J217- failure (e.g power supply failure or harness
connector disconnected) the transmission immediately continues to operate in "Mechanical Limp Home with
Non-Active Control Module".
Mechanical Limp Home with Non-Active Control Module
 Transmission shifts out of all forward gears into the hydraulic 4th gear. Converter clutch is open. All
solenoids have no power.
 Maximum shift pressure on the powertrain elements.
 Reverse gear can be engaged. Shift lock (in "P" and "N") is active.
1:50:13 AM Page 2
Fig. 2: Mechanical Limp Home With Non-Active Control Module

 All segments of the gear selector display are dark.

 The Transmission Control Module (TCM) -J217- is completely inoperative, which means that On Board
Diagnostic (OBD) is not possible.
Technical data for the On Board Diagnostic (OBD) system
DTC memory
 Permanent memory Yes
Data output
Rapid data transmission Yes
Blink code output No
Control element diagnosis/Output Diagnostic Yes
Test Mode (DTM)
Basic setting No 1)
Coding control module Yes
Reading Measured Value Block Yes
Electrical/Electronic components and component Refer to Electrical/electronic components and
locations component locations
1) Resetting adaptation values for Transmission Control Module (TCM). Refer to Adaptation values for
Transmission Control Module (TCM), basic setting
ELECTRICAL/ELECTRONIC COMPONENTS AND COMPONENT LOCATIONS
Electrical/electronic components and component locations
1:50:13 AM Page 3
Fig. 3: Electrical/Electronic Components And Component Locations

1 - Transmission Control Module (TCM) -J217-
 Component location and removal and installation. Refer to Transmission Control Module (TCM) -
J217-, removing and installing
 Loosening multiple connector. Refer to Transmission Control Module (TCM) -J217-, removing and
installing
 Control module is tested by On Board Diagnostic (OBD)
 Component location. See Fig. 4
3 - Shift Lock Solenoid -N110-
1:50:13 AM Page 4

 Can be tested in Measured Value Block. Refer to Test procedure and Electrical Testing
 Removal and installation:
Refer to
 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC

TRANSMISSION 01V
TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS,
SERVICING
4 - Internal transmission wiring harness with integrated Transmission Fluid Temperature Sensor (ATF) -
G93-

 -G93- is tested by On Board Diagnostic
 Removing and installing wiring harness or Transmission Fluid Temperature Sensor -G93-:
Refer to
 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS for 5 SPD.

AUTOMATIC TRANSMISSION 01V
AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL
COMPONENTS, SERVICING
5 - Valve body

 Solenoid Valves -N88-, -N89-, -N90- and Pressure Control Valves -N215-, -N216-, -N217- and -N218-
are attached to the valve body.
 Components are tested by On Board Diagnostic
Refer to

6 - Multi-function Transmission Range (TR) Switch -F125-
1:50:13 AM Page 5

 Is tested by On Board Diagnostic
Refer to

7 - Shift control mechanism cover
Refer to

TRANSMISSION 01V
SERVICING
8 - Tiptronic Switch -F189-

 Can be tested in Measured Value Block. Refer to Test procedure
Refer to

TRANSMISSION 01V
SERVICING
9 - Starter Interlock Alarm System Relay -J60-

 Testing. Refer to Starter Interlock Alarm System Relay -J60-, checking
10 - Sensor for transmission RPM -G182-
1:50:13 AM Page 6

Refer to

11 - Sender for transmission output RPM -G195-
 Measures transmission output RPM

Refer to

12 - Transmission Range (TR) Selector Lever Display -Y6-

 Gear display not illuminated indicates limp home operation with non-active Transmission Control
Module (TCM).
 Completely illuminated gear display indicates limp home operation with active Transmission Control
Module (TCM).
Refer to
 90 INSTRUMENTS
13 - Kickdown Switch -F8-
 Component location. See . Fig. 15
1:50:13 AM Page 7
 No mechanical switch; a specific value from Throttle Position Sensor and Sender for accelerator pedal
position -G79-/-G185- is stored in Engine Control Module (ECM)
 Signal transmission from ECM to TCM over CAN-bus
 Accelerator pedal module removal and installation:
Refer to 20 - FUEL SUPPLY SYSTEM
14 - Brake light switch -F-

 Signal transmission from Engine Control Module (ECM) to Transmission Control Module (TCM) over
CAN-bus
Refer to 46 - BRAKES - MECHANICAL COMPONENTS
15 - Cruise Control Switch -E45-

Refer to
 94 LIGHTS, SWITCHES - EXTERIOR

 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET
1:50:13 AM Page 8

Component location: The DLC is located under the knee bolster to the left of the steering wheel.
Shift Lock Solenoid -N110-
Fig. 5: Shift Lock Solenoid -N110-

Component location: The Shift Lock Solenoid is located in the shift control mechanism -arrow-.
Valve body
1:50:13 AM Page 9

Component location: The valve body is bolted underneath the transmission housing and is covered by the
transmission oil pan.
Solenoid Valves -N88-, -N89-, -N90- and Pressure Control Valves 1 -N215-, 2 -N216-, 3 -N217- and 4 -N218-
are attached to the valve body.
Internal transmission wiring harness with integrated Transmission Fluid Temperature Sensor -G93-
1:50:13 AM Page 10

Component location: The wiring harness is attached to the valve body.
The wiring harness can be replaced with the transmission installed and the valve body removed.
Multi-Function Transmission Range (TR) Switch -F125-
1:50:13 AM Page 11
Fig. 8: Disconnecting Connector For Multi-Function Transmission Range (TR) Switch -F125- At Front
Left Of Transmission
Component location: The Multi-Function Transmission Range (TR) Switch is located on the left side of the
transmission, harness connector for Multi-Function Transmission Range (TR) Switch -arrow-
Tiptronic Switch -F189-
Fig. 9: Tiptronic Switch -F189-

Component location: The Tiptronic Switch is integrated into the circuit board for the icon insert which is
located in the cover for the shift control mechanism.
It consists of 3 Hall sensors (A, B, C), which are energized by a solenoid on the transverse slide on the roll
cover
A - Downshift switch sensor
B - Tiptronic recognition sensor
C - Upshift switch sensor
1:50:13 AM Page 12
 If malfunctions occur test Tiptronic Switch in the Measured Value Block. Refer to Test procedure for
malfunctions.
Fig. 10: Checking Whether Solenoid Is Properly Attached To Roll Cover

In the event of malfunctions, first check whether the solenoid is properly attached to the roll cover -C-
transverse slide, if necessary replace transverse slide. The icon insert with the integrated circuit board must not
be replaced until the wiring connections have been inspected. In the case of vehicles with multi-function
steering wheel, the buttons on the steering wheel and their wiring must also be inspected.
Starter Interlock Alarm System Relay -J60-
Fig. 11: Starter Interlock Alarm System Relay -J60-

Component location: On the relay carrier in the E-Box plenum.
4 - Starter Interlock Alarm System Relay -J60-
Sender for transmission output RPM -G195-
1:50:13 AM Page 13
Fig. 12: Sender For Transmission Output RPM -G195-

Component location: The Sender for transmission RPM is located in the transmission at the right rear
Sensor for Transmission RPM -G182-
Component location: The sensor -A- is a Hall sensor and is attached behind the valve body to the transmission
housing.
Transmission Range Selector Lever Display -Y6-
1:50:13 AM Page 14
Fig. 14: Mechanical Limp Home with Active Control Module

Component location: Integrated in the instrument cluster
NOTE: The Transmission Range (TR) Selector Lever Display can only be replaced
together with the instrument cluster.
Kickdown Switch -F8-
Fig. 15: Kick Down Switch F8

 No mechanical switch; a specific value from the Throttle Position Sensor and the Sender for accelerator
pedal position -G79-/-G185- is stored in the Engine Control Module (ECM)
1:50:13 AM Page 15

Component location: The brake light switch -arrow- is located on the pedal cluster.
NOTE: In order to ensure adequately tight fit the switch must be installed only one
time.
Cruise Control Switch -E45-
Fig. 17: Cruise Control Switch -E45-

Component location: The Cruise Control Switch is located at the steering column switch.
Transmission Control Module (TCM) -J217-, removing and installing
 Switch ignition OFF.

 Remove rubber seal from the plenum panel cover.
1:50:13 AM Page 16
Fig. 18: Identifying Plenum Chamber Cover & Removing Rubber Seal
 Remove plenum panel cover toward front -1- -arrows-.
Fig. 19: Removing Securing Clips And Cowl

 Pry off two cover caps -3- with a screwdriver.

 Loosen hex head nuts -4- a few turns.
 Remove wiper arms -2- from wiper shaft by tilting them slightly.
 Remove hex head nuts completely and remove wiper arms.
 Remove safety clips -1- and remove cowl grille -5-.
1:50:13 AM Page 17
Fig. 20: Removing Screws And Cover From E-Box In Plenum Chamber
 Remove cover for plenum panel E-box -arrows-.
Fig. 21: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
 Pry off retaining bracket with a screwdriver -arrows-.

 Place Engine Control Module (ECM) with harness connectors attached to one side.
 Unclip retaining bracket for Transmission Control Module (TCM).
NOTE: The harness connector for the control module must not removed or connected
for 30 seconds after the ignition has been switched OFF.
1:50:13 AM Page 18
Fig. 22: Unlocking Harness Connector And Pulling It Off Transmission Control Module (TCM)
 Unlock harness connector -arrow- and pull it off Transmission Control Module (TCM).
NOTE: When the harness connector is removed, the adaptation values in the
Transmission Control Module (TCM) are reset. The control module has to
relearn these values after resumption of operation. During this "learning
process" shift quality may be worse than normal.
Installation is carried out in the reverse order.
ON BOARD DIAGNOSTIC (OBD) PROGRAM
Safety Precautions
If the use of test and measuring equipment is required during test drives, the following precautions must
be observed:
WARNING:  The test and measurement equipment must always be secured on

the rear seat and operated from there by a second person.
 If the test and measurement equipment is operated from the

passenger seat, the person sitting there could be injured in an
accident as the result of deployment of the passenger side airbag.
In order to prevent injuries to persons and/or destruction of electrical and electronic components, the
following precautions must be observed:
 Attach measurement and test equipment terminals only with the ignition switched OFF.
 With some tests it may happen that the control module detects and saves a trouble code. For this reason,
the DTC memory must be scanned and if necessary deleted after completing all tests and repairs.
 Disconnecting and attaching battery terminals must only be carried out with the ignition switched OFF,
otherwise the Transmission Control Module (TCM) can be damaged.
1:50:13 AM Page 19
CAUTION: Observe precautions when disconnecting battery terminals.
Refer to

 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for
ELECTRICAL EQUIPMENT, CABRIOLET
Notes on towing
CAUTION: When the vehicle is towed, the transmission selector lever must be in
position N, and it must not be towed more than 50 km and not above 50
km/h, otherwise the transmission will be destroyed.
NOTE: It is not possible to tow the vehicle in order to start the engine, for example
when the battery is too weak or the starter is not working.
VAS 5051 Vehicle Diagnosis, Measurement and Information System, connecting and selecting functions
Test requirements:
 Parking brake applied.

 Vehicle voltage supply O.K.
 Voltage supply and fuses for particular system O.K.
Refer to Wiring Diagrams, Electrical Troubleshooting and Component Locations binder
 Ground connections for transmission O.K.
 Check ground connections for corrosion and damaged connection, repair as needed.
 Check battery ground strap and ground strap between battery and transmission.
Test procedure
1:50:13 AM Page 20
Connector (DLC)
 Connect VAS 5051 Vehicle Diagnosis, Measurement and Information System with diagnostic lead VAS
5051/1.
NOTE: The Data Link Connector (DLC) is located in the left side knee bolster.
CAUTION: Please observe safety precautions. Refer to Safety Precautions
NOTE: If an error message appears in the display:
Refer to Users Manual for VAS 5051 Vehicle Diagnosis, Measurement and Information System VAS 5051
1:50:13 AM Page 21

Display on VAS 5051:
 Touch "Vehicle On Board Diagnostic System" button.

NOTE: By touching "00 - Scan DTC Memory - Complete System" in the selection -1- the
automatic test sequence is performed, i.e. a scan is performed of the DTC
memory for all systems in the vehicle capable of On Board Diagnostic (OBD).
Depending on the desired function:
 Switch ignition ON.
Or
 Start engine.
 In selection -1- touch vehicle system "02 - Transmission Electronics".
 Wait until next display appears on screen.
1:50:13 AM Page 22
Fig. 26: Diagnostic System VAS 5051: Display - System In Basic Setting
1 - Control module identification number of the Transmission Control Module (TCM).
Identification number of Transmission Control Module (example)

02 - Transmission electronics Vehicle system
8E0927156. Part number; application.
AG5 01V 1) 3.0l5V 2) USA 3) 1) Automatic 5-Speed Transmission 01V
0809 4) 2) Engine Version 3.0 liter 5V
3) Market, USA, Canada and Mexico
4) Control module data status (software status)
Code 1002 Control module coding (check. Refer to Transmission Control
Module (TCM), coding)
Operating number 12345 Operating identification of the VAS 5051 with which the last coding
was performed.
LIST OF SELECTABLE FUNCTIONS
List of Selectable Functions
Refer to
02 Reading DTC Memory Diagnostic Trouble Code (DTC) memory,
- scanning
03 Control element diagnosis/Output Diagnostic Control element diagnosis/Output Diagnostic
- Test Mode (DTM) Test Mode (DTM)
05 Erasing DTC Memory Diagnostic Trouble Code (DTC) memory,
- erasing
06 Ending Output
-
07 Coding Control Module Transmission Control Module (TCM), coding
1:50:13 AM Page 23
-
08 Reading Measured Value Block Test procedure
-
DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, SCANNING
Diagnostic Trouble Code (DTC) memory, scanning
 Connect VAS 5051 Vehicle Diagnosis, Measurement and Information System. Refer to VAS 5051
Vehicle Diagnosis, Measurement and Information System, connecting and selecting functions and in
selection touch vehicle system "02 - Transmission Electronics". Ignition must be switched ON.

 In selection touch -1- diagnostic function "02 - Scan DTC memory".
Fig. 28: Identifying Content Of DTC Memory & Identification Of Fault On Diagnostic System VAS 5051
Display
1:50:13 AM Page 24
1 - Contents of the DTC memory:
0 DTCs detected
Or
X DTCs detected
2 - DTC
DTC number
Location of DTC
Type of DTC
A - If DTCs were recognized:
 Print out contents of screen or OBD protocol.

 End function "02 - Scan DTC memory" by touching <-- button.

 Repair malfunction(s) using the Test Chart. Refer to Diagnostic Trouble Code (DTC) table.
 In selection touch diagnostic function "02 - Scan DTC memory" again and delete DTC memory. Refer to
Diagnostic Trouble Code (DTC) memory, erasing.
 Touch "06 - End output".
B - If no DTC was detected:
1:50:13 AM Page 25
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
Diagnostic Trouble Code (DTC) table
NOTE:  In the following all the possible DTCs are listed by ascending order of DTC
numbers. These trouble codes can be recognized by the Transmission
Control Module -J217-. Then they are displayed on the Vehicle Diagnosis,
Measurement and Information System VAS 5051 during scanning of the
DTC memory content.
 If faults occur only occasionally or if the DTC memory was not deleted
after the fault was corrected, these faults will be displayed for a
predetermined time as "intermittently occurring faults". Refer to
Transmission Control Module (TCM) DTC recognition.
 If faulty components are displayed when the DTC memory is read, make an
additional check of wiring connections to the components for a short
circuit and open circuit.
DTC CHART PART 1, UP TO DIAGNOSTIC TROUBLE CODE 18112/P1704
DTC Chart Part 1, up to Diagnostic Trouble Code 18112/P1704
Output at printer Possible cause Repair

16987 P0603
Control module faulty  Transmission  Replacing Control
Control Module Module. Refer to
(TCM) -J217- Electrical/electronic
faulty components and
component
locations
16989 P0605
Control module faulty  Transmission  Replacing Control
Control Module Module. Refer to
component
locations
Notes on Diagnostic Trouble Codes 16987/P 0603 and 16989/P0605:
Only after determining the possible fault cause and correcting the following faults:
1:50:13 AM Page 26
 Mechanical faults
 Hydraulic faults
 Electrical/electronic components and wiring connections

17087 P0703
Brake light switch -F-
Electrical fault in circuit  Wiring connection  Read Measured
between brake test Value Block. Refer
switch, brake light to Test procedure;
switch F and display group
Engine Control number 3.
Module (ECM)  Check wiring
faulty connections and
harness connectors
using wiring
diagram
 Read DTC memory

for Engine Control
Module (ECM) and
repair fault.
 Brake light switch  Replace brake light
F faulty switch -F-. Refer to
46 - BRAKES -
MECHANICAL
COMPONENTS
Notes on DTC 17087/P0703:
 The signal from the brake light switch -F- is transmitted by the Engine Control Module (ECM) over the
CAN-bus circuit to the Transmission Control Module (TCM).
 Conditions for DTC recognition: The signals from the brake light switch and the brake test switch are
transmitted over the CAN-bus circuit to the Transmission Control Module (TCM) and evaluated there. In
the event of an implausibility this DTC is displayed in the Transmission Control Module (TCM).

17090 P0706
Multi-function Transmission Range (TR)
Switch. Refer to Multi-Function Transmission
Range (TR) Switch -F125--F125-
Implausible signal  Selector lever  Adjust selector lever
cable wrongly cable. Refer to
1:50:13 AM Page 27
adjusted  37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Connector at the  Read Measured Value
Multi-function Block. Refer to Test
Transmission procedure; display
Range (TR) group number 4.
Switch -F125- not  Check wiring and wiring
attached connectors following
 Open circuit or wiring diagram 2)
short circuit to
ground or B+
 Multi-function  Perform electrical test.
Transmission Refer to Electrical
Range (TR) Testing
Switch -F125-  Replace Multi-function
faulty Transmission Range
(TR) Switch -F125-.
Refer to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
1:50:14 AM Page 28
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
2) First check 8-pin harness connectors for corroded terminals or water entry and replace if necessary.

17094
P0710
Transmission Fluid
Temperature Sensor -
G93-
Electrical  Open circuit or  Check wiring and wiring connectors following
fault in short circuit to wiring diagram 3)
circuit ground or B+
 Transmission  Read Measured Value Block. Refer to Test
Fluid procedure; display group number 004.
Temperature  Perform electrical test. Refer to Electrical
Sensor -G93- Testing.
faulty
 Replace transmission wiring harness 4). Refer to
 38 - AUTOMATIC TRANSMISSION -
GEARS, HYDRAULIC CONTROLS for
5 SPD. AUTOMATIC TRANSMISSION
01V
01V FRONT AND ALL WHEEL DRIVE -
INTERNAL COMPONENTS, SERVICING
1:50:14 AM Page 29
3) First check harness connectors for corroded terminals or water entry and replace if necessary. If DTCs are
displayed, pay particular attention to the 16-pin harness connector at the transmission between the valve body
and the wiring harness.
4) The Transmission Fluid Temperature Sensor -G93- is integrated in the transmission wiring harness and can
only be replaced as a unit with the wiring harness.

17095
P0711
Transmission Fluid
Temperature Sensor -
G93-
Implausible  Open circuit or  Check wiring and wiring connectors following
signal short circuit to wiring diagram 3)
ground or B+
Fluid procedure; display group number 004.
Temperature  Perform electrical test. Refer to Electrical
Sensor -G93- Testing.
faulty
01V
01V FRONT AND ALL WHEEL DRIVE -
INTERNAL COMPONENTS,
SERVICING
4) The Transmission Fluid Temperature Sensor G93 is integrated in the transmission wiring harness and can
Note on DTC 17095/P0711:
 Condition for DTC recognition: Transmission fluid temperature does not increase after the engine is
started or makes erratic changes in temperature.
1:50:14 AM Page 30

17096
P0712
Transmission Fluid
Temperature
Sensor -G93-
Signal  Open circuit or  Check wiring and wiring connectors following wiring
too low short circuit to diagram 3)
ground or B+
Fluid Temperature procedure; display group number 004.
Sensor -G93-  Perform electrical test. Refer to Electrical Testing.
faulty
GEARS, HYDRAULIC CONTROLS for 5
SPD. AUTOMATIC TRANSMISSION 01V
FRONT AND ALL WHEEL DRIVE -

17097
P0713
Transmission Fluid
Temperature
Sensor -G93-
Signal  Open circuit or  Check wiring and wiring connectors following wiring
too short circuit to diagram 3)
high ground or B+
Fluid Temperature procedure; display group number 004
Sensor -G93-  Perform electrical test. Refer to Electrical Testing.
faulty
1:50:14 AM Page 31


17100 P0716
Sensor for transmission RPM -G182-
Implausible signal  Open circuit or  Check wiring and wiring
short circuit to connectors following
ground or B+ wiring diagram 5)
 Sensor for  Read Measured Value
transmission Block. Refer to Test
RPM -G182- procedure; display
faulty. group number 001.
 Replace sensor for
transmission RPM -
G182-. Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
1:50:14 AM Page 32
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Transmission  Correct fault according
RPM signal faulty to DTC 17105/P0721
Continued ?
5) First check harness connectors for corroded terminals or water entry and replace if necessary.

DTC continued
17100 P0716
Implausible signal  ATF level not  Check ATF level. Refer
O.K. to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
1:50:14 AM Page 33
SERVICING
 Faulty or  Check converter
incorrect identification.
converter
 Clutches or  Read Measured Value
brakes slipping Block. Refer to Test
procedure; display
group number 005 to 007
and confirm during a
drive which servos are
faulty or not activated.
 Solenoid valve or  Perform control element
pressure control diagnosis. Refer to
valve is sticking Control element
diagnosis/Output
Diagnostic Test Mode
(DTM).
 If necessary, replace
solenoid valves, pressure
control valves or valve
body. Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
1:50:14 AM Page 34
SERVICING
 Condition for DTC recognition: One transmission position (D or S) has been positively engaged, not an
intermediate position. Engine RPM while driving is higher than 608 RPM. Transmission output RPM
while driving is higher than 416 RPM.
 The DTC is displayed when the conditions for DTC recognition are met and transmission input RPM is
equal 0 RPM or higher than 8000 RPM.

17105 P0721
Implausible signal  Open circuit or  Check wiring and wiring
short circuit to connectors following
 Shielding for -  Read Measured Value
G195- faulty Block. Refer to Test
 Sender for procedure; display
transmission group number 001.
output RPM -  Perform electrical test.
G195- faulty Refer to Electrical
Testing.
 Replace sender for

transmission output RPM
-G195-. Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
1:50:14 AM Page 35
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Engine or  Correct fault according
transmission to DTC 17100/P0716.
input RPM signal
incorrect
Continued ?

DTC continued
17105 P0721
Implausible signal  ATF level not  Check ATF level. Refer
O.K. to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:14 AM Page 36

converter
 Clutches or  Read Measured Value
brakes slipping Block. Refer to Test
procedure; display
group number 005 to 007
and confirm during a
drive where servos are
faulty or not activated.
 Solenoid valve or  Perform control element
pressure control diagnosis. Refer to
valve is sticking Control element
diagnosis/Output
(DTM).
solenoid valves, pressure
control valves or valve
body. Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:14 AM Page 37

17114 P0730
Gear/gear ratio monitoring
Wrong gear ratio  ATF level not O.K.  Check ATF level. Refer
or ATF to
contaminated  37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Clutch is slipping  Perform control element
or faulty or diagnosis. Refer to
solenoid valve Control element
contaminated/faulty diagnosis/Output
(DTM).
 Incorrect  Verify control module
Transmission identification number.
Control Module
(TCM) installed or
incorrectly coded
 Sensor for  Correct fault according
transmission RPM to DTC 17100/P0716.
-G182- faulty
 Sender for  Correct fault according
transmission output to DTC 17105/P0721.
1:50:14 AM Page 38
RPM -G195- faulty
 The gear monitoring function of the Transmission Control Module checks the gear ratios by comparing
transmission input and transmission output RPM, taking into consideration the gear currently engaged.
This DTC is displayed when a detected, unacceptable gear ratio (implausibility) is found.
 When testing full braking RPM, transmission input RPM in the converter with the vehicle stationary and
gear engaged must be almost zero. If this is not the case, this DTC is also displayed because clutch
damage may be present (Read Measured Value Block. Refer to Test procedure; display group number
001).
Output at Possible cause Repair

printer
17115
P0731
1. Gear
Wrong  This DTC is displayed in  For correction see also DTC 17114/P0730:
gear addition to DTC 17114/P0730
ratio
 Clutch for the gear indicated is  Perform control element diagnosis. Refer to
slipping/faulty or solenoid Control element diagnosis/Output Diagnostic
valve for this gear is Test Mode (DTM).
contaminated/faulty  See clutch logic or solenoid valve logic. Refer to
CONTROLS, HOUSING for 5 SPD.
CONTROLS, HOUSING for 5 SPD.
This DTC is displayed in addition to DTC 17114/P0730 when a detected, unacceptable gear ratio
(implausibility) is found.

17116 P0732
2. Gear
Wrong gear ratio  This DTC is  For correction see also
1:50:14 AM Page 39
displayed in DTC 17114/P0730:

addition to DTC
17114/P0730
 Clutch for the gear  Perform control element
indicated is diagnosis. Refer to
slipping/faulty or Control element
solenoid valve for diagnosis/Output
this gear is Diagnostic Test Mode
contaminated/faulty (DTM).
 See clutch logic or
solenoid valve logic.
Refer to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

17117 P0733
1:50:14 AM Page 40
3. Gear
addition to DTC
17114/P0730
Refer to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:14 AM Page 41

17118 P0734
4. Gear
addition to DTC
17114/P0730
Refer to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:14 AM Page 42

17119 P0735
5. Gear
addition to DTC
17114/P0730
Refer to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:14 AM Page 43
(implausibility) is found

17125 P0741
Clutch for torque converter lock up
No transmission of  ATF level not  Check ATF level. Refer
power O.K. or ATF to
contaminated  37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
converter
 Pressure control  Read Measured Value
valve 4 -N218- Block. Refer to Test
faulty procedure; display
 Problems in the group number 007 and
ATF feed to the check converter clutch
pressure control (closed) and permissible
valve 4 -N218- torque converter
slippage.
 Torque converter  Replace pressure control
pressure valve valve or valve body.
1:50:14 AM Page 44
faulty Refer to
 Torque converter  38 -
clutch valve AUTOMATIC
faulty TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Clutch for torque  Replace torque
converter lock up converter. Refer to
faulty/worn  32 - TORQUE
CONVERTER
for 5 SPD.
AUTOMATIC
TRANSMISSION
01V
 32 - TORQUE
CONVERTER
for 5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:14 AM Page 45
 Electrical  Correct fault according

energizing of to DTC 18237/P1829 or
Pressure Control 18238/P1830.
Valve 4 -N218-
faulty
 The ratio of transmission input RPM -G182- to engine RPM with the torque converter clutch closed does
not match (implausibility).

17135 P0751
Shift valve 1. Refer to solenoid valve 1 N88
Open circuit/short  Open circuit or  Check wiring and wiring
circuit to ground short circuit to connectors following
ground wiring diagram 3)
 Solenoid valve  Perform control element
faulty diagnosis. Refer to
Control element
diagnosis/Output
(DTM).
 Read Measured Value
Block. Refer to Test
procedure; display
group number 005.
 Perform electrical test.

Refer to Electrical
Testing.
 Replace solenoid valve
or valve body. Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
1:50:14 AM Page 46
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Short circuit to B+ is already checked with the ignition switched ON. All types of DTCs are recognized
during operation.

17136 P0752
Shift valve 1. Refer to Solenoid Valve 1 -N88-
Short circuit to B+  Short circuit to  Check wiring and wiring
B+ connectors following
wiring diagram 3)
Control element
diagnosis/Output
(DTM).
procedure; display
group number 005.

Refer to Electrical
Testing.
1:50:14 AM Page 47

 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
during operation.

17137 P0753
Shift Valve 1. Refer to Solenoid Valve 1 -N88-
Electrical fault in  Open circuit or  Check wiring and wiring
circuit short circuit to connectors following
Control element
1:50:15 AM Page 48
diagnosis/Output
(DTM).
procedure; display
group number 005.

Refer to Electrical
Testing.
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

17140 P0756
1:50:15 AM Page 49

Control element
diagnosis/Output
(DTM).
procedure; display
group number 005.

Refer to Electrical
Testing.
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:15 AM Page 50
during operation.

17141 P0757
wiring diagram 3)
Control element
diagnosis/Output
(DTM).
procedure; display
group number 005.

Refer to Electrical
Testing.
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
1:50:15 AM Page 51
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
during operation.

17142 P0758
Control element
diagnosis/Output
(DTM).
procedure; display
group number 005.

Refer to Electrical
Testing.
 38 -
AUTOMATIC
1:50:15 AM Page 52
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

17145 P0761
Control element
diagnosis/Output
(DTM).
procedure; display
group number 005.
1:50:15 AM Page 53

Refer to Electrical
Testing.
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
during operation.

17146 P0762
1:50:15 AM Page 54
wiring diagram 3)
Control element
diagnosis/Output
(DTM).
procedure; display
group number 005.

Refer to Electrical
Testing.
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:15 AM Page 55
during operation.

17147 P0763
Control element
diagnosis/Output
(DTM).
procedure; display
group number 005.

Refer to Electrical
Testing.
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
1:50:15 AM Page 56
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

17968 P1560
Maximum engine RPM exceeded  Signal from  Read Measured Value
engine RPM Block. Refer to Test
sensor to Engine procedure; display
Control Module group number 001.
(ECM) faulty  Read DTC memory for
 Engine Speed Engine Control Module
(RPM) sensor - (ECM) and repair fault.
G28- faulty
 Engine RPM
signal is being
falsified by
incorrectly routed
electrical wiring
(e.g. aftermarket
installation of a
telephone)
 Unacceptable  Read Measured Value
transmission Block. Refer to Test
downshifting (e.g. procedure; display
as the result of a group number 005 and
mechanically determine while driving
faulty valve body) where servos are faulty
or not active.
individual solenoid
valves or valve body.
Refer to
 38 -
AUTOMATIC
TRANSMISSION
1:50:15 AM Page 57
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Condition for DTC recognition: Engine speed higher than 7400 RPM.

18112 P1704
Kickdown Switch -F8- 6)
Electrical fault in circuit  Open circuit in  Read Measured
CAN-bus wire Value Block. Refer
to Test procedure;
display group
number 125.
 Check CAN-bus.
Refer to Data
Exchange between
Transmission
Control Module
(TCM) and CAN-
Capable Control
Modules,
checking.
 Short circuit or  Read DTC memory
1:50:15 AM Page 58
open circuit for Engine Control

between accelerator Module (ECM) and
pedal module and repair fault.
Engine Control  Check wiring
Module (ECM) connections and
 Accelerator pedal harness connectors
module faulty using wiring
diagram.
 Replace accelerator
pedal module.
Refer to 20 -
FUEL SUPPLY
SYSTEM
6) No mechanical switch; a specific value from the throttle and accelerator position sensors -G79-/-G185- is set
in the Engine Control Module (ECM). Signal transmission from Engine Control Module (ECM) to
Transmission Control Module takes place over CAN-bus.
 With the brake pedal depressed and simultaneous full depression of the accelerator pedal as far as
Kickdown (wide-open throttle) this fault can be displayed erroneously.
DTC CHART PART 2, UP TO DIAGNOSTIC TROUBLE CODE 18269/P1861
DTC Chart Part 2, up to Diagnostic Trouble Code 18269/P1861

18141 P1733
Tiptronic Switch, downshift -F189-
Short circuit to ground  Tiptronic Switch,  Read Measured Value
downshift -F189- Block. Refer to Test
group number 011.
 Short circuit to  Check wiring
ground in the connections and harness
electrical wiring connectors using wiring
 Short circuit to diagram.
ground in the
Tiptronic buttons
on the multi-
function steering
wheel or in the
wiring
1:50:15 AM Page 59
 Solenoid in the  Replace printed circuit

roll cover for shift board 7) or roll cover 8)
mechanism has for shift mechanism.
become detached Refer to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
7) The Tiptronic Switch -F189- consists of switches for recognition, upshift and downshift. It is integrated in
the shift mechanism printed circuit board, i.e. if the Tiptronic Switch -F189- is faulty, the printed circuit board
has to be replaced.
8) The Tiptronic Switch -F189- receives its Tiptronic gate recognition or upshift/downshift information through
the solenoid on the transverse slide on the roll cover. If the solenoid has become detached, the roll cover must
be replaced.
 DTC is displayed if the downshift switch 7) was detected shifting outside selector lever position D.

18147 P1739
Tiptronic Switch, upshift -F189-
upshift -F189- Block. Refer to Test
1:50:15 AM Page 60

group number 011.
ground in the
Tiptronic buttons
on the
multifunction
steering wheel or
in the wiring
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
has to be replaced.
1:50:15 AM Page 61
be replaced.
 DTC is displayed if the upshift switch7) was detected shifting outside selector lever position D.

18152 P1744
Tiptronic Switch, recognition -F189-
recognition - Block. Refer to Test
F189- 9) faulty procedure; display
group number 011.
ground in the
Tiptronic buttons
on the
multifunction
steering wheel or
in the wiring
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
1:50:15 AM Page 62
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
has to be replaced.
be replaced.
9) If the transmission is shifted into the Tiptronic gate with the selector lever in D this shift procedure is
recognized by the Tiptronic recognition switch -F189- and transmitted to the Transmission Control Module
(TCM).
 DTC is displayed if Tiptronic recognition was detected, although the selector lever is not in the Tiptronic
gate.

18153 P1745
Power supply for solenoid valves
Short circuit to B+  Short-circuit of  Check power supply
Transmission for Transmission
Control Module Control Module
(TCM) -J217- (TCM) -J217-, also
terminals 52, 53 to read Measured Value
B+. Block. Refer to Test
procedure; display
group number 003.
 Check wiring and
wiring connectors
following wiring
diagram 3)
 Perform electrical
test. Refer to
Electrical Testing.
 Transmission  Replace
Control Module Transmission Control
(TCM) -J217- Module. Refer to
1:50:16 AM Page 63
faulty Electrical/electronic
components and
component
locations.

18155 P1747
Power supply for solenoid valves
Open circuit/short circuit  Open circuit in  Check power supply
to ground wiring or short for Transmission
circuit to ground Control Module
in Transmission (TCM) -J217-, also
Control Module read Measured Value
(TCM) -J217- Block. Refer to Test
terminals 52, 53 procedure; display
group number 003.
 Check wiring and
wiring connectors in
accordance with
wiring diagram 3)
test. Refer to
Electrical Testing.
components and
component
locations.
18156 P1748
Control module faulty  Transmission  Replace
components and
component
locations.
1:50:16 AM Page 64
Only after determining the possible fault cause and correcting the following faults:
 Mechanical faults
 Hydraulic faults
 Electrical/electronic components and wiring connections

18158 P1750
Power supply
Voltage too low  Open circuit or  Check power supply
short circuit to for Transmission
ground Control Module
 Battery monitoring (TCM) -J217-, also
detects fault read Measured Value
procedure; display
group number 003.
 Check wiring
connections and
harness connectors
using wiring diagram.
test. Refer to
Electrical Testing.
 Open circuit/short  Replace
circuit to Transmission Control
permanent B+ in Module. Refer to
the Transmission Electrical/electronic
Control Module components and
(TCM) component
locations.
 Condition for DTC recognition: Battery voltage 9 volts or less. Refer to transmission goes into limp home
mode. Refer to Safety functions of the Transmission Control Module (TCM).
 With a loss of electrical system voltage (terminal 30) the adaptation values in the Transmission Control
Module (TCM) are reset. The control module has to relearn these values after resumption of operation.
During this "learning process" shift quality may be worse than normal.
1:50:16 AM Page 65

18159 P1751
Power supply
Voltage too high  Generator or  Check power supply
voltage regulator for Transmission
faulty Control Module
 Second battery (TCM) -J217-, also
was inadvertently read Measured Value
connected in Block. Refer to Test
series, for procedure; display
example while group number 003.
jump starting.  Check wiring
connections and
harness connectors

Refer to Electrical
Testing.
 Voltage regulator  Check voltage
for Generator regulator for generator
faulty/faulty and replace if
necessary. Refer to
 27 BATTERY,
STARTER,
GENERATOR,
CRUISE
CONTROL
 27 BATTERY,
STARTER,
GENERATOR,
CRUISE
CONTROL for
ELECTRICAL
EQUIPMENT,
CABRIOLET
 Condition for DTC recognition: Battery voltage above 16 volts

 This DTC was also displayed, for example, when jump starting with a 24 volt battery.
 Battery monitoring distinguishes four ranges (U = battery voltage):
1) U less than 7 volts. Refer to transmission goes into limp home mode. Refer to Safety functions of the
Transmission Control Module (TCM)
1:50:16 AM Page 66
2) U 7...9 volts. Refer to gear is held for about 2.5 seconds, if U is still in this range afterward, transmission
goes into limp home mode. Refer to Safety functions of the Transmission Control Module (TCM)
3) U 9...16 volts. Refer to voltage is O.K.
4) U higher than 16 volts. Refer to transmission goes into limp home mode. Refer to Safety functions of the

18161 P1753
Tiptronic Switch -F189-
Implausible signal  Individual Hall  Check adjustment of selector
sensors are not lever cable. Refer to
switching to  37 - AUTOMATIC
ground TRANSMISSION -
CONTROLS,
HOUSING for 5 SPD.
AUTOMATIC
TRANSMISSION 01V
 37 - AUTOMATIC
TRANSMISSION -
CONTROLS,
HOUSING for 5 SPD.
AUTOMATIC
TRANSMISSION 01V
FRONT AND ALL
WHEEL DRIVE -
INTERNAL
COMPONENTS,
SERVICING
procedure; display
group number 002.
 Replace printed circuit
board 7) for shift
mechanism. Refer to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
1:50:16 AM Page 67
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Connector at the  Check wiring connections and
shift mechanism harness connectors using
not attached wiring diagram.
 Shift mechanism
has no power
supply
 All 3 Tiptronic
wires have an
open circuit
has to be replaced.

18169 P1761
Shift Lock. Refer to Solenoid -N110-
Short circuit to ground  Short circuit to  Check wiring and wiring
ground in the connectors in accordance
electrical wiring with wiring diagram.
11)
 Fuse faulty
 Shift Lock  Perform control element
Solenoid -N110- diagnosis. Refer to
faulty Control element
diagnosis/Output
(DTM).
1:50:16 AM Page 68

procedure; display
group number 00 3.

Refer to Electrical
Testing.
 Replace Shift Lock
Solenoid -N110-. Refer
to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Short circuit on  Replace shift mechanism
the shift printed circuit board.
mechanism Refer to
printed circuit  37 -
board AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
1:50:16 AM Page 69
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Transmission  Replace Transmission
Control Module Control Module. Refer to
component locations.
11) Shift Lock Solenoid -N110- cannot be switched OFF, i.e. the selector lever cannot be shifted out of selector
lever positions P or D, even by actuating the brake pedal.

18170 P1762
Shift Lock. Refer to Shift Lock Solenoid -
N110-
Short circuit to B+  Short circuit to  Check wiring
B+ in the connections and harness
12) diagram.
 Shift Lock  Perform control element
Solenoid -N110- diagnosis. Refer to
faulty Control element
diagnosis/Output
(DTM).
procedure; display
group number 003.

Refer to Electrical
1:50:16 AM Page 70
Testing.
 Replace Shift Lock
Solenoid -N110-. Refer
to
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
 Short circuit on  Replace shift mechanism
the shift printed circuit board.
mechanism Refer to
printed circuit  37 -
board AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
TRANSMISSION
01V
 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING for 5
SPD.
AUTOMATIC
1:50:16 AM Page 71
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
Control Module - Control Module. Refer to
J217- faulty Electrical/electronic
components and
component locations.
12) Shift Lock Solenoid -N110- cannot be activated in selector lever position P and N, i.e. it cannot be shifted
out of P and N without actuating the brake pedal.

18171 P1763
Shift Lock. Refer to Shift Lock Solenoid -N110-
Open circuit  Open  Check wiring
circuit in connections
the and harness
electrical connectors
wiring 12) using wiring
diagram.
 Shift Lock  Perform control element diagnosis.
Solenoid - Refer to Control element
N110- faulty diagnosis/Output Diagnostic Test
Mode (DTM).
 Read Measured Value Block. Refer
to Test procedure; display group
number 003.
 Perform electrical test. Refer to

Electrical Testing.
 Replace Shift Lock Solenoid -N110-
. Refer to
 37 - AUTOMATIC
TRANSMISSION -
CONTROLS, HOUSING
for 5 SPD. AUTOMATIC
TRANSMISSION 01V
 37 - AUTOMATIC
TRANSMISSION -
1:50:16 AM Page 72
CONTROLS, HOUSING
TRANSMISSION 01V
FRONT AND ALL WHEEL
DRIVE - INTERNAL
COMPONENTS,
SERVICING
 Transmission  Replace Control Module. Refer to
Control Electrical/electronic components
Module -J217- and component locations.
faulty
12) Shift Lock Solenoid -N110- for shift lever lock cannot be activated in selector lever position P and N, i.e. it
cannot be shifted out of P and N without actuating the brake pedal.

18222 P1814
Pressure Control Valve 1 -N215-
circuit to ground short circuit to connectors in accordance
ground with wiring diagram 3)
 Pressure control  Perform control element
valve faulty diagnosis. Refer to
Control element
diagnosis/Output
(DTM).
procedure; display
group number 006.

Refer to Electrical
Testing.
 Replace pressure control
valve or valve body.
Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
1:50:16 AM Page 73
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

18223 P1815
B+ connectors in accordance
with wiring diagram 3)
Control element
diagnosis/Output
(DTM).
procedure; display
group number 006.

Refer to Electrical
Testing.
 Replace Pressure Control
1:50:16 AM Page 74
Valve or valve body.

Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

18227 P1819
Control element
diagnosis/Output
(DTM).
1:50:16 AM Page 75

procedure; display
group number 006.

Refer to Electrical
Testing.
Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

18228 P1820
1:50:16 AM Page 76

Control element
diagnosis/Output
(DTM).
procedure; display
group number 006.

Refer to Electrical
Testing.
Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING
1:50:17 AM Page 77

18232 P1824
Control element
diagnosis/Output
(DTM).
procedure; display
group number 006.

Refer to Electrical
Testing.
Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
1:50:17 AM Page 78
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

18233 P1825
Control element
diagnosis/Output
(DTM).
procedure; display
group number 006.

Refer to Electrical
Testing.
Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
1:50:17 AM Page 79
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

18237 P1829
Control element
diagnosis/Output
(DTM).
procedure; display
group number 007.

Refer to Electrical
Testing.
Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
1:50:17 AM Page 80
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

18238 P1830
Control element
diagnosis/Output
(DTM).
procedure; display
group number 007.

Refer to Electrical
1:50:17 AM Page 81
Testing.
Refer to
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V
 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS for
5 SPD.
AUTOMATIC
TRANSMISSION
01V FRONT AND
ALL WHEEL
DRIVE -
INTERNAL
COMPONENTS,
SERVICING

18249 P1841
Engine Control Module (ECM)/Transmission
Control Module (TCM)
Versions do not match  Incorrect  Check
Transmission Transmission
Control Module Control Module
(TCM) installed (TCM)
identification
number.
 Incorrect or faulty  Verify Engine
1:50:17 AM Page 82
Engine Control Control Module

Module (ECM) (ECM)
identification
number and scan
DTC memory.
18258 P1850
Data bus drive 13)
Missing message from  Open circuit in  Read Measured
Engine Control Module CAN-bus wire Value Block. Refer
(ECM) to Test procedure;
display group
number 125.
 Check CAN-bus.
Refer to Data
Exchange between
Transmission
Control Module
(TCM) and CAN-
Capable Control
Modules,
checking.
13) The data bus is also described as a CAN-bus.
 Condition for DTC recognition: The Transmission Control Module (TCM) is not receiving a message
from the Engine Control Module (ECM). However, communication with the ABS control module and the
instrument cluster is working.
 The exchange of data and information between the Engine Control Module (ECM), ABS control module,
Transmission Control Module (TCM) and instrument cluster is carried out over what is called a CAN-
bus. All information signals are transmitted over 2 lines.

18259 P1851
Data bus drive 13)
ABS control module CAN-bus wire Value Block. Refer
to Test procedure;
display group
number 125.
 Check CAN-bus.
Refer to Data
Exchange between
1:50:17 AM Page 83
Transmission
Control Module
(TCM) and CAN-
Capable Control
Modules,
checking.
 Condition for DTC recognition: The Transmission Control Module (TCM) is not receiving a signal from
the ABS control module. However, communication with the Engine Control Module (ECM) and the
instrument cluster is functioning.

18262 P1854
Data bus drive 13)
Faulty  Transmission  Replace
Control Module - Transmission Control
J217- faulty Module. Refer to
Electrical/electronic
components and
component
locations.
18263 P1855
Data bus drive 13)
Monitoring software  Open circuit in  Read Measured
status CAN-bus wire Value Block. Refer to
Test procedure;
display group number
125.
 Check CAN-bus.
Refer to Data
Exchange between
Transmission
Control Module
(TCM) and CAN-
Capable Control
Modules, checking.
 Incorrect  Check Transmission
1:50:17 AM Page 84
Transmission Control Module

Control Module (TCM) identification
(TCM) number.
Note on DTCs 18262/P1854 and 18263/P1855:

18265 P1857
Load signal
Error message from  Error in the "Signal  Read Engine
Engine Control Module for Actual Engine Control Module
(ECM) Torque" diagnosed (ECM) DTC
by Engine Control memory and repair
Module (ECM) fault.
 Incorrect or faulty  Check Engine
Module (ECM) or (ECM)
engine components identification
faulty number and read
DTC memory.
 The signal for actual engine torque is transmitted by the Engine Control Module (ECM) over the CAN-
bus circuit to the Transmission Control Module (TCM).
 Conditions for DTC recognition: The Engine Control Module (ECM) diagnoses the fault in the particular
component. This fault diagnosis is transmitted over the CAN-bus circuit to the Transmission Control
Module (TCM).

18269 P1861
Throttle Position Sensor (TP) -G79- 14)
Error message from the  Short circuit or  Read DTC memory
Engine Control Module open circuit for Engine Control
between accelerator Module (ECM) and
pedal module and repair fault.
Engine Control  Check wiring and
Module (ECM) wiring connectors
1:50:17 AM Page 85
 Accelerator pedal in accordance with

module faulty wiring diagram 5)
 Replace accelerator
pedal module.
Refer to 20 -
FUEL SUPPLY
SYSTEM
14) The Throttle Position Sensor and sender for accelerator pedal position -G79-/-G185- are present.
 The signal for throttle position and accelerator pedal position sensors is transmitted by the Engine Control
Module (ECM) over the CAN-bus circuit to the Transmission Control Module (TCM).
 Conditions for DTC recognition: The Engine Control Module (ECM) diagnoses the fault in the particular
component. This fault diagnosis is transmitted over the CAN-bus circuit to the Transmission Control
Module (TCM).
CONTROL ELEMENT DIAGNOSIS/OUTPUT DIAGNOSTIC TEST MODE (DTM)
Control element diagnosis/Output Diagnostic Test Mode (DTM)
NOTE:  Control element diagnosis can only be performed if the ignition is ON, the
selector lever is in position "P", the engine is not running and the vehicle
is stationary.
 Control element diagnosis is terminated if the engine is started.
 Solenoid Valve 1 -N88-, Solenoid Valve 2 -N89-, Solenoid Valve 3 -N90-,
Pressure Control Valve 1 -N215- and Shift Lock Solenoid -N110- are tested
acoustically during control element diagnosis. Ambient noises must be
avoided during the acoustical test.
 Pressure Control Valve 2 -N216-, Pressure Control Valve 3 -N217- and
Pressure Control Valve 4 -N218- are energized through control element
diagnosis. Acoustical testing is made more difficult by the fact that these
valves click very quietly, which can be heard only in the area of the ATF oil
pan. However, any electrical faults that occur when the valves are
energized are saved in the DTC memory by the On Board Diagnostic (OBD)
system.
 During control element diagnosis the individual actuators are energized
for approximately 45 seconds, unless the test is automatically advanced to
the next actuator by pressing the delta button.
 To repeat control element diagnosis, switch the ignition OFF and ON
again.
1:50:17 AM Page 86
Energizing sequence
1. Shift Valve 1. Refer to Solenoid Valve 1 -N88-
4. Shift Lock. Refer to Solenoid -N110-
5. Pressure Control Valve 1 -N215-
9. Power supply for solenoid valves
Test sequence
 Connect VAS 5051 Vehicle Diagnosis, Measurement- and Information System. Refer to VAS 5051

 In selection touch -1- diagnostic function "03 - Control element diagnosis".

 Touch delta button.
1:50:17 AM Page 87
Fig. 31: Display On VAS 5051 - (Actuator Test Is Pending/Shift Valve (Solenoid Valve 1 -N88-))
A - Actuator test is pending - Test must be advanced
1 - Shift Valve 1. Refer to Solenoid Valve 1 -N88-
A - Actuator test is running - Test may be advanced
 This valve is energized (clicks) for approximately 45 seconds , unless the test is automatically advanced
to the next actuator by touching the delta button.
NOTE: Any electrical malfunctions are saved in the DTC memory. Refer to Diagnostic
Trouble Code (DTC) table.
If the valve is not energized (does not click):
 Perform electrical test. Refer to Electrical Testing

1:50:17 AM Page 88

1:50:18 AM Page 89
 This valve is energized (clicks) for approximately 45 seconds, unless the test is automatically advanced to
the next actuator by touching the delta button.

1:50:18 AM Page 90
Fig. 34: Display On VAS 5051 - (Actuator Test Is Pending/Shift Lock Solenoid -N110-))
4 - Shift Lock Solenoid -N110-
 The Shift Lock Solenoid -N110- is triggered at intervals for about 45 seconds (clicks), unless control
element diagnosis is terminated by touching the delta button.
NOTE: In addition, the brake symbol on the shift mechanism cover must illuminate at
intervals.
If the solenoid is not energized (does not click):

1:50:18 AM Page 91
Fig. 35: Display On VAS 5051 - (Actuator Test Is Pending/Pressure Control Valve 1 -N215-))
5 - Pressure Control Valve 1 -N215-

1:50:18 AM Page 92
NOTE: The valve can be heard clicking very faintly only in the area of the ATF oil pan.
Any electrical malfunctions are saved in the DTC memory. Refer to Diagnostic

1:50:18 AM Page 93

1:50:18 AM Page 94

1:50:18 AM Page 95
Fig. 39: Display On VAS 5051 - (Actuator Test Is Pending/Power Supply For Solenoid Valves))
9 - Power supply for solenoid valves
NOTE: This actuator can be ignored. To continue control element diagnosis, touch the
delta button.
Fig. 40: Display On VAS 5051 - (Output Diagnostic Test Mode Is Completed)
A - Actuator test is concluded
1:50:18 AM Page 96
 End function "03 - Control element diagnosis" by touching <-- button.
DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, ERASING
Diagnostic Trouble Code (DTC) memory, erasing
Requirements:
 DTC memory scanned. Refer to Diagnostic Trouble Code (DTC) memory, scanning.
 All malfunctions corrected.
After DTC scan has been checked:

 In selection touch -1- diagnostic function "05 - Delete DTC memory".

1:50:18 AM Page 97
1 - No display (before deletion)
Or
DTC memory deleted
NOTE: If the message appears in display field -1-: "DTC memory has not been scanned
yet", the test procedure was not followed exactly. The DTC memory can only be
deleted if the DTC memory was scanned previously.
2 - you sure you want to do this? will be deleted!
 Touch "OK" button in display -2-.

 End function "05 - Delete DTC memory" by touching <-- button.
 After repair scan DTC memory again.
NOTE: This deletes DTCs which were stored during repair of the fault, for example by
removing harness connectors.
 After scanning and deleting DTC memory, test drive vehicle and scan DTC memory again.
The scan of the DTC memory must display:
"No DTC recognized"
ADAPTATION VALUES FOR TRANSMISSION CONTROL MODULE (TCM), BASIC SETTING
Adaptation values for Transmission Control Module (TCM), basic setting
NOTE:  Following repairs to the valve body (e.g. replacing solenoid valves), if the
valve body, the torque converter or the transmission is replaced, the
adaptation values in the Transmission Control Module (TCM) should be
reset. This allows the adaptation values for normal operation in the
Transmission Control Module (TCM) to be learned more quickly following
resumption of operation.
 Adaptation values in the Transmission Control Module (TCM) are reset if:
 Multiple connector is removed from Transmission Control Module (TCM) for at least 15 minutes. Refer
to Transmission Control Module (TCM) -J217-, removing and installing
 Battery is disconnected for at least 15 minutes
Refer to
1:50:18 AM Page 98

 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT,
CABRIOLET
TRANSMISSION CONTROL MODULE (TCM), CODING
Transmission Control Module (TCM), coding
The Transmission Control Module (TCM) can be coded.
NOTE: Coding can only be performed with the ignition ON and with the selector lever
in position "P" or "N". Accelerator pedal must remain in idle position. Vehicle
must be stationary and the engine must not be started.
Test procedure
selection, touch vehicle system "02 - Transmission Electronics". Ignition must be switched ON.

 In selection, touch -1- diagnostic function "07 - Coding control module".
1:50:18 AM Page 99

1 - Enter code word
 On keypad -2- enter control module coding.
Code For vehicles

Number
01002 USA, Canada, Mexico
 Confirm entry by pressing Q button.
NOTE: After coding, the Transmission Control Module DTC memory is automatically
deleted.

1:50:19 AM Page 100

1 - Coding is being carried out
Fig. 46: Diagnostic System VAS 5051: Display - (Coding Of Vehicle System Performed & Control Module
Identification With New Coding)
1 - Coding in the vehicle system completed
2 - Control module identification number with new coding
(previous coding in parentheses)
 Terminate function "07 - Coding Control Module" by pressing <-- button.
MEASURED VALUE BLOCK, READING
Measured Value Block, reading
Test procedure
 Connect VAS 5051 Vehicle Diagnosis, Measurement- and Information System. Refer to VAS 5051
or, depending on the desired operation:
 Start engine.
1:50:19 AM Page 101


 In selection touch -1- diagnostic function "08 - Read Measured Value Block".

1 - Enter display group
 On key pad -2- enter desired 3-digit display group number. Refer to List of Selectable Display Group
Numbers and confirm entry by touching Q-button.
Example:
 Entry "001" for "Display group number 001" and confirm by touching Q button.
1:50:19 AM Page 102

Fig. 49: Diagnostic System VAS 5051: Display Zones

1 - Read Measured Value Block
2 - Display field 1
Display field 2
Display field 3
Display field 4
3 - Display Group X
NOTE:  If a display field is not being used, there will be no display.

 To switch to another display field, proceed as follows:
Display group VAS 5051

Higher Press button s
Lower Press button t
 End function "08 - Read Measured Value Block" by touching <-- button.
List of Selectable Display Group Numbers
Display on screen (example)

Display fields: Display Display Description
Group Field
Number
1 2 3 4
1:50:19 AM Page 103

Read Measured Value Block 001 1 Engine RPM

2 Sensor for transmission RPM -G182-
0 RPM 0 RPM 0 RPM 4 3 Sender for transmission output RPM -G195-
4 Gear selected
Read Measured Value Block 002 1 Current program
2 Accelerator pedal value
DS 0% 0 RPM 4 3 Sender for transmission output RPM -G195-
4 Gear selected
Read Measured Value Block 003 1 Brake light switch -F-
2 Shift Lock Solenoid -N110-
PN active 0 kph 12.8 V 3 Speed
4 Supply voltage terminal 15
Display on screen
(example)
Group
Number Field
1 2 3 4
Read Measured Value 004 1 ATF-temperature
Block
2 Selector lever position - Multi-function Transmission
Range (TR) Switch -F125-
21.0°C P 1000 0101 3 Multi-function Transmission Range (TR) Switch position
4 Information for On-Board-Diagnostic System
Read Measured Value 005 1 Solenoid Valve 1 -N88-
Block
2 Solenoid Valve 2 -N89-
0 0 0 4 3 Solenoid Valve 3 -N90-
4 Gear selected
Read Measured Value 006 1 Specified current for Pressure Control Valve 1 -N215-
Block
2 Specified current for Pressure Control Valve 2 -N216-
0.048 0.048 0.048 0 3 Specified current for Pressure Control Valve 3 -N217-
A A A
4 Can be ignored

Group
Number Field
1 2 3 4
1:50:19 AM Page 104

Read Measured Value Block 007 1 ATF temperature

2 Specified current for Pressure Control Valve
4 -N218-
21.0°C 0.048 Torque 0 3 Torque converter clutch
A Converter clutch RPM
open
4 Torque converter slip RPM
Read Measured Value Block 008 1 Kick-down Switch
2 Accelerator pedal value
0% Deceleration 3 Deceleration/Power mode
4
Read Measured Value Block 009 1 Actual engine torque
2 Engine RPM
176 0 RPM 0 % 0 Nm 3 Accelerator pedal value
Nm
4 Transmission input torque

Group
Number Field
1 2 3 4
Read Measured Value Block 010 1 Torque increase in the torque converter
2 Engine RPM
0.0 0 RPM 4 0.00 ms2 3 Gear selected
4 Actual vehicle acceleration
Read Measured Value Block 011 1 Selector lever position
2 Tiptronic recognition
D M switch Upshift switch 3 Tiptronic Switch, upshift/downshift -F189-
4
Read Measured Value Block 012 1 Type of driving, load
2 Dynamic code number
E 56 80 45 3 Rolling resistance index
4 Driver evaluation

Group
Number Field
1 2 3 4
Read Measured Value Block 013 1 CAN-bus normalizing torque
2 CAN-bus engine code number
1:50:19 AM Page 105

420 Nm 4 0 11 3 CAN-bus transmission code number

4 CAN-bus software status code number
Read Measured Value Block 125 1 Engine Control Module (ECM) is participant on the
CAN-bus
2 CAN-bus
Engine ABS Steering 3 Steering column electronics system is participant on
1 1 wheel 1 the CAN-bus
4
Test table
Display Display Description Test conditions Specified Steps in the events of

group field Value deviations from specified
number Displayed value
001 1 Engine RPM With the engine 0...  See DTC
running 8200 17968/P1560
RPM
2 Transmission input While With gear  See DTC
RPM from sensor for driving engaged 17100/P0716
transmission RPM - 1)
G182-
R 0...
8200
RPM
1. 1m 0...
2000
RPM
2 0...
8200
RPM
3 0...
8200
RPM
Continued 4 0...
8200
RPM
? 5 0...
8200
RPM
1) While driving: A second technician is needed to read the specified values.

group field Value deviations from
1:50:19 AM Page 106

number Displayed specified value

001 3 Transmission output While With gear  See DTC
RPM from transmission driving engaged 17105/P0721
output RPM sensor - 1)
G195-
R 0...
2000
RPM
1.1 m 0...
2000
RPM
2 0...
4000
RPM
3 0...
5800
RPM
Continued 4 0...
8200
RPM
? 5 0...
8200
RPM
Note on display group number 001, display fields 2 and 3:
 Test condition: Shifting must be completed. Vehicle not decelerating (not driving downhill or engine
braking).
Display Display Description Test conditions Specified Steps in the events of deviations
group field Value from specified value
number Displayed
001 4 Gear While Selector  Check solenoid valves and
selected driving lever pressure control valves,
1) position display group number 005,
006 and 007
"N" "1"..."5" 2)
"R" "R"  Check selector lever
position, display group
number 004
"D" "1m" "2"
"3" "4" "5"
1:50:19 AM Page 107

"S" "1m" "2"

"3" "4"
2) The Transmission Control Module (TCM) is equipped with automatic gear slaving. The forward gear, which
the Transmission Control Module (TCM) would activate during a driving mode change with the selector lever
in "D", is displayed.
Notes on display group number 001, display field 4:
 Faulty solenoid valves or other diagnosed faults can prevent a specific gear from being engaged.
Display Display Description Test conditions Specified Steps in the events of deviations from
group field Value specified value
number Displayed
002 1 Current In normal Is determined by driving style and road
program operation 1) conditions (acceleration, accelerator
pedal movement, speed and load)
Dynamic shift DS Shifts are avoided as much as possible
program is
activated
Warm up WL Upshifts are made sooner in order to
program is avoid high RPM
activated
Automatic AS
Traction Control
activated
Continued Tiptronic TT  See DTCs 18141/P1733,
? recognition 18147/P1739 and 18152/P1744
activated

002 2 Accelerator Engine Accelerator 0...1 % When accelerating from idle
pedal value not pedal not to Wide Open Throttle the %
running depressed value increases steadily
Accelerator 99...100  See DTC 18269/P1861
pedal fully %
depressed
3 Transmission See display group number 001, display field 3
output RPM
1:50:19 AM Page 108

4 Gear selected See display group number 001, display field 4

group field Value deviations from specified value
number Displayed
003 1 Brake light Brake Actuated Brake  See DTC 17087/P0703
switch F pedal
Not -
actuated
2 Shift Lock In selector lever  See DTCs 18169/P1761,
Solenoid - position P or N 18170/P1762 and
N110- 18171/P1763
Brake Actuated PN
pedal inactive
Not P N active
actuated
3 Speed While driving 1) ..km/h The speedometer display and
values on the tester can show
minor divergences
4 Supply voltage Stationary min. 10.0 V  Check fuses and wiring
terminal 15 following wiring diagram
max. 16.0 V  Perform electrical test.
Refer to Electrical
Testing
Display Display Description Test conditions

Specified Steps in the events of
004 1 ATF temperature Stationary with the ..°C  See DTCs 17094/P0710,
engine running 17095/P0711,
17096/P0712 and
17097/P0713
2 Selector lever Stationary Selector  Check conformance with
position - lever Transmission Range
Multi-function position (TR) Selector Lever
Transmission Display -Y6- in the
Range (TR) instrument cluster
Switch -F125-
P P  Check Multi-function
Transmission Range
(TR) Switch -F125-
1:50:20 AM Page 109

Display group number

004, display field 3
R R
N N
Continued D D
? S S
Notes on ATF temperature:
 A detected temperature of -50°C indicates a short circuit to ground.

 A detected temperature of 180°C indicates a short circuit to B+ or an open circuit.

004 2 Selector lever Stationary Selector  Check Multi-function
position - lever Transmission Range
Multi-function position (TR) Switch -F125-
Transmission between Display group number
Range (TR) 004, display field 3
Switch -F125-
Intermediate P and R Z1
positions when Or
operating the R and N
selector lever
Continued N and D Z2
? D and S Z3
Notes on the intermediate positions:
If the selector lever is shifted into one of the intermediate positions mentioned, "Z1", "Z2" or "Z3" is shown on
the display. No selected gear must be shown in the display in the instrument cluster , that is to say, only PRNDS
is displayed, without a gear being lit up.

004 3 Selector lever Stationary Selector L1 L2 L3 L4  See DTC
position - lever 17090/P0706
Multi-function position
Transmission Range
(TR) Switch -F125-
P 1 0 0 0
R 0 1 0 0
1:50:20 AM Page 110

N 1 1 1 0
Continued D 1 0 1 1
? S 0 1 1 1
Notes on display field 3 in display group number 004:
 The input signals for Multi-function Transmission Range (TR) Switch -F125- can be checked at the
Transmission Control Module (TCM).
Display field 3 (from left to right):

L1 L2 L3 L4
Wiring connection to Transmission Terminal 36 of Terminal 8 of Terminal 37 of Terminal 9 of
Control Module (TCM) -J217- -J217- -J217- -J217- -J217-
Display Display Description Test Specified Steps in the events of

group field conditions Value deviations from specified
004 4 On-Board-Diagnostic While
System information driving 1)
Readout on display from
left to right
Malfunction display Switched 1
ON
Switched 0
OFF
Trip Completed 1
Not 0 Can be ignored
completed
Transmission warm-up Completed 1
Not 0
completed
Engine start Detected 1
Not detected 0

005 1 Solenoid Valve While Gear  See DTCs 17135/P0751,
1 -N88- driving 1) selected 17136/P0752 and
17137/P0753
R, 1, 1m, X
1:50:20 AM Page 111

2, 5
3, 4 0
2 Solenoid Valve While Gear  See DTCs 17140/P0756,
17142/P0758
Continued 1, 2, 3 X
? R, 1m, 4, 0
5
Note on the solenoid valves:
 Non-switched (inactive) solenoid valves are shown with "0", switched (active) solenoid valves are shown
with "X".

005 3 Solenoid Valve While Gear  See DTCs 17145/P0761,
17147/P0763
X 5)
R, 1, 1m, 0
2, 3, 4, 5
5) Solenoid Valve 3 -N90- is actuated only briefly during certain shift operations.
Note on the solenoid valves:
 Non-switched (inactive) solenoid valves are shown with "0", switched (active) solenoid valves are shown
with "X".

006 1 Specified current for While  See DTCs 18222/P1814
Pressure Control Valve 1 driving 1) and 18223/P1815
-N215-
min. 0.0 A
max. 2.0
1:50:20 AM Page 112

A
2 Specified current for While  See DTCs 18227/P1819
-N216-
min. 0.0 A
max. 2.0
A
3 Specified current for While  See DTCs 18232/P1824
-N217-
min. 0.0 A
max. 2.0
A
4 Can be ignored
Note on specified current for pressure control valves:
 Faulty solenoid or pressure control valves, clutches or other faults can prevent a specific gear from being
engaged.

007 1 ATF temperature See display group number 004, display field 1
2 Specified current for While  See DTCs
Pressure Control Valve driving 1) 18237/P1829 and
4 -N218- 18238/P1830
min. 0.0 A
max. 2.0 A
3 Torque converter While Torque  See DTC
clutch driving 1) Converter 17125/P0741
clutch open
Continued Torque
Converter
clutch control
? Converter
clutch closed
Note on specified current for pressure control valves:
1:50:20 AM Page 113

 Faulty solenoid or pressure control valves, clutches or other faults can prevent a specific gear from being
engaged.
Display Display Description Test conditions Specified Steps in the events of deviations from
group field Value specified value
number Displayed
007 4 Torque While Torque 0...full  See DTCs 17105/P0721 and
converter driving converter Braking 17125/P0741
slip RPM 1) clutch open RPM
Torque 20...120  Determine which servo is faulty or
converter RPM not activated. Refer to
clutch
 37 - AUTOMATIC
control
(last shift at TRANSMISSION -
least 20 CONTROLS, HOUSING
seconds for 5 SPD. AUTOMATIC
previously) TRANSMISSION 01V
 37 - AUTOMATIC
TRANSMISSION -
CONTROLS, HOUSING
TRANSMISSION 01V
FRONT AND ALL
WHEEL DRIVE -
INTERNAL
COMPONENTS,
SERVICING
; Power Train Chart; Position of
Shift Elements
Converter 0...20  Check plausibility between
clutch RPM engine, transmission input RPM-
closed and transmission RPM; display
group number 001
Test conditions for torque converter slip RPM:
 "Converter clutch closed" The shift must be completed (wait at least 1 second), the torque converter
lockup clutch (WK) must be closed and accelerator pedal value must be constant.
 "Converter clutch control": The values given apply to the "adjusted condition" of the converter clutch.
Under unfavorable conditions (for example, accelerating on a hill) this condition will not be reached until
20 seconds after the completion of the shift. During this adjustment phase, slip values up to 350 RPM can
be reached.
 Excessive converter slip RPM figures can also indicate slipping clutches or servos not activated.
1:50:20 AM Page 114


008 1 Kickdown Switch - Engine Not actuated -  See DTC
F8- not 18112/P1704
running
Kickdown Kickdown
actuated)
2 Accelerator pedal See display group number 002, display field 2
value
3 Deceleration/Power While Deceleration Deceleration While driving downhill
signal driving mode or slowing down (engine
1) brake)
Power mode - In normal operation,
engine is delivering
power
6) Kickdown point passed at throttle pedal.
Display Display Description Test Specified Steps in the events of deviations from
group field conditions Value specified value
number Displayed
009 1 Engine torque While Nm The signal for actual engine torque is
driving 1) transmitted by the Engine Control Module
(ECM) over the CAN-bus circuit to the
transmission control module (TCM)
See DTC 18265/P1857


2 Engine RPM See display group number 001, display field 1

3 Accelerator See display group number 002, display field 2
pedal value
4 Transmission While .. Nm Should behave similarly to display field 1.
input torque driving 1) Can be ignored at this time
Note on display field 1
The signal for actual engine torque is transmitted by the Engine Control Module (ECM) over the CAN-bus
circuit to the Transmission Control Module (TCM)
Display Display Description Test Specified Steps in the events of deviations

group field conditions Value from specified value
1:50:20 AM Page 115

number Displayed
010 1 Torque increase in While 0...3.2 Is calculated by the Transmission
the converter driving 1) Control Module (TCM) from
converter slip RPM
2 Engine RPM See display group number 001, display field 1
4 Actual vehicle While min. -10 Can be ignored
acceleration driving 1) m/s2

011 1 Selector lever position See display group number 004, display field 2
2 Tiptronic Switch, Selector lever in M switch  See DTC
recognition -F189- the Tiptronic gate 18152/P1744
Selector lever not -
in the Tiptronic
gate
3 Tiptronic Switch, Selector lever in  See DTCs
upshift/downshift - the Tiptronic gate 18141/P1733 and
F189- 18147/P1739
Not actuated -
Upshifting 7) Upshift
switch
Downshifting 8) Downshift
switch
7) You must activate the upshift switch (+) by tapping the selector lever forward. On vehicles with multi-
function steering wheel the upshift switch has to be activated by additionally tapping the upper left or right
button (+) on the steering wheel.
8) You must activate the downshift switch (-) by tapping the selector lever to the rear. On vehicles with multi-
function steering wheel the downshift switch has to be activated by additionally tapping the lower left or right
button (-) on the steering wheel.

012 1 Type of No load driving, for E
driving, load example on a level road
Driving under load, for B
example driving uphill
1:50:20 AM Page 116

2 Dynamic code Is calculated from rolling 0...256 Can be ignored at this

number resistance index and driver time
evaluation
3 Rolling Is required in order to 0...256
resistance index calculate the dynamic code
number
4 Driver Is required in order to 0...256
evaluation calculate the dynamic code
number

013 1 CAN-bus Stationary with .. Nm Can be ignored
Standardization the ignition ON
torque
2 CAN-bus 0... 63  See DTC 18249/P1841
Engine code
number
3 CAN-bus 1  Verify Engine Control
Transmission code Module (ECM) coding
number
4 CAN-bus 0... 63  See DTC 18263/P1855
Software status
code number
Note on display group number 013:
 Display field 2 and 4: When the Engine Control Module (ECM) is replaced, the same display as on the
old control module must appear after installing the new control module. If this is not the case, the wrong
Engine Control Module (ECM) has been installed, or it has been incorrectly coded.

125 1 Participant on Stationary Participates Engine 1  Check CAN-bus. Refer to
CAN-bus drive: Data Exchange between
Engine Control Transmission Control
Module (ECM) Module (TCM) and
CAN-Capable Control
Modules, checking
Does not Engine 0
participate
2 Participant on Stationary Participates ABS 1  Check CAN-bus. Refer to
CAN-bus drive:
1:50:20 AM Page 117

ABS control Data Exchange between

module Transmission Control
Module (TCM) and
CAN-Capable Control
Modules, checking
Does not ABS 0
participate
3 Participant on Stationary Participates Steering  Check CAN-bus. Refer to
CAN-bus drive: wheel 1 Data Exchange between
Control module Transmission Control
for steering Module (TCM) and
column CAN-Capable Control
electronics Modules, checking
Does not Steering
participate wheel 0
Notes on display group number 125
 If "1" is displayed, communication from the corresponding control module to the Transmission Control
Module (TCM) is O.K.
 If "0" is displayed and no fault has been set in the DTC memory, the corresponding control module does
not have CAN capability (or is faulty).
ELECTRICAL TESTING
Electrical Testing
1:50:21 AM Page 118

Fig. 50: Identifying Special Tools - Electrical Testing

 V.A.G 1526 A
 V.A.G 1527 B
 V.A.G 1594 A
 V.A.G 1598/20
NOTE:  For testing, use Multimeter V.A.G 1526 A or Vehicle Diagnosis,

Measurement and Information System VAS 5051. The charts contain the
specific measurement methods which have to be set up before the
corresponding measurements.
 The specified values given are valid for an ambient temperature of 0°C to
1:50:21 AM Page 119

40°C.
 If the values measured deviate from the specified values, determine
malfunctions following the wiring diagram.
 If the values measured show only a minor deviation from the specified
values, clean cavities and connectors on the test equipment and test
leads, repeat test. Before replacing the components in question, check
their wires and connectors. In particular, with specified values under 10
ohms , repeat the resistance measurement on the component.
 The terminal numbers of the connector and the cavity numbers on the
V.A.G 1598/20 test box match. Refer to Multiple harness connector (88-pin
connector) of Transmission Control Module (TCM) -J217- (cavities on
V.A.G 1598/20).
CAUTION: In order to avoid destroying electronic components, the specific

measurement range on the measuring equipment must be switched on
before connecting the test leads.
Test requirements:

Test procedure

 Remove Transmission Control Module (TCM). Refer to Transmission Control Module (TCM) -J217-,
removing and installing and separate multiple connector. Refer to Transmission Control Module
(TCM) -J217-, removing and installing.
1:50:21 AM Page 120

Fig. 51: V.A.G 1598/20 Test Box

 Connect V.A.G 1598/20 test box to control module wiring harness.

 If values measured deviate from specifications, perform "Steps in event of deviations from specified
value" in right-hand column of test table. Refer to Test table.
 Perform all steps in column "Steps in the event of deviations from specified value"
 Perform only test steps recommended in Test table ("selective troubleshooting")
Multiple harness connector (88-pin connector) of Transmission Control Module (TCM) -J217- (cavities on V.A.G 1598/20)
1 Pressure Control Valve 2 -N216- 18 Not used

2 Shift Lock Solenoid -N110- 19 Not used
3 Not used 20 Not used
4 Pressure Control Valve 4 -N218- 21 Transmission Fluid Temperature Sensor -G93-
(ATF)
5 Pressure Control Valve 1 -N215- 22 Transmission Fluid Temperature Sensor -G93-
(ATF)
6 Ground for power consumers (terminal 31) 23 Not used
8 Multi-function Transmission Range (TR) Switch - 25 Not used
F125- L2
9 Multi-function Transmission Range (TR) Switch - 26 Supply voltage (terminal 30)
F125- L4)
12 Not used 29 Pressure Control Valve 3 -N217-
13 Tiptronic Recognition 30 Solenoid Valve 1 -N88-
14 Sender for transmission output RPM -G195- 31 Not used
15 Sender for transmission output RPM -G195- 32 Solenoid Valve 3 -N90-
(suppression shield)
16 Sensor for transmission RPM -G182- 33 Solenoid Valve 2 -N89-
1:50:21 AM Page 121

17 Not used 34 Ground for power consumers (terminal 31)
35 Not used 54 Supply voltage (terminal

15)
36 Multi-function 55 Supply voltage (terminal
Transmission Range (TR) 15)
Switch -F125- L1
37 Multi-function 56 Not used
Transmission Range (TR)
Switch -F125- L3
38 Not used -
39 Not used -
40 Not used -
41 Not used -
42 Sender for transmission -
output RPM -G195-
43 Not used -
44 Sensor for transmission - Cavities 57 to 83 are not
RPM -G182- used
45 Not used -
46 Tiptronic upshift -
47 Tiptronic downshift -
48 Not used -
50 Not used 85 CAN-bus 1)
51 Not used 86 CAN-bus 1)
52 Power supply for the 87 Not used
solenoid valves
53 Power supply for the 88 K-Diagnostic circuit
solenoid valves
1) Signal is transmitted over the Engine Control Module (ECM) to the Transmission Control Module (TCM)
and can only be checked in the Measured Value Block. Refer to Test procedure.
Chart of Test Steps (88-pin multiple connector)
 Perform only the test steps listed by component in the DTC Chart and the Measured Value Block.
Component Tested Component Tested

Power supply for  Perform Pressure Control  Perform test steps 11 and 6.
control module - test steps 1 Valve 2 -N216-
J217- and 5.
Shift Lock Solenoid  Perform Pressure Control  Perform test steps 12 and 6.
1:50:21 AM Page 122

-N110- test steps 2 Valve 3 -N217-

and 14.
Multi-function  Perform Pressure Control  Perform test steps 13 and 6.
Transmission Range test steps 3 Valve 4 -N218-
(TR) Switch -F125- and 4.
Solenoid Valve 1 -  Perform Sender for  Perform test step 15.
N88- test steps 7 transmission output
and 6. RPM -G195-
Solenoid Valve 2 -  Perform Transmission Fluid  Perform test step 16.
N89- test steps 8 Temperature Sensor
and 6. -G93- (ATF)
Solenoid Valve 3 -  Perform CAN-bus  Check CAN-bus. Refer to Data
N90- test steps 9 Exchange between Transmission
and 6. Control Module (TCM) and CAN-
Capable Control Modules,
checking.
Pressure Control  Perform
Valve 1 -N215- test steps
10 and 6.
Test table
Switch on measurement range: Voltage measurement

Test V.A.G What is being tested  Test
Specified Steps in the event of
step 1598/20 conditions Value deviations from specified
value
 Additional
procedures
1 54 + 34 Power supply for the  Ignition
Approximate  Check wiring routing
54 + 6 Transmission Control switched battery voltage using wiring diagram.
55 + 34 Module (TCM) -J217- ON
55 + 6
26 + 6 Electrical system  Ignition Approximate  Check wiring routing
26 + 34 voltage terminal 30 switched battery voltage using wiring diagram.
from Transmission OFF
-J217-
2 2 + 6 Shift Lock Solenoid -  Ignition Approximate  Check wiring routing
N110- switched battery voltage using wiring diagram.
ON  Check Multi-function
Transmission Range
(TR) Switch -F125- for
short circuit.
1:50:21 AM Page 123

 Check solenoid -N110-

for short circuit.
 Perform test step 14.

Test V.A.G What is being  Test
Specified Steps in the event of deviations
step 1598/20 tested conditions Value from specified value
 Additional
procedures
3 36 + 34 Multi-function  Ignition Approximate  Check harness connector at
36 + 6 Transmission switched ON battery voltage Multi-function Transmission
Range (TR) Range (TR) Switch for
Switch -F125-  Selector corroded terminals.
lever in "P",
"N" or "D"
 Selector Less than  Check Multi-function
lever in "R" 1 volt Transmission Range (TR)
or "S" Switch. Refer to Multi-
function Transmission
Range (TR) Switch -F125-,
checking.
8 + 34  Selector Approximate  Check power supply to
8+6 lever in "R", battery voltage Multi-function Transmission
"N" or "S" Range (TR) Switch. Refer to
Check power supply to
Multi-function TR switch.
 Selector Less than  Perform test step 4.
lever in "P" 1 volt
or. "D"
37 + 34  Selector Approximate
37 + 6 lever in "N", battery voltage
"D" or "S"
 Selector Less than
lever in "P" 1 volt
or. "R"
9 + 34  Selector Approximate
9+6 lever in "D" battery voltage
or "S"
 Selector Less than
lever in "P", 1 volt
"R" or. "N"
1:50:21 AM Page 124

Switch on measurement range: Resistance measurement

 Additional
procedures
4 55 + 36 Multi-function  Ignition Less than  Check harness connector at
Transmission switched OFF 1 ohms Multi-function Transmission
Range (TR) Switch Range (TR) Switch for
-F125-  Selector lever corroded terminals.
in "P", "N" or
"D"
 Selector lever infinity  Check Multi-function
in "R" or "S" ohms Transmission Range (TR)
Switch. Refer to Multi-
function Transmission Range
(TR) Switch -F125-, checking.
55 + 8  Selector lever Less than  Perform test step 3.
in "R", "N" or 1 ohms
"S"
 Selector lever infinity
in "P" or "D" ohms
55 + 37  Selector lever Less than
in "N", "D" 1 ohms
or "S"
in "P" or "R" ohms
55 + 9  Selector lever Less than
in "D" or "S" 1 ohms
in "P", "R" or ohms
"N"

Specified Steps in the event of deviations from
step 1598/20 tested conditions specified value
Value
 Additional
procedures
5 6+ Ground  Ignition
Less than  Check wiring routing using wiring
ground to connections for switched 1 ohms diagram.
battery the control OFF
1:50:21 AM Page 125

module -J217-
34 + Less than
ground to 1 ohms
battery
6 52 + 53 Feed wires for  Ignition Less than  Check wiring routing using wiring
solenoid valves switched 1.5 ohms diagram.
OFF  Check harness connector control
module to 16-pin connector. Refer
to Harness connectors between
the Transmission Control Module
(TCM) and transmission,
checking.
 Perform test step 1.

 Check wiring harness intermissions
following wiring diagram.

Test V.A.G What is  Test
Specified Steps in the event of deviations from specified
step 1598/20 being conditions value
tested Value
 Additional
procedures
7 52 + 30 Solenoid  Ignition
25...35  Check 16-pin harness connector to
Valve 1 - switched ohms transmission for corroded terminals.
N88- OFF
30 + 34 infinity  Perform test step 6.
ohms
25...35  Check harness connector from control
Valve 2 - switched ohms module to 16-pin connector. Refer to
N89- OFF Harness connectors between the
and transmission, checking.
33 + 34 infinity  Check wiring harness intermissions
ohms following wiring diagram, replace if
necessary.
25...35  Replace solenoid valve.
Valve 3 - switched ohms
N90- OFF
32 + 34 infinity Refer to
ohms
1:50:22 AM Page 126


01V
01V FRONT AND ALL WHEEL DRIVE
- INTERNAL COMPONENTS,
SERVICING

Test V.A.G What is  Test
Specified Steps in the event of deviations from specified
step 1598/20 being conditions value
tested Value
 Additional
procedures
10 52 + 5 Pressure  Ignition
6...8  Check 16-pin harness connector to
Control switched ohms transmission for corroded terminals.
Valve 1 - OFF
N215-
5 + 34 infinity  Perform test step 6.
ohms
6...8  Check harness connector from control
Control switched ohms module to 16-pin connector. Refer to
Valve 2 - OFF Harness connectors between the
N216- Transmission Control Module (TCM)
and transmission, checking.
1 + 34 infinity
ohms
6...8  Check wiring harness intermissions
Control switched ohms following wiring diagram, replace if
Valve 3 - OFF necessary.
N217-
29 + 34 infinity  Replace pressure control valve.
ohms
6...8 Refer to
Control switched ohms
Valve 4 - OFF  38 - AUTOMATIC TRANSMISSION -
N218- GEARS, HYDRAULIC CONTROLS
TRANSMISSION 01V
GEARS, HYDRAULIC CONTROLS
TRANSMISSION 01V FRONT AND
1:50:22 AM Page 127

ALL WHEEL DRIVE - INTERNAL

4 + 34 infinity
ohms

step 1598/20 tested conditions Value specified value
 Additional
procedures
14 2 + 54 Shift Lock  Ignition 14...28  Check wiring routing using wiring
Solenoid - switched ohms diagram.
N110- OFF  Replace Shift Lock Solenoid -N110-..
Refer to
 Selector
 37 - AUTOMATIC
lever in "P"
TRANSMISSION -
CONTROLS, HOUSING for 5
SPD. AUTOMATIC
TRANSMISSION 01V
 37 - AUTOMATIC
TRANSMISSION -
SPD. AUTOMATIC
TRANSMISSION 01V FRONT
AND ALL WHEEL DRIVE -
SERVICING
15 14 + 42 Sender for  Ignition Minimum  Check wiring routing using wiring
transmission switched 0.8 k diagram.
output RPM - OFF ohms
G195-
Maximum
1.2 k
ohms
14 + 34 infinity  Replace sender for transmission output
14 + 54 ohms RPM -G195-.. Refer to
42 + 54
 38 - AUTOMATIC
42 + 34
TRANSMISSION - GEARS,
HYDRAULIC CONTROLS for
5 SPD. AUTOMATIC
TRANSMISSION 01V
 38 - AUTOMATIC
1:50:22 AM Page 128

HYDRAULIC CONTROLS for

5 SPD. AUTOMATIC
SERVICING
15 + 34 Suppression infinity  Check wiring routing using wiring
15 + 54 shield for - ohms diagram.
G195-

 Additional
procedures
16 21 + 22 Transmission  Ignition  Check harness connector from
Fluid switched control module to 16-pin
Temperature OFF connector. Refer to Harness
Sensor -G93- connectors between the
(TCM) and transmission,
checking.
 ATF
Temperature
Approximately Approximately
20°C 0.83 k ohms 1)
60°C 1.28 k ohms 1)
20°C 1.88 k ohms 1)
21 + 34  Ignition infinity ohms  Check wiring harness in
22 + 34 switched transmission, replace if
OFF necessary.
21 + 54 infinity ohms Refer to
22 + 54
 38 - AUTOMATIC
HYDRAULIC CONTROLS
TRANSMISSION 01V
 38 - AUTOMATIC
HYDRAULIC CONTROLS
1:50:22 AM Page 129


SERVICING
; Removing and Installing Valve

Body
1) Permissible tolerance: ± 0.1 k ohms
Harness connectors between the Transmission Control Module (TCM) and transmission, checking
Perform this test if the control element diagnosis or the electrical test points to problems between the
transmission and Transmission Control Module (TCM) -J217-.
Test procedure

 Connect V.A.G 1598/20 test box to control module wiring harness.
1:50:22 AM Page 130

Fig. 53: Removing Sound Insulation

 Remove sound deadening -arrows-.
Checking harness connectors to the 16-pin connector at the transmission
And Cable Tie
 Unscrew retainer -1- for sound deadening.

 Rotate locking lever -3- and remove connector for transmission wiring harness.
1:50:22 AM Page 131

Fig. 55: Identifying 16-Pin Connector

 Connect Multimeter to make a resistance measurement between terminals of 16-pin connector and
cavities of test box V.A.G 1598/20, as described in following chart.
 Specified value always less than 1.5 ohms
Connector Test box V.A.G 1598/20 Connector Test box V.A.G 1598/20
Terminal Cavity Terminal Cavity
1 42 9 33
2 5 10 14
3 1 11 4
4 32 12 52
5 16 13 22
6 44 14 21
7 29 15 Terminal is not used
8 30 16 53
NOTE:  In the event of deviations from the specified value, repair open circuit
following wiring diagram and check connector for corroded terminals,
water entry and leakage.
 If this test revealed no unacceptable deviations, the wiring harness in the
transmission must be tested.
Refer to

1:50:22 AM Page 132

; Removing and Installing Valve Body
 Only if the wiring harness in the transmission is O.K. should the appropriate solenoids or pressure control
valves be replaced.
Refer to

; Removing and Installing Valve Body
Multi-function Transmission Range (TR) Switch -F125-, checking
NOTE:  Before performing the electrical test on the Multi-function Transmission

Range (TR) Switch, you must first check the Measured Value Block for the
multifunction switch. Refer to Test procedure, display ground number 004
 Make sure that the selector lever cable is correctly adjusted.
Refer to

TRANSMISSION 01V
SERVICING
Functional Test
Fig. 56: Disconnecting Connector For Multi-Function Transmission Range (TR) Switch -F125- At Front
1:50:22 AM Page 133

 Disconnect connector -arrow- for Multi-function Transmission Range (TR) Switch -F125- at front left of
transmission.
Fig. 57: Identifying Multi-Function Transmission Range (TR) Switch -F125- Connector
Terminal pinout at the connector for Multi-function Transmission Range (TR) Switch -F125-.

Test Terminals What is being  Test
step for -F125- tested conditions specified value
1) Value
 Additional
procedures
1 1+2 Multi-function  Ignition
Less than  Check connector at Multi-
Transmission switched 1 ohms function TR switch for corroded
Range (TR) OFF terminals, water entry or a loose
Switch -F125- fit.
 Selector
lever in "P",
"N" or "D"
 Selector
infinity  Check adjustment of selector
lever in "R" ohms lever cable.
or "S"
1+3  Selector
Less than Refer to
lever in "R", 1 ohms
"N" or "S"  37 - AUTOMATIC
TRANSMISSION -
SPD. AUTOMATIC
TRANSMISSION 01V
1:50:23 AM Page 134

 37 - AUTOMATIC
TRANSMISSION -
SPD. AUTOMATIC
SERVICING
 Selector infinity  Replace Multi-function TR
lever in "P" ohms switch.
or "D"
1+4  Selector Less than Refer to
lever in "N", 1 ohms
"D" or "S"  37 - AUTOMATIC
TRANSMISSION -
SPD. AUTOMATIC
TRANSMISSION 01V
 37 - AUTOMATIC
TRANSMISSION -
SPD. AUTOMATIC
SERVICING
 Selector infinity
lever in "P" ohms
or "R"
1+5  Selector Less than
lever in "D" 1 ohms
or "S"
 Selector infinity
lever in "P", ohms
"R" or "N"
1) Terminal pinout at the connector for Multi-function TR switch

Test Terminals What is  Test
Step at -F125- being conditions specified value
1) tested Value
 Additional
procedures
1:50:23 AM Page 135

2 9 + 10 Multi-  Ignition infinity  Check connector at Multi-function TR

function switched ohms switch for corroded terminals, water
TR switch OFF entry or a loose fit.
P/N signal
 Selector
lever in "R",
"D" or "S"
 Selector Less than  Check adjustment of selector lever
lever in "P" 1 ohms cable.
or "N"
3 7+8 Multi-  Ignition infinity . Refer to
function switched ohms
TR switch OFF  37 - AUTOMATIC
backup TRANSMISSION - CONTROLS,
light  Selector HOUSING for 5 SPD. AUTOMATIC
signal lever in "P", TRANSMISSION 01V
"N", "D" or  37 - AUTOMATIC
"S" TRANSMISSION - CONTROLS,
HOUSING for 5 SPD. AUTOMATIC
TRANSMISSION 01V FRONT AND
ALL WHEEL DRIVE - INTERNAL
 Selector Less than  Replace Multi-function Transmission
lever in "R" 1 ohms Range (TR) Switch -F125-. Refer to
 37 - AUTOMATIC
TRANSMISSION -
SPD. AUTOMATIC
TRANSMISSION 01V
 37 - AUTOMATIC
TRANSMISSION -
SPD. AUTOMATIC
SERVICING
1) Terminal pinout at the connector for Multi-function TR switch
Check power supply to Multi-function TR switch
1:50:23 AM Page 136


 Attach Multimeter for a voltage measurement between following terminals of 10-pin connector.
Connector Specified value

Terminal
1 + 10 Approximate battery
Voltage
7 + 10 Approximate battery
Voltage
If a specified value is not reached:
 Repair open circuit or short circuit as necessary.
Check wiring connection between 10-pin connector for multi-function switch and Transmission Control Module (TCM)
1:50:23 AM Page 137


 Connector V.A.G 1598/20 test box to control module wiring harness.

 Connect multimeter to make a resistance measurement between terminals of 10-pin connector and
cavities of test box V.A.G 1598/20, as described in following chart:
Connector Test box V.A.G 1598/20 Specified value

Terminal Cavity
1 54 or 55 < or = 1.5 ohms
2 36 < or = 1.5 ohms
3 8 < or = 1.5 ohms
4 37 < or = 1.5 ohms
5 9 < or = 1.5 ohms
6 Terminal is not used
7 Refer to Test Step 3,
8
9 Refer to Test Step 2,
1:50:23 AM Page 138

10
NOTE:  In the event of deviations from the specified value, repair open circuit
following wiring diagram and check connector for corroded terminals,
water entry and leakage.
 If this test revealed no unacceptable deviations, Multi-function
Transmission Range Switch -F125- must be replaced.
Refer to

TRANSMISSION 01V
SERVICING
Starter Interlock Alarm System Relay -J60-, checking
removing and installing and place it to one side with connector still attached.
 Turn ignition key to "Start" position.
 Move selector lever from "S" to "P" and back.
Fig. 61: Identifying Starter Interlock Alarm System Relay -J60-

 It must be possible both to hear and feel the Starter Interlock Alarm System Relay -J60- (in the relay
carrier plenum panel E-box, pin location 4) engage
 As long as no malfunction is present, the starter can be operated with the selector lever in position "N" or
"P"
If the relay does not engage:
1:50:23 AM Page 139

 Check Starter Interlock Alarm System Relay -J60-. Refer to Check power supply to Starter Interlock
Alarm System Relay -J60-.
If the relay engages but the starter does not turn:
 Check wiring connections from Starter Interlock Alarm System Relay -J60- to starter terminal 50
following wiring diagram, or check starter respectively.
Check power supply to Starter Interlock Alarm System Relay -J60-
 Disconnect Starter Interlock Alarm System Relay -J60-.

 Connect V.A.G 1527 B voltage tester as follows:
Relay carrier in the plenum panel E-Box, pin location 4 Measure to

Terminal
1 Engine ground
5 Engine ground
 Turn ignition key to "Start" position.
 LED must illuminate each time
If the LED does not illuminate:
Check activation of Starter Interlock Alarm System Relay -J60-
1:50:23 AM Page 140


 Connect V.A.G 1527 B voltage tester as follows:
Relay carrier in the plenum panel E-Box, pin location 4 Measure to

Terminal
3 B+
 Move selector lever from "S" to "P" and back.
 With the selector lever in "N" or "P" the LED must illuminate, but not in other selector lever positions
If the LED does not illuminate:
 Check adjustment of selector lever cable.
Refer to

TRANSMISSION 01V
SERVICING
 Check Multi-function Transmission Range (TR) Switch -F125-. Refer to Multi-function Transmission
Range (TR) Switch -F125-, checking.
Data Exchange between Transmission Control Module (TCM) and CAN-Capable Control Modules, checking
NOTE:  The exchange of data between the individual control modules is carried
1:50:23 AM Page 141

out by means of a bus system.

 "CAN-bus" describes a system to carry and distribute data.
 The wiring connections between the control modules, over which the data
are transmitted, are described as data lines.
 Data are transmitted serially, that means in sequence, over these data
lines to the attached control modules (e.g. engine RPM, accelerator pedal
position).
Checking bus system
In the DTC Chart you were instructed to verify the exchange of data between the Transmission Control Module
(TCM) and CAN-capable control modules.

 In selection touch -1- diagnostic function "08 - Read Measured Value Block".
1:50:24 AM Page 142


NOTE: Measured Value Block 125 shows the participants on the data BUS drive.
 On keypad enter -2- "125" for "Display Group Number 125" and confirm by touching Q button.
Fig. 66: Diagnostic System VAS 5051: Display - Display Fields

 Check display in display fields -1- to -3-.
The display shows the control modules which are CAN-capable with the Engine Control Module (ECM):
 Display 1: CAN capable control module is participant on the data bus

 Display 0 or no display: CAN-capable control module is not participant on the data bus or not CAN-
capable
1:50:24 AM Page 143

 End function "08 - Read Measured Value Block" by touching <-- button.

 In selection -1- touch diagnostic function "00 - Scan DTC memory - complete system".
 Now the DTC memory of all systems in the vehicle capable of self-diagnosis is scanned.
If a control module responds and identifies itself, the number of stored trouble codes or "No trouble code" is
displayed.
Any stored DTCs in a system are shown in sequence. Then the VAS 5051 sends the next address word.
If a DTC referring to "Data bus drive..." Or "...CAN-bus" is displayed:
 Check whether correct Engine Control Module (ECM) and other CAN-capable control modules have
been installed (Part No. and Code).
If the correct control modules have been installed:
 Check whether multiple connectors for control modules are fully seated.
If the multiple connectors are fully seated.
 Check CAN-bus system.
Checking a "Dual-Wire-Bus System"
Communication takes place between two or more control modules over a "Dual-Wire-Bus System".
 Analyze DTCs stored in control modules.
1:50:24 AM Page 144

NOTE: The analysis helps you to pinpoint the wiring fault.
Example 1:
Based on the DTCs entered in the DTC memories, you can see that control module 1 is not connected to control
modules 2 and 3.
Control module DTCs entered in the DTC memory:

1  Message missing from control module 2
 Message missing from control module 3

 Disconnect control modules connected by bus wiring and check whether one bus wiring connection has
an open circuit.
 If no malfunction is found in bus wiring, replace control module 1.
Example 2:
Based on the DTCs entered in the DTC memories, you can see that control module 2 is not connected to control
modules 1 and 3.


 Disconnect control modules connected by bus wiring and check whether one of bus wiring connections
has an open circuit.
Example 3:
1:50:24 AM Page 145

Based on the DTCs entered in the DTC memory, you see that no transmission or reception activity is possible in
any of the control modules.

1  Data bus drive faulty
Fig. 68: Checking Bus Wires For Short Circuit To B+ Or Ground

 Disconnect control modules connected by bus wiring and inspect bus wiring for a short circuit to B+ and
to ground.
If you are unable to determine any cause in the bus wiring for the DTC "Data bus drive faulty", check to
see whether one of the control modules is responsible for this DTC.
Test requirement:
 VAS 5051 Vehicle Diagnosis, Measurement and Information System connected and Vehicle Self
Diagnosis selected. Refer to VAS 5051 Vehicle Diagnosis, Measurement and Information System,
connecting and selecting functions.
All the control modules which use the CAN-bus for communication are disconnected. The ignition is switched
OFF.
 Connect one control module.
1:50:24 AM Page 146



 Touch appropriate vehicle system in Display -1-.
 Read DTC memory of control module just connected and delete it.
 In display touch -1- diagnostic function "06 - End output".

 Switch ignition OFF and ON again.
 Leave ignition switched ON for 10 seconds. Then, using scan tool, read DTC memory of control module
just connected.
 If DTC "Data bus drive faulty" is read, control module just connected must be replaced.
 If DTC "Data bus drive not faulty" is not read, connect next control module and repeat procedure.
1:50:24 AM Page 147



1 - Transmission Control Module J217
 Component location and removing and installing --> Component location of Transmission Control
Module (TCM) J217
 Disconnecting multi-pin connector --> Disconnecting Transmission Control Module (TCM) J217
from multi-pin harness connector
1:42:27 AM
1:42:36 Page 1
 Installation location Data Link Connector (DLC)
 Component location and removing and installing --> Multi-Function Transmission Range (TR) Switch
F125
4 - Internal transmission wiring harness with integrated Transmission Fluid Temperature Sensor G93 (ATF)
 Component location and removing and installing --> Internal transmission wiring harness with
integrated Transmission Fluid Temperature Sensor G93 (ATF)
5 - Valve body
 Component location and removing and installing Valve body

 Calculates transmission RPM

 Component location and removing and installing --> Sensor for transmission RPM G182
G195 )
 Calculates transmission output RPM

 Component location and removing and installing --> Transmission Vehicle Speed Sensor (VSS) G38
 Component location and removing and installing --> Tiptronic Switch F189
9 - Shift Lock Solenoid N110
 Component location and removing and installing --> Shift lock solenoid N110
10 - Throttle Position (TP) Sensor G79 and G185
1:42:27 AM Page 2
 Component location and removing and installing and under Throttle Position (TP) sensor G79 and
G185
11 - Starting Interlock Relay J207
 Installation location --> Starting Interlock Relay J207
12 - Transmission Range (TR) Selector Lever Display Y6
 Component location and removing and installing --> Transmission Range (TR) Selector Lever Display
Y6
 Unlit selected gear display indicates emergency mode with inactive Transmission Control Module
(TCM).
 Completely lit selected gear display indicates emergency mode with active Transmission Control Module
(TCM).
13 - Brake light switch F
 Component location and removing and installing --> Brake light switch F
Component location of Transmission Control Module (TCM) J217
Fig. 19: Component Location Of Transmission Control Module (TCM) J217

Control module is located in left plenum chamber in e-box under Engine Control Module (ECM).
Removing and installing the control module
-->
 97 WIRING
1:42:27 AM Page 3
 97 WIRING for ELECTRICAL EQUIPMENT, CABRIOLET
If control module for engine or transmission is replaced, the system must be put into basic setting.
 Perform basic setting in "Vehicle Self-Diagnosis" using the tester VAS5051.
Disconnecting Transmission Control Module (TCM) J217 from multi-pin harness connector
Fig. 20: Disconnecting Transmission Control Module (TCM) J217 From Multi-Pin Harness Connector
 Disengage harness connector (arrow) and disconnect it from Transmission Control Module (TCM).

Installation location: Data Link Connector (DLC) is located under driverside storage compartment.
 Connect tester VAS5051 to Data Link Connector (DLC) using diagnostic cable VAS5051/1 and adapter
VAS6017 with ignition switched off.
1:42:27 AM Page 4
Valve body

Installation location: Valve body is bolted on to transmission housing below and covered by transmission oil
pan.
Solenoid valves N88 , N89 , N90 , and pressure control valves N215 , N216 , N217 , N218 are fastened to valve
body.
Removing and installing valve body
--> Valve body, removing and installing
1:42:27 AM Page 5
Internal transmission wiring harness with integrated Transmission Fluid Temperature Sensor G93 (ATF)
Fig. 23: Internal Transmission Wiring Harness With Integrated Transmission Fluid Temperature Sensor
G93 (ATF)
Installation location: Transmission Fluid Temperature Sensor (arrow) is located in the wiring harness on valve
body.
Wiring harness may be replaced with transmission installed and valve body removed.
--> Wiring harness inside transmission, removing and installing
Transmission Vehicle Speed Sensor (VSS) G38
Fig. 24: Transmission Vehicle Speed Sensor -G38-

Installation location: Transmission Vehicle Speed Sensor is located on rear right of transmission. Also referred
to as the sender for transmission output RPM G195.
Removing and installing Transmission Vehicle Speed Sensor (VSS)
1:42:27 AM Page 6
--> Transmission Vehicle Speed Sensor (VSS) G38 , removing and installing
Sensor for transmission RPM G182
Sensor for transmission RPM - A - is fastened to transmission housing behind valve body. This sensor is a Hall
sensor.
Removing and installing Sensor for transmission RPM G182
--> Sensor for transmission RPM G182 , removing and installing
Multi-Function Transmission Range (TR) Switch F125
Fig. 26: Location Of Multi-Function Transmission Range (TR) Switch

1:42:27 AM Page 7
Installation location: Multi-Function Transmission Range (TR) Switch - 1 - is located at left on transmission;
multi-pin connector for Multi-Function Transmission Range (TR) Switch - 2 -.
Removing and installing Multi-Function Transmission Range (TR) Switch
--> Multi-Function Transmission Range (TR) Switch F125 , removing and installing
Tiptronic Switch F189
Fig. 27: Tiptronic Switch F189

Installation location: Tiptronic switch is integrated into circuit board of symbol insert, which is located in shift
mechanism cover.
--> Tiptronic Switch F189 , removing and installing
Fig. 28: Shift Lock Solenoid N110

1:42:27 AM Page 8
Installation location: Shift lock solenoid is located in the shift mechanism - arrow -.
Shift lock solenoid, removing and installing
--> Shift Lock Solenoid N110 , removing and installing
Starting Interlock Relay J207
Fig. 29: Starting Interlock Relay J207

Installation location: Relay is located in central electronics.
Assignment
--> Electrical Wiring Diagrams, Troubleshooting and Component Locations
Throttle Position (TP) sensor G79 and G185
Fig. 30: Throttle Position (TP) Sensors -G69- and -G79- Accelerator Pedal Position Sensor and Kickdown
Switch -F8- For Vehicles With EPC
Throttle Position (TP) sensor G79 and G185 (arrow), component of electronic engine power control (E-Gas), is
1:42:27 AM Page 9
located at pedal assembly.
The kick down function is performed (controlled) via Throttle Position (TP) sensor G79 and G185.
Checking, removing and installing Throttle Position (TP) sensor:
--> 20 - FUEL SUPPLY SYSTEM

Installation location: Brake light switch (arrow) is located in foot pedal assembly.
Brake light switch, removing and installing
--> 46 - BRAKES - MECHANICAL COMPONENTS
Transmission Range (TR) Selector Lever Display Y6
Fig. 32: Transmission Range (TR) Selector Lever Display Y6

1:42:27 AM Page 10
Installation location: in instrument cluster
Removing and installing Transmission Range (TR) Selector Lever Display
-->
 90 INSTRUMENTS
SELECTOR LEVER MECHANISM, SERVICING
Selector lever mechanism, servicing


.


.
1:42:27 AM Page 11
 Depress brake pedal and hold.
 Shifting selector lever out of position "P" must be possible with the button at shift lever depressed without
"sticking".
 It must not be possible to remove ignition key with selector lever in any position other than "P".
 It must only be possible to remove ignition key in "P" position.

 Selector lever cannot be shifted out of position "P" with the button pressed and foot brake operated.
Shift mechanism, checking
Selector lever in position "P" and ignition switched on:
Selector lever is locked and cannot be shifted out of position "P" with the button at selector lever pressed. Shift
lock solenoid is locking the selector lever.
Slowly shift selector lever from "P" through "R, N, D, S" checking whether selector lever position in dash panel
insert agrees with selector lever position.
Selector lever in position "N" and ignition switched on:
Selector lever is locked and cannot be shifted out of position "N" with the button at selector lever handle
pressed. Shift lock solenoid is locking the selector lever.
Selector lever in position "D" , ignition and lights switched on:
1:42:27 AM Page 12
Move selector lever in Tiptronic gate. The "D" symbol must no longer be illuminated and "+" and "-" symbols
must illuminate.
 Start engine and let run at idle

 Engage parking brake and operate brake pedal
The selector lever display in dash panel insert must change from "PRNDS" to "54321" when selector lever is
moved in Tiptronic gate.
NOTE:  The starter must not operate in the selector lever positions "D" , "S" and
"R".
 For speeds exceeding 5 km/h and shifting into selector lever position "N" ,
the shift lock solenoid must not engage to lock the selector lever. Selector
lever can be shifted into a driving mode.
 For speeds below 2 km/h (almost standstill) and shifting into selector lever
position "N" , the shift lock solenoid must only engage after approx. 1
second. Selector lever can only be shifted out of position "N" with the
brake pedal operated.
Shift mechanism cover and selector lever knob, exploded view
052 142 A2.
1:42:27 AM Page 13
Fig. 33: Shift Mechanism Cover And Selector Lever Knob, Exploded View
1 - Selector lever
2 - Shaft piece for selector lever
 Removing and installing selector lever knob --> Selector lever handle, removing and installing
4 - Cover
 With selector scale and Tiptronic gate and selector lever lock indicator
1:42:27 AM Page 14
 Removing and installing Tiptronic switch F189 --> Tiptronic Switch F189 , removing and installing
and additionally unclipping cover
5 - Symbol insert
 Clipped in cover
 with integrated Tiptronic Switch F189

 Removing and installing --> Tiptronic Switch F189 , removing and installing
7 - Masking panel
 With solenoid for Tiptronic switch F189 on reverse slide

 Removing and installing Tiptronic Switch F189 --> Tiptronic Switch F189 , removing and installing
8 - Guide
 For masking panel

 Separate both halves by applying careful levering movements
Removing

 Turn sleeve - 1 - to left and push downward as far as stop.

 Carefully pull switch - 2 - just enough out of selector lever knob - 3 - until a cable tie can be inserted
1:42:27 AM Page 15
NOTE:  Do not remove button further under any circumstances, otherwise the
selector lever knob will be damaged.
 Remove selector lever knob upward.
Installing

NOTE:  To install new selector lever knob - 3 - , button 2 must be pulled out as far
as stop and secured with a cable tie - arrow - or using assembly aid
included with new knob.
 If the button was accidentally not secured, then it must not be pulled from
selector lever knob using mechanical tools. Apply compressed air gun to
bottom of knob and carefully press button out with compressed air.
 Position complete selector lever knob - 3 - on selector lever - button 2 faces driver. During this, the knob
must engage into ring groove of the selector lever.
 Remove cable tie - arrow - or assembly aid, then button actuation engages in vertical groove of selector
lever. If necessary press button into selector lever knob.
 Pull sleeve - 1 - upward and engage by turning clockwise.
Shift mechanism cover, removing and installing
Removing
1:42:27 AM Page 16


Installing
Tiptronic switch is integrated into circuit board ( ), which is located in shift mechanism cover.
1:42:27 AM Page 17
It consists of 3 camshaft position sensors, which are activated by a magnet on the cross slide masking panel.
To replace Tiptronic switch, circuit board ( ) must be replaced.
Check also whether solenoid is correctly fixed on transverse slide of masking panel, replace masking panel with
guide if necessary.
Removing
 Press the 4 lugs (arrows) inward and remove cover - 2 - from guide - 1 -.
 Remove circuit board with integrated Tiptronic Switch F189 from cover - 2 -.
NOTE:  If necessary, masking panel with solenoid for Tiptronic Switch F189 can be
removed as described below. As replacement part the masking panel is
only available together with guide.
1:42:27 AM Page 18
 Separate both guide parts by applying careful levering movements (arrows).

 Remove masking panel with solenoid for Tiptronic Switch F189.
Installing
Shift mechanism, overview
052 142 A2.
1:42:27 AM Page 19

3 - Bearing bushing
5 - Pivot pin
6 - Selector lever
1:42:27 AM Page 20
 Removing and installing --> Shift Lock Solenoid N110 , removing and installing
8 - Actuating lever
9 - Lock
10 - Lever
11 - Catch lever
12 - Gate
13 - 10 Nm
17 - Retaining clip
 Always replace
19 - Pivot pin
20 - 10 Nm
1:42:27 AM Page 21


Removing


1:42:27 AM Page 22

 Disengage locking cable (arrows).

ENGINE CODE(S): BKH
1:42:27 AM Page 23




1:42:27 AM Page 24
 Pull selector lever cable - 4 - out of shift mechanism at the same time, and do not bend.

NOTE:  A second mechanic is required when detaching shift mechanism below

vehicle.
Installing
1:42:27 AM Page 25
 Install selector lever cable.
 Install locking cable Installing.


ENGINE CODE(S): BKH
Tightening torques
1:42:27 AM Page 26
Component Nm
Shift mechanism, disassembling and assembling (sequence)
NOTE:  Removing and installing securing spring for locking cable Securing spring
for locking cable, removing and installing.
Disassembly of suspension strut
 Move selector lever into position "S".

 Remove selector lever lock solenoid - 7 - --> Shift Lock Solenoid N110 , removing and installing.
 Carefully unbolt gate - 12 -.
NOTE:  If gate - 12 - or selector housing - 14 - is damaged, complete selector

housing with gate must be replaced.
 Release pivot pins - 5 - and - 19 - and pull them out from the side.
 Unclip retainers - 2 - and - 16 -.
 Remove retaining clip - 17 -.
 Pull selector lever - 6 - with bushes - 3 - and - 15 - together with locking levers for Tiptronic - 4 - and - 18
- downward out of selector housing - 14 -.
Assembly of suspension strut
 Check whether selector lever is still in position "S".

 Insert selector lever - 6 - into selector housing - 14 - from below.
 Push locking levers for Tiptronic - 4 - and - 18 - along with bushes - 3 - and - 15 - onto selector lever.
 Press selector lever - 6 - with bushes into selector housing and position it with retaining clip - 17 -.
 Engage retainers - 2 - and - 16 - to selector housing.
 Press pivot pins - 5 - and - 19 - into mounting bracket until they engage.
 Check whether pivot pins engage in locking lever for Tiptronic.
 Install selector lever lock solenoid - 7 - --> Shift Lock Solenoid N110 , removing and installing.
 Tighten gate - 12 - to selector housing - 14 - with the 3 securing bolts to 0.4 Nm.
NOTE:
1:42:27 AM Page 27
 If gate - 12 - or selector housing - 14 - is damaged by tightening too much,

complete selector housing with gate must be replaced.
 Gate is matched to selector housing and cannot be replaced separately.

Securing spring for locking cable, removing and installing
1:42:28 AM Page 28
Fig. 50: Securing Spring For Locking Cable, Removing And Installing
Removing
 Slightly lift spring at top (arrow B) and remove locking cable from shift mechanism.
 Unhook spring (arrow A) at retaining clip (arrow C) and remove toward top.
Installing
 Insert spring (arrow B) from top and hook in at retaining clip (arrow C).
 Align spring so that it is seated evenly in groove (arrow A).
 Slightly lift spring at top (arrow B) and insert locking cable into shift mechanism.
Shift Lock Solenoid N110 , removing and installing
Removing
1:42:28 AM Page 29
 Release lugs and remove selector lever lock solenoid forward (arrows).
Installing
 Press selector lever lock solenoid into guide until it engages; actuating lever - 2 - of solenoid must engage
in locking lever - 1 - on shift mechanism.
Selector lever cable and locking cable, assembly overview

 Lubricate pull ring and ball socket with polycarbamide grease, part no. G
052 142 A2.
1:42:28 AM Page 30

 Removing and installing --> Selector lever cable, removing and installing
2 - Lock nuts - 12 Nm
3 - Boot

 Fasten into bottom cover of shift mechanism
1:42:28 AM Page 31
4 - Locking clamp
5 - Ignition/Starter Switch
6 - Locking cable

7 - Hex-bolt - 9 Nm
8 - Clamping screw - 13 Nm

 To adjust, loosen by approx. 1 turn, do not fully remove
9 - Pin

 To remove selector lever cable, pull plastic securing spring on shift mechanism slightly forward and push
pin up only as far as necessary
10 - Retaining clip

 Always replace
11 - Pivot
 For selector lever cable to transmission
12 - Hex-bolt, 23 Nm
Selector lever cable, removing and installing
1:42:28 AM Page 32




Removing

 Raise vehicle.
ENGINE CODE(S): BKH
1:42:28 AM Page 33




1:42:28 AM Page 34


1:42:28 AM Page 35
Installing
1:42:28 AM Page 36

 Press pin - 3 - downward (arrow)
 Check whether plastic securing spring - 2 - has locked pin.
 Fasten selector lever cable boot into lower cover of shift mechanism.

 Bolt lower cover to shift mechanism (arrows).
 Install front heat shield, if present, under shift mechanism housing.
1:42:28 AM Page 37
 Push lever/selector shaft - 2 - on transmission fully forward into position "S" - arrow -.

1:42:28 AM Page 38

 Bolt heat shield for driveshaft onto transfer box (arrows).

ENGINE CODE(S): BKH
Tightening torques
Component Nm
 Special tool T40031
1:42:28 AM Page 39

Procedure
 Remove left front exhaust pipe. -->

ENGINE CODE(S): BKH
 Remove shielding plate/selector lever cable.
All:
1:42:28 AM Page 40


 Grasp selector lever cable - 1 - and push lever/selector shaft - 2 - fully forward into position "S" - arrow -
.
1:42:28 AM Page 41

 Loosen rear clamping screw on selector lever cable approx. 1 turn through the hole in shift mechanism
using special tool T40031.
NOTE:  Loosen clamping screw approx. 1 turn. Do not remove.

 Selector lever must remain in position "S" while clamping screw is loose.
Fig. 70: Checking Exact Position Of Selector Lever In Position "S" By Pushing Selector Lever Lightly
Toward Drivers Seat
 Check exact position of selector lever in position "S" by pushing selector lever lightly toward drivers seat
1:42:28 AM Page 42
(arrow - A - ).
NOTE:  When adjusting, do not move selector lever backward or forward, or

adjustment will be falsified.
 Tighten clamping screw to 13 Nm in this position using special tool T40031.

 Install shielding plate/selector lever cable.

 Install left front exhaust pipe. -->
ENGINE CODE(S): BKH
Tightening torques
Component Nm
Removing
NOTE:  Locking cable must not be kinked.

 Note radio code (for vehicles equipped with coded anti-theft radio/radio navigation system).
See Caution before beginning repairs on electrical system --> Selector lever mechanism, servicing
1:42:28 AM Page 43
 Disconnect Ground (GND) strap from battery.

 Remove steering column cover: -->


Installing
 Route locking cable kink-free behind dash panel strut (arrow).

 Check that interlock lever - 2 - is locked.
 Bring ignition/starter switch into locking position (ignition off).

 Check whether selector lever is still in position "P".
 Engage locking cable eye in pin - 3 -.
 Slightly lift securing spring - 4 -.
 Push locking cable support bracket - 5 - into shift mechanism from the right until securing spring - 4 -
engages.
 Adjusting locking cable --> Locking cable, adjusting.
See Caution for connecting Telematics battery --> Selector lever mechanism, servicing
NOTE:  Be sure to activate vehicle features (radio/radio-navigation system, clock,
1:42:28 AM Page 44
electric window regulators) according to owners manual when the battery

is reconnected.
 Further measures after re-connecting power supply: -->
 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V
TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V
TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT
 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL
INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V ENGINE MECHANICAL,
ENGINE CODE(S): BKH
 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BNS
 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BHF
1:42:28 AM Page 45

1:42:28 AM Page 46
 Adjusting gauge 3352A for locking cable

Preliminary work
NOTE:  The following described procedure saves the work of removing center
console.

 Cut through adjusting gauge 3352A at rear end of flat area - arrow - using a parting grinder.
 Order a new adjusting gauge 3352A for locking cable as replacement for later use.
Procedure
1:42:28 AM Page 47
 Remove center console trim --> Shift mechanism cover, removing and installing.
NOTE:  Selector lever knob and cover can remain installed.

Adjustment requirements:
 Locking cable in installation position

 Selector lever in position "P".
 Ignition key in removal position.

 Push modified adjusting gauge 3352A between pin on lever for locking cable and locking cable eye.
 Move locking cable in direction of arrow to stop and tighten bolt - 1 - to 9 Nm.
 It must be possible to easily remove and insert adjusting gauge 3352A in this position.
 Remove adjusting gauge.
 Check ignition key removal lock after every adjustment of the locking cable --> Ignition key removal
lock, checking.
Tightening torque
Component Nm
1:42:28 AM Page 48


.


.
1:42:29 AM Page 49

 Engine support bridge 10-222A

 Support 10-222A/1
 Adapter 10-222A/3
 Shackle 10-222A/12
 Pry lever 80-200 for removing outside mirror

1:42:29 AM Page 50


 Testing Mandrels 3393
 Transport device 3457

 Ladder VAS5085
Removing
1:42:29 AM Page 51
NOTE:  All cable ties opened or cut during engine removal must be reinstalled at
the same locations.
 First determine whether a coded radio is installed. If so, determine the correct coding.
See Caution before beginning repairs on the electrical system --> Transmission, removing and installing
 Switch ignition off and disconnect battery Ground (GND) strap.

 Remove cover - 1 - in engine compartment (left side).

 Remove cover - 1 - in engine compartment (right side).
1:42:29 AM Page 52


 Remove intake air duct from intake manifold.
 Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 -.

 Remove bolts (arrows) and remove intake air guide - 2 -.
1:42:29 AM Page 53
 Fit support bar 10-222A together with supports 10-222A/1 and fit adapters 10-222A/3.
 Secure spindles to engine. To do so, additionally use a shackle 10-222A/12 at the front side of the engine
to avoid damage.
 Take up weight of engine/transmission assembly on spindles.
 Loosen wheel bolts.
 Raise vehicle.
 Remove front wheels.

1:42:29 AM Page 54

ENGINE CODE(S): BKH

 Remove heat shields for left, if installed, and right drive axles (arrows).
 Unbolt left and right drive axles - 1 - from transmission flanges and tie up. --> 40 - FRONT
SUSPENSION
1:42:29 AM Page 55
And Cable Tie
 Remove noise insulation bracket - 1 -.

 Disconnect connector - 2 - of wire for multi-function switch.
 Swing securing lever - 3 - , disconnect connector for transmission wiring harness.
 Cut cable ties - 4 -.
Make sure the wire for multi-function switch is not damaged when doing this.
Fig. 85: Location of Speedometer Vehicle Speed Sensor (VSS) G22, and Engine Speed (RPM) Sensor G28
 Disconnect connector from Speedometer Vehicle Speed Sensor (arrow - A - ).

 Unbolt Engine Speed (RPM) Sensor G28 (arrow - B - ) from transmission.
1:42:29 AM Page 56

 Unscrew nut - 2 - for clamp for ATF lines.

 Always clean area of ATF line/transmission connection.
 Mark ATF lines if no color markings are present.

 Disconnect ATF lines - 1 -.

 Plug ATF lines with clean plug.
 Remove starter. -->

1:42:29 AM Page 57

 Unbolt 3 torque converter bolts from drive plate (turn crank shaft an additional 1/3 turn every time).

 Remove heat shield for driveshaft at transmission (arrows).
Fig. 90: Unbolting Driveshaft On Transmission And Securing To Panel With Wire
1:42:29 AM Page 58
 Unbolt driveshaft - 1 - on transmission and secure to panel - 2 - with wire (arrow). -->

 Mark position of mounting bracket for selector lever cable to transmission housing for re-installation,
unbolt mounting bracket (arrow).
 Remove left transmission support with transmission mount --> Right and left transmission mounts,
1:42:29 AM Page 59
Damage
 Unbolt multi-function Transmission Range (TR) switch F125 for protection against damage (arrows) and
expose wiring harness.

1:42:29 AM Page 60

 Fill space between gearbox support and sump with washers.
Automatic Transmission 01V with All Wheel Drive is supported at the same positions as the Front Wheel Drive
version.
 Remove right transmission support with transmission mount --> Right and left transmission mounts,
Fig. 96: Unclipping Clamp For Coupling Rod For Left Front Level Control System Sensor G78 From
Control Arm
 Unclip retaining clip for coupling rods - 1 - of Left Front Level Control System Sensor G78 from left
front control arm - 2 -.
1:42:29 AM Page 61

 Unbolt bolts (arrows) for stop/torque support - 1 -.
All:
Fig. 98: Identifying Engine Mount Bolts and Positioning Sleeves

 Mark installation positions for threaded assemblies - 1 - and positioning sleeves - 2 -.

 Remove nuts - 1 - on left and right engine mounts.
NOTE:  When installing, make sure that locating sleeves - 2 - engage again.
1:42:29 AM Page 62

 Before loosening subframe, check on both sides of vehicle, using testing Mandrels 3393 , that at least
holes - 1 - and - 2 - align.
If this is not the case, axle alignment must be carried out after tightening of subframe.
Hole - 3 - is not applicable here.

 Remove bolts - 1 - and - 2 - at rear of subframe on both sides of vehicle.

 Remove bolts - 3 - at front of subframe on both sides of vehicle.
 Remove bolts - 4 - (2 bolts at each vehicle side).
 Remove lower connecting bolts for engine/transmission.
1:42:29 AM Page 63
 Lower engine-transmission-subframe using the spindles approx. 4 turns. To do this use Support
VAS5058.
 To do this lower engine/gearbox assembly using spindles in turn, 2 turns at a time.
 At the same time lower engine-transmission-subframe using lifter VAG1383A (second mechanic).
NOTE:  When lowering transmission, ensure that no components are damaged.
 Remove upper connecting bolts for engine/transmission.

 Press transmission off engine, while pressing torque converter out of drive plate.
Fig. 102: Press Torque Converter Against ATF Pump

1:42:29 AM Page 64
 Press torque converter against the ATF pump (arrow).


 Secure converter so it does not fall out.
For disassembly and assembly, secure transmission to assembly stand using Transport device 3457 and Holding
plate VW309 --> Transmission, attaching to assembly stand.
Installing
Installation of transmission is the reverse of removal. The following points must also be observed:
Before installing:
 Clean threads in output flange/driveshaft flange using a tap.

 Clean ATF lines --> ATF lines and ATF cooler, cleaning.
 Insert torque converter correctly into transmission

1:42:30 AM Page 65

 Make sure bushings are correctly seated.
NOTE:  If the bushings get stuck in the transmission housing, they must be
removed and new bushings must be installed on the engine.

Item A = bushings
1:42:30 AM Page 66

Item A = bushings

 Place transmission onto transmission support.
1:42:30 AM Page 67


 Move transmission into position between the lowered subframe and vehicle floor.
 Align transmission properly to engine.
 Tighten one engine/transmission connecting bolt at either side by hand.
 Make sure that wires do not get pinched as transmission is docked at engine.
CAUTION: Keep checking whether the torque converter behind the drive plate can be
turned before and during tightening of the bolts at engine/transmission
flange. If the torque converter cannot be turned, it must be assumed that it
has not been inserted properly and that the coupling plate of the torque
bolts.

 Bolt together torque converter and drive plate.

 To do this insert bolts by hand and tighten to tightening torque.
1:42:30 AM Page 68
 Insert top engine/transmission connecting bolts and tighten to tightening torque.
NOTE:  Some bolts also have a bracket or a Ground (GND) connection attached
refer to tightening torque tables starting on --> --> Tightening torques.
 Raise engine-transmission-subframe using the spindles approx. 4 turns. To do this use Support VAS5058.
 To do this raise engine/gearbox assembly using spindles in turn, 2 turns at a time.
 At the same time raise engine-transmission-subframe using lifter VAG1383A (second mechanic).
 Insert remaining engine/transmission connecting bolts and tighten to tightening torque

1:42:30 AM Page 69
 Install subframe, observe tightening sequence and alignment with master bore hole. --> 40 - FRONT
SUSPENSION
 Only perform vehicle alignment if necessary. --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT
 Install right transmission support with transmission mount --> Right and left transmission mounts,
Fig. 112: Screwing On Lower Nuts On Left And Right Engine Mounts
 Screw on lower nuts - A - on left and right engine mounts. -->

ENGINE CODE(S): BKH
1:42:30 AM Page 70

 Bolt on torque support stop - 1 - (arrows). -->

ENGINE CODE(S): AMB
 10 ENGINE - ASSEMBLY for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE
CODE(S): AVK, BGN
 10 - ENGINE - ASSEMBLY for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH

(S): BNS
(S): BHF
All:
 Attach retaining clip for coupling rods of Left Front Level Control System Sensor G78 to left front
control arm, if present. --> 40 - FRONT SUSPENSION
1:42:30 AM Page 71
 After subframe is installed, remove bolt - A - and remove transmission jack VAG1383A.
 Apply corrosion protection to contact surface between bolt - A - and oil pan.

 Bolt on mounting bracket for selector lever cable to transmission corresponding to marking for re-
installation of transmission.
1:42:30 AM Page 72
Damage
 Install Multi-Function Transmission Range (TR) Switch F125 --> Multi-Function Transmission Range
(TR) Switch F125 , removing and installing ; removing and installing Multi-Function Transmission
Range (TR) Switch F125
 Bolt driveshaft to transmission. -->

 Install heat shield for driveshaft at transmission (arrows).

 Install starter. -->

1:42:30 AM Page 73

 Connect ATF lines - 1 - according to the respective color markings.

 Engage clamp for ATF lines and tighten nut - 2 -.
Fig. 121: Location of Speedometer Vehicle Speed Sensor (VSS) G22, and Engine Speed (RPM) Sensor
G28
1:42:30 AM Page 74
 Connect connector of Speedometer Vehicle Speed Sensor (arrow A-).

 Bolt Engine Speed (RPM) Sensor G28 (arrow - B - ) to transmission.
And Cable Tie
 Install noise insulation bracket - 1 -.

 Connect connector - 2 - of wire for multi-function switch.
 Connect connector for transmission wiring harness and swivel securing lever - 3 -.
 Replace cable ties - 4 -.

 Bolt on left and right driveshafts - 1 - to transmission flanges. --> 40 - FRONT SUSPENSION
 Install heat shields for left, if present, and right drive axles (arrows).
1:42:30 AM Page 75

ENGINE CODE(S): BKH

 Install noise insulation panel (arrows).

 Install front wheels. --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT
 Remove engine support bridge 10-222A.
 Fit intake air duct to intake manifold.
 Install intake air guides.

 Install engine cover.
 Install left and right covers in engine compartment.
See Caution for connecting Telematics battery --> Transmission, removing and installing
 After connecting battery, enter anti-theft code for radio operating manual.
 Check adjustment of selector lever cable --> Selector lever cable, checking and adjusting.
 Check gear oil in front final drive with transmission installed --> Gear oil in front final drive, checking.
1:42:30 AM Page 76
 Then check ATF level and top off onward --> Automatic Transmission Fluid (ATF), checking and
changing.
 Fully close power windows to stop.

 Then activate all power window switches ( "up" ) for at least one second to activate automatic window
raising/lowering.
 Set clock to correct time.
Tightening torques
greased, oiled, covered with a thin coat of phosphate or blackened.
 Other lubricants are permitted, e.g. engine oil or transmission fluid,
however they may not contain graphite.
 Do not use any degreased parts.

Item no. Bolt Nm

1 M12 X 67 65
2 * See note M12 x 110 65
3 M12 x 90 65
4 * See note M10 x 60 45
5 M10 X 45 45
6 * See note M12 X 67 65
*with nut
*with bracket for wiring harness
1:42:30 AM Page 77
*with cable bracket
Item A = bushings

Item no. Bolt Nm

1 M10 x 60 45
2 M10 x 90 65
3 M12 x 110 65
4 M12 x 80 65
5 M12 x 90 65
6 M12 x 90 65
7 M10 x 100 45
8 M12 x 90 65
9 * See note M10 x 70 45
10 M10 x 60 45
11 M10 x 60 45
*with nut
Item A = bushings
1:42:30 AM Page 78
Fig. 127: Identifying Noise Insulation And Fasteners

Valid for all engine/transmission types:
Components Tightening torques

Support bracket -B- to transmission (2x M8), item no. 2 and 3 23 Nm
Heat shield/selector lever cable -A- to transmission, M8, item no. 1 and 23 Nm
4
Component Nm
Nuts/Bolts M6 10
M8 20
M10 45
M12 65
Drive plate to
Torque converter M10 x1 85
Installing ATF lines --> ATF lines, removing and
installing (overview) onward
Multi-function Transmission Range (TR) switch F125 to transmission onward
1:42:31 AM Page 79

The attachment and holding rig 3457 can be used when transporting the transmission and for setting up the
 Remove ATF lines from transmission (only for vehicles with 6-cylinder engine).
 Plug ATF connections with plugs.
 Unbolt left and right transmission supports.

1:42:31 AM Page 80


 Holding fixture VW540 (only for FWD transmissions) (Not for US/Canada)
 Holding fixture VW313
 Holding plate VW309
 Engine Hoist VAG1202A
1:42:31 AM Page 81

 Bolt the attachment and holding rig to the holding plate VW309 and place this into the holding fixture
VW313 using a workshop crane.
For transmissions with Front Wheel Drive (FWD), the holding fixture VW540 can also be used to secure the
transmission to the holding fixture VW313 (Not for US/Canada).
Fig. 132: Securing Transmission To Holding Fixture VW540 And Inserting In Holding Fixture VW313
 Secure transmission to holding fixture VW540 (arrows) and insert in holding fixture VW313.
CAUTION: The center of gravity of the transmission is located outside the turning
center at holding fixture. To turn the transmission, a second technician
must hold the transmission housing to prevent back-swing.
turning a filled transmission on the assembly stand so that the oil pan
faces upward.
1:42:31 AM Page 82
Right and left transmission mounts, removing and installing
Fig. 133: Identifying Special Tools - Right And Left Transmission Mounts, Removing And Installing

Removing
NOTE:  Transmission must be supported as indicated when both transmission

supports are removed. Transmission does not need to be supported this
1:42:31 AM Page 83
way when only one of the transmission supports is being removed.


NOTE:  If transmission support 3282 is not available, transmission can be

supported using the transmission lift VAG1383A and the 1359/2 universal
mount.
1:42:31 AM Page 84
Right transmission support

 Remove right heat shield -D- by removing bolts - A - from transmission.
Left transmission support

NOTE:  The left heat shield is not installed on 4 cylinder gasoline engines.
 Remove left heat shield -D- by removing bolts - A - from transmission.
Left and right transmission supports
1:42:31 AM Page 85
 Unscrew nuts - A - on subframe.
Fig. 138: Removing Transmission Supports

 Remove transmission supports -E-.
NOTE:  Items - C - and - B - are not installed on vehicles with hydraulic

transmission bearing H, because bolt G is threaded directly into the
transmission bearing.
Installing
Tightening torques for left and right transmission supports
Item no. Nut/Bolt Number of pieces Nm

A M8 2 each 23
B to F M 10 x 70 1 50
G M 10 x 35 1 50
Tightening torques for left transmission support
1:42:31 AM Page 86


A M 10 x 30 M 10 x 50 21 40
B M 6 x 22 3 10
Tightening torques for right transmission support


A M 10 x 30 3 40
B M 6 x 22 3 10
AUTOMATIC TRANSMISSION FLUID (ATF), CHECKING AND CHANGING
ATF level, checking
1:42:31 AM Page 87
Fig. 141: Identifying Special Tools - ATF Level, Checking

 Tester VAS5051
 Diagnostic cable VAS5051/1 or VAS5051/3
Test requirements:
 Transmission must not be in emergency running mode.
1:42:31 AM Page 88
 Vehicle on level ground.

 Selector lever in "P" , let engine run at idle.
 A/C system and heating switched off.
NOTE:  ATF level changes with ATF temperature.

 Performing ATF level check when ATF temperature is too low causes
overfilling.
 Performing ATF level check when ATF temperature is too high causes
insufficient filling.
 Excess filling and insufficient filling both affect the function of the
transmission.
 ATF temperature is read off using the tester VAS5051.
Procedure
1:42:31 AM Page 89
Connect tester VAS5051
All functions previously performed with the VAG1551 can also be performed using the new tester VAS5051 in
operating mode "Vehicle On Board Diagnostic (OBD)" :
Connector (DLC)
 Connect tester VAS5051 to Data Link Connector (DLC) using diagnostic cable VAS5051/1 with ignition
switched off.
1:42:31 AM Page 90
Fig. 145: Special Tool - VAS 5051 & On Switch

 Switch on tester (arrow).
The tester now requires up to 3 minutes to finish booting.
 Switch on ignition.
 Select operating mode: Press "Vehicle Self-Diagnosis" selection on display.
 Press "02 - Transmission electronics" on display.
 Perform dialog to confirm control module number belonging to selected system.
 Select "08 - Read Measuring Value Block" on display.

 Choose Display Group 4 via the "Read Measuring Value Block" and "Change Display Group" touch
screen displays.
Fig. 146: Display On VAS5051 (ATF Temperature)

The first line of display field - 1 - displays ATF temperature.
NOTE:  ATF level is checked at the ATF check plug.

between 35 ° and 45 ° C * See note (dependent on the fluid level when
warming up).
 Start engine.
1:42:32 AM Page 91
 Raise vehicle.
Fig. 147: Removing And Installing ATF Inspection Plug From Oil Pan
 Once an ATF temperature of 35 ° C is reached, remove ATF check plug (arrow) and drain excess ATF if
necessary.

 If ATF flows out from the ATF filler plug hole before the ATF reaches 40 ° C, the ATF level (arrow) is
OK.
NOTE:  ATF check plug must be closed again by 45 ° C * See note at the latest.
1:42:32 AM Page 92
 Add ATF if no ATF has escaped from the ATF check plug hole by 40 ° C.
Fig. 149: Inserting ATF Filler Tool VAG1924 Into An Opening In Protective Cap
upward.

1:42:32 AM Page 93
Fig. 151: Replacing Seal For ATF Check Plug

 Always replace seal (arrow) for ATF check plug.

 Tighten ATF check plug to 80 Nm.
 Switch off motor.
 Select diagnostic function "06 - end output" in selection.

 Switch off ignition and disconnect diagnostic connector after this indication is displayed.
ATF, changing or topping off after repairs
1:42:32 AM Page 94



 Engine switched off.
1:42:32 AM Page 95

 Raise vehicle.


 Engine must not be started without ATF and vehicle must not be towed!
 Place Drip tray VAG1306 under transmission.
Fig. 157: Identifying ATF Drain Plug and ATF Inspection Plug
 Remove drain plug (arrow - 1 - ).

 Let ATF drain.
 Tighten new drain plug (arrow - 1 - ) to 40 Nm.
1:42:32 AM Page 96
 Remove ATF check plug (arrow - 2 - ).
Fig. 158: Guiding V.A.G 1924 In Through An Opening In Deflector Cap

upward.

 Start engine.
 Keeping the brake pedal depressed, shift into all selector lever positions at idle speed. Each position must
remain selected for at least 10 seconds.
1:42:32 AM Page 97
NOTE:  Observe all notes and test requirements for "Checking ATF level".
POWER TRANSFER, OVERVIEW
Transmission diagram (All Wheel Drive (AWD) vehicles)
Fig. 160: Transmission Diagram (All Wheel Drive (AWD) Vehicles)

A - Clutch A
B - Clutch B
1:42:32 AM Page 98
E - Clutch E
F - Clutch F
C - Brake C
D - Brake D
G - Brake G
F1 - Freewheel 1
1 - Engine
2 - Torque converter with lock-up clutch
4 - Automatic transmission
5 - Drive pinion
6 - Output shaft
7 - Center differential
8 - Driveshaft
Z1, Z2 and Z3 = spur gears of front intermediate drive; ratio --> Code letters, allocation, ratios, equipment
Z4, Z5 = front gear set; ratio --> Code letters, allocation, ratios, equipment
Z6, Z7 = spur gears of rear intermediate drive; ratio All Wheel Drive (AWD)
Z8, Z9 = rear ring gear, ratio All Wheel Drive (AWD)
NOTE:  Arrows point in direction of travel.
Shift element positions
 When dealing with problems relating to poor acceleration and performance or general malfunctions, the
following chart indicates which selector elements are actuated in the various gears. This should help to
identify the selector elements that are not working properly.
1:42:32 AM Page 99
Solenoid valves Clutches

Solenoid valves Pressure regulation Clutch Brake Freewheel
valves
Position/gear N88 N89 N90 N215 N216 N217 N218 A B E F C D G 1. Gear
R = Reverse x x x x x x
N = Neutral x x x x x
D, 1st gear x x x x x x x
D, 2nd gear x x x x x x x x
D, 3rd gear x x-x x x x x x
D, 4th gear x-x x x x x
D, 5th gear x x-x x x x x x
2, 1. Gear x x x x x x x
D, 5th to 4th x x x x x (x) x x (x)
gear
x = Component is actuated
- = Component is not actuated
(x) = Component actuation is dependent on driving condition
 Observe general repair instructions --> Servicing notes.
only!

 Check the following fluid levels after installing, top off if necessary. ATF in planetary gear --> ATF
level, checking , gear oil in front final drive --> Gear oil in front final drive, checking , gear oil in
center differential --> Gear oil in center differential, checking and topping off. Capacities and
specifications --> Capacity onward.
1:42:32 AM Page 100

ATF lines, removing and installing (overview)

1:42:32 AM Page 101

Fig. 162: ATF Lines, Removing And Installing, Overview (Vehicles With 4-Cylinder Engine)
1 - Bolt (21Nm)
4 - O-ring
1:42:33 AM Page 102


 Always replace
5 - O-ring

 Always replace
6 - Bolt (5Nm)
7 - O-ring

 Always replace
8 - Bolt (5Nm)
10 - Bracket
11 - Hex bolt
 Does not need to be removed when removing and installing ATF lines.
12 - Nut - 5 Nm
13 - Clamp
14 - Bracket
 On engine/transmission support
1:42:33 AM Page 103

Fig. 163: ATF Lines, Removing And Installing Overview (Vehicles With 6 Cyl. Engine)
1 - Bolt (21Nm)


1:42:33 AM Page 104

4 - O-ring

 Always replace
5 - O-ring

 Always replace
6 - Bolt (5Nm)
7 - O-ring

 Always replace
9 - Bracket
10 - Bolt (5Nm)
11 - Double bolt - 10 Nm
12 - Bracket
14 - Clamp
1:42:33 AM Page 105



 Hose, approx. 18 mm
 Compressed air gun, standard
NOTE:  Always blow compressed air through oil cooler and ATF lines (max. 10
mbar) before installing a replacement transmission.
 When installing ATF lines, insert into transmission or cooler by hand until
impact first and then tighten bolts.

1:42:33 AM Page 106

 Disconnect ATF lines from transmission.
 Slide a hose with approx. 18 mm diameter onto ATF line - A - and secure with hose clamp. Place the
other end of the hose into an appropriate container.
 Blow through ATF line - B - with compressed air gun.
 Change hose from ATF line - A - to ATF line - B - and repeat procedure.
 Replace O-ring - 1 -.
 Coat O-ring with ATF.
 Insert ATF lines completely into transmission by hand until stop.
 Re-secure ATF lines.

 Then check ATF level and top off --> ATF level, checking onward.
1:42:33 AM Page 107


OIL PAN, OIL STRAINER AND VALVE BODY, REMOVING AND INSTALLING
Oil pan, oil strainer and valve body, removing and installing
CAUTION: Do not run engine with the oil pan removed or without ATF filling and do
not tow vehicle.

 Coat O-rings and sealing rings with ATF. Other lubricating substances
lead to functional problems in the hydraulic transmission control.
Removed parts for transmission with hydraulic control E18/2, overview
1:43:29 AM
1:43:33 Page 1
Fig. 166: Valve Body For Transmissions With Hydraulic Control Type E18/2, Assembly Overview
1 - Drain plug - 40 Nm
 With seal
 Always replace
 Remove to drain ATF
2 - Bolt - 10 Nm
 Tighten bolts for oil pan in several stages in diagonal sequence
3 - Oil pan
1:43:29 AM Page 2
 Removing and installing --> Oil pan, removing and installing
4 - Gasket
 Always replace
5 - Oil strainer
 Removing and installing --> Oil strainer, removing and installing
6 - Bolt - 8 Nm
 For mounting valve body: 16 bolts M6 x 60

 Observe tightening sequence --> Fig. 177
7 - Valve body
 Removing and installing --> Valve body, removing and installing
8 - Bolt - 8 Nm
9 - Bracket
 For wiring harness

 Hook in wiring harness
 Mounted with valve body bolts
10 - Bolt - 6 Nm
G195 )
 Removing and installing --> Transmission Vehicle Speed Sensor (VSS) G38 , removing and installing
12 - Spacer sleeve
 Height: 8 mm
13 - Inner oil line
 Always replace
 Removing and installing --> Oil line inside transmission, removing and installing
14 - O-ring
1:43:29 AM Page 3
 Always replace
15 - Speedometer Vehicle Speed Sensor (VSS) G22
 Removing and installing --> Speedometer Vehicle Speed Sensor (VSS) G22 , removing and installing
16 - O-ring
 Always replace
 Coat with gear oil and insert
 Removing and installing --> Multi-Function Transmission Range (TR) Switch F125 , removing and
installing
 Replacing shift rod sealing ring --> Shift rod seal, replacing
18 - Bolt - 8 Nm
19 - O-ring
 Always replace
 Coat with ATF and insert
20 - Locking clamp
 Always replace
21 - Wiring harness in transmission
 Always replace --> Wiring harness inside transmission, removing and installing
 Transmission Fluid Temperature Sensor G93 is integrated into the wiring harness
 Unhook from bracket for wiring harness, item 10
 Installation position wiring harness connector: Flat part of rear collar points toward oil pan, the tabs at
collar are horizontal
22 - Bolt - 9 Nm
 Removing and installing --> Sensor for transmission RPM G182 , removing and installing
24 - Connector
1:43:29 AM Page 4
 Is connected at wiring harness in transmission

 Must be disconnected before removing the valve body
25 - Bolt - 6 Nm
26 - Bracket
 For solenoid valve
 With O-ring
 Without O-ring
 Without O-ring
30 - Bolt - 6 Nm
31 - Bracket
 For solenoid valves
 With O-ring
 With O-ring
 With O-ring
1:43:29 AM Page 5
 Without O-ring
 Remove and install oil pan to replace --> Oil pan, removing and installing and unbolt guide plate for
park locking mechanism
 When installing, do not tighten bolts for guide plate (23 Nm) in selector lever position "P".
36 - Bolt - 6 Nm
37 - Magnet
 4 pieces in the oil pan recesses

 Clean after every removal of oil pan
 Ensure full surface contact in oil pan
38 - O-ring
 Always replace
39 - ATF check plug - 80 Nm

Removing
1:43:29 AM Page 6


Fig. 169: Identifying ATF Drain Plug And ATF Inspection Plug
 Remove ATF drain plug (arrow) and drain ATF.

 Loosen oil pan bolts diagonally and remove oil pan.
Installing
 Clean all 4 magnets in oil pan recesses. Ensure full surface contact of the magnets on the oil pan.
 Replace gaskets.
1:43:29 AM Page 7
Tightening torques
Component Nm
Drain plug to oil pan 40
Oil pan to transmission housing (diagonally in 10
sequence)
Oil strainer, removing and installing
Removing

 Removing oil strainer bolts (arrows).

 Pull oil strainer off of valve body.
Installing
 Lightly coat seal on suction collar of oil strainer with ATF.

 Carefully press suction collar of oil strainer into the opening at valve body up to stop.
 Bolt on oil strainer.
Tightening torque
Component Nm
Oil strainer to valve body 6
1:43:29 AM Page 8

Removing

 Removing oil strainer --> Oil strainer, removing and installing.

 Disconnect clip for wiring harness connectors (arrow).
Fig. 172: Identifying Connector Transmission Vehicle Speed Sensor -G38- And Connector transmission
RPM Sensor -G182-
 Disconnect harness connector from Transmission Vehicle Speed Sensor (VSS) G38 ( - A - ).
 Disconnect harness connector from Sensor for transmission RPM G182 ( - B - ).
1:43:29 AM Page 9
 Loosen mounting bolts (arrows) of valve body and remove valve body with wiring harness.
NOTE:  Only the marked mounting bolts (arrows) must be loosened.

 When loosening other bolts, the function of the valve body can be
 The bolt (arrow A) is not installed on transmissions with hydraulic control
 Remove valve body from transmission while advancing the wiring harness connector.
Installing
 Lightly coat O-rings of wiring harness connector with ATF.

 Insert wiring harness connector into transmission housing.
 Installation position: Flat part of rear collar points downward, the tabs at collar are horizontal
1:43:29 AM Page 10
the valve body.
Fig. 175: Installing Valve Body, Note Position Of A, B And C

 Insert connector with flat part (arrow - A - ) facing toward oil pan into transmission housing.
 Align valve body to hole in transmission housing (arrow - C - ) using alignment pin (arrow - B - ).
1:43:29 AM Page 11
Fig. 176: Installing Valve Body, Note Position Of Pin Of Detent Plate And Selector Slide
 Set valve body in place without force while placing bolt of notched disc - 1 - into the groove of the
selector register - 2 -.
 Next, tighten valve body bolts (arrows) by hand.
NOTE:  The bolt (arrow A) is not installed on transmissions with hydraulic control
 Then tighten valve body bolts from inside out to final tension.
1:43:29 AM Page 12
Fig. 178: Connecting Connector To Connector At Wiring Harness

 Pull wiring with connector - B - of Sensor for transmission RPM G182 between valve body and wiring
harness upward.
 Connect connector - B - to connector - A - at wiring harness.
 Connect connector - C - to Transmission Vehicle Speed Sensor (VSS) G38.

 Connect clip to wiring harness connector (arrow).

 Installing oil strainer --> Oil strainer, removing and installing.
Tightening torque
Component Nm
Valve body to transmission housing (from inside 8
out)
1:43:29 AM Page 13
Oil line inside transmission, removing and installing
Fig. 180: 3381 Fitting tool

 3381oil line installer
NOTE:  Faulty O-rings at inner oil line allow ATF to enter the differential, which
becomes over-filled and oil escapes at differential vent.
 A removed oil line generally must be replaced.
 The oil line must only be inserted using 3381oil line installer. Otherwise
there is a risk of leaks because of bending of the oil line.
Removing
Fig. 181: Pry Internal Oil Line Off Transmission Housing Using Screwdriver
 Lever off inner oil line evenly from transmission housing.
1:43:29 AM Page 14
Installing
 Replace O-rings.
 Insert oil line into oil line installer 3381.

 Drive oil line into transmission housing by lightly tapping on the oil line installer 3381 up to stop using a
plastic mallet.
NOTE:  The open side of oil line installer 3381 faces toward the outer wall of the
transmission.
 Do not cant oil line. Drive in both line ends uniformly.

Shift rod seal, replacing
1:43:29 AM Page 15
Fig. 183: 3385 Thrust piece

 Sealing ring installer 3385

Removing
 Removing Multi-Function Transmission Range (TR) Switch F125 --> Multi-Function Transmission
Range (TR) Switch F125 , removing and installing.
1:43:29 AM Page 16
 Pry off selector lever cable from lever/shift rod (arrow).
 Drive out spring dowel sleeve - 1 - at lever/shift rod - 2 - in direction of travel toward the front (arrow),
until the lever/shift rod can be pulled off the shift rod.
1:43:29 AM Page 17
 Pierce sealing ring using a small screwdriver and pull out.
Installing
 Coat outer circumference and gap between sealing lips with ATF.
Fig. 188: Drive In New Seal Until Using Thrust Piece 3385
 Slide new sealing ring onto sealing ring installer 3385 without canting and drive in up to stop of pressure
piece.
 Installing Multi-function switch --> Multi-Function Transmission Range (TR) Switch F125 ,
 Drive back spring dowel sleeve with transmission not yet removed in opposite direction through the lever.
 Slide transmission shift lever onto shift rod and drive in spring dowel sleeve.
1:43:30 AM Page 18
 Rotate multi-function switch - 3 - until the alignment bore - 4 - at switch housing can be fitted on the
alignment pin - 2 - at transmission housing.
Tightening torques
Component Nm
Multi-Function Transmission Range (TR) Switch F125 , removing and installing
Removing
 Unbolt Multi-Function Transmission Range (TR) Switch F125 from transmission and pull off from shift
rod.
Installing
1:43:30 AM Page 19
 Connect Multi-Function Transmission Range (TR) Switch F125 to shift rod. Flap part at splines in switch
- 3 - must align with flat part of shift rod - 1 -.
NOTE:  Set Multi-Function Transmission Range (TR) Switch F125 onto shift rod in
centered manner. Do not cant and do not set with force. Risk of damage at
switch terminals.
 Rotate switch until the alignment bore - 4 - at switch housing can be fitted on the alignment pin - 2 - at
Tightening torques
Component Nm
1:43:30 AM Page 20
Speedometer Vehicle Speed Sensor (VSS) G22 , removing and installing
Removing

 Remove heat shield - 1 - for left drive axle (arrows), if installed.
Fig. 194: Removing Speedometer Vehicle Speed Sensor -G22- And Vehicle Speed Sensor -G68-
 Disconnect harness connector from Speedometer Vehicle Speed Sensor (VSS) G22 (arrow - A - ).
 Push retaining bracket of sensor downward, and turn (arrow).
 Remove sensor.
Installing
1:43:30 AM Page 21
Fig. 195: Installing Speedometer Vehicle Speed Sensor -G22- And Vehicle Speed Sensor -G68-
 Replace sealing rings (arrows).

 Insert O-rings with gear oil.
 Insert sensor.
 Engage retaining bracket at mounting bracket for flange shaft.

 Install heat shield - 1 - for left drive axle (arrows), if present.
Sensor for transmission RPM G182 , removing and installing
Removing
1:43:30 AM Page 22
 Unbolt Sensor for transmission RPM - A - from transmission.
Installing
 Bolt on Sensor for transmission RPM - A - at transmission via bolt - B -. Tightening torque is 9 Nm.
the valve body.
Transmission Vehicle Speed Sensor (VSS) G38 , removing and installing
Also referred to as Sender for transmission output RPM G195.
Removing
1:43:30 AM Page 23

 Disconnect harness connector from Transmission Vehicle Speed Sensor (VSS) G38 (arrow).
 Remove Transmission Vehicle Speed Sensor (VSS) - 2 -.
Installing
1:43:30 AM Page 24
 Install and tighten Transmission Vehicle Speed Sensor (VSS) - 2 - using spacer sleeve - 1 - (height: 8
mm) to 6 Nm.

 Connect connector at Transmission Vehicle Speed Sensor (VSS) G38.

Wiring harness inside transmission, removing and installing
Removing
1:43:30 AM Page 25
 Lever out retainer straps of connectors at solenoid valves and pressure control valves using a small
screwdriver and disconnect connectors - A - in sequence.
 Unhook wiring harness at side retainer straps - B - of valve body.
1:43:30 AM Page 26
 Turn valve body on its back side and loosen connector - 1 - at Pressure Control Valve 1 for Auto.
Transmission N215.
 Remove retaining clip (arrow A) and unclip wiring harness from retaining clip (arrow B).
Installing
 When installing, connect connectors of wiring harness to the corresponding solenoid valves and pressure
control valves.
 Clip wiring harness into the respective retaining clips. In case of deviations, the wiring harness can be
pinched during installation of the valve body.
Transmission Fluid Temperature Sensor G93 , replacing
NOTE:  Transmission Fluid Temperature Sensor G93 is integrated in the

transmission wiring harness.
Removal
 Remove wiring harness in transmission --> Wiring harness inside transmission, removing and
installing.
Installing
 Replace wiring harness with a new one.

 Install new wiring harness in transmission --> Wiring harness inside transmission, removing and
1:43:30 AM Page 27
installing.
1:43:30 AM Page 28

GEAR OIL IN FRONT FINAL DRIVE, CHECKING


Procedure
 Warm up gear oil in front final drive to approx. 60 ° C by performing a short road test.
1:45:37 AM
1:45:47 Page 1

destroyed.
 With engine switched off, allow gear oil to drip out for approx. 2 minutes.
Oil level is correct when the front final drive is filled up to lower edge of oil filler hole.
 Let excessive gear oil drain or top up gear oil --> Gear oil in front final drive, filling up after servicing.
 When the oil level is correct, tighten locking bolt using hex ball socket 3247 (8mm socket) to 30 Nm.
GEAR OIL IN FRONT FINAL DRIVE, FILLING UP AFTER SERVICING
Gear oil in front final drive, filling up after servicing
1:45:37 AM Page 2


Procedure
1:45:37 AM Page 3

destroyed.
 Slowly and uniformly fill front final drive over a time period of at least 5 minutes until gear oil escapes at
lower edge of oil filler hole.
 Specification --> Capacity
NOTE:  Filling time of at least 5 minutes is essential, so that the internal oil level
compensation between differential and retaining area can occur.

1:45:37 AM Page 4
 Screw in old locking screw (arrow).

 Perform a short test drive to warm gear oil to approx. 60 ° C.
 Check front final drive oil level --> Gear oil in front final drive, checking.
 When the oil level is correct, tighten locking bolt using hex ball socket 3247 (8 mm socket) to 30 Nm.
NOTE:  General repair notes --> Servicing notes.

1:45:37 AM Page 5
Fig. 211: Front Final Drive, Overview

1 - Seal

 Always replace --> Final drive sealing ring/transmission housing, replacing
2 - Adjustment shim
4 - Locking screw - 30 Nm
1:45:37 AM Page 6
 With seal
 Always replace
5 - Bolt - 23 Nm
6 - Right drive flange
7 - Right drive flange seal
 Always replace --> Sealing ring for right drive flange, replacing
8 - Bolt - 23 Nm
 Observe tightening sequence
12 - O-ring
 Always replace --> O-ring at cover for final drive, replacing
13 - Differential
14 - Bolt - 23 Nm
15 - Cover for front final drive
 Front wheel drive version shown
16 - Bushing
17 - Gasket
18 - Spring dowel sleeve
19 - Lever
1:45:38 AM Page 7
 For shift rod
20 - Seal
 For shift rod

 Always replace --> Shift rod seal, replacing
21 - Bolt - 23 Nm
22 - Left drive flange seal
23 - Drive gear
 For speedometer Vehicle Speed Sensor (VSS) G22

 Installation position --> Fig. 231
24 - Left drive flange
 Removing and installing --> Sealing ring and grooved ball bearing for left drive flange, replacing
onward
25 - Mounting bracket for drive flange
26 - Grooved ball bearing for drive flange
27 - Snap ring
28 - O-ring
 Square cross section

 Remove and install left drive flange to replace --> Sealing ring and grooved ball bearing for left drive
flange, replacing
Sealing ring for right drive flange, replacing
1:45:38 AM Page 8
Fig. 212: Identifying Special Tools - Sealing Ring For Right Drive Flange, Replacing

 Right sealing ring installer 3382
Removing
1:45:38 AM Page 9

SUSPENSION
 Remove wheel.

 Remove heat shield for right drive axle (arrows).
 Unbolt right drive axle - 1 - from transmission flange and remove. --> 40 - FRONT SUSPENSION
1:45:38 AM Page 10


 Pull out drive flange seal.
Installing
 Coat outer edge of oil seal with gear oil.
1:45:38 AM Page 11
Fig. 217: Driving New Seal Using Drift 3382

 Drive in new seal to stop, without canting seal.

 Install bolt for drive flange (arrow, 23 Nm) while securing drive flange against turning, using a drift.
1:45:38 AM Page 12

 Install right drive axle - 1 -. --> 40 - FRONT SUSPENSION

 Install heat shield for right drive axle (arrows).
 Install front wheel. --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT

Tightening torques
Component Nm
Sealing ring and grooved ball bearing for left drive flange, replacing
1:45:38 AM Page 13
Replacing (1 Of 2)

 Punch VW407
 Punch VW412

1:45:38 AM Page 14
Replacing (2 Of 2)
 Press tube 2040

 Assembly mandrel 3384
1:45:38 AM Page 15

SUSPENSION
 Remove wheel.

 Remove heat shield for left drive axle (arrows), if installed.
 Unbolt left drive axle - 1 - from transmission flange and remove. --> 40 - FRONT SUSPENSION
1:45:38 AM Page 16
Fig. 224: Extracting Gear Oil From Front Final Drive Using VAG 1358 A
 Remove oil filler plug (arrow) and siphon off at least 0.5 L gear oil from front final drive using oil
siphoning unit VAG1358A
NOTE:  Oil must be siphoned from final drive, otherwise there is a risk that the
gear oil could mix with the ATF.
 Remove Speedometer Vehicle Speed Sensor (VSS) --> Speedometer Vehicle Speed Sensor (VSS) G22 ,
 Remove harness connector bracket from mounting bracket for drive flange.

 Remove drive flange mounting bracket (arrows).

 Pull out drive flange.
1:45:38 AM Page 17
NOTE:  The left drive flange can be pulled out between body and subframe with
the transmission installed if the mounting bracket for drive flange is
turned approx. 60 ° to the right against the installation position.
Removing seal

 Remove circlip (arrow A) for grooved ball bearing.
1:45:38 AM Page 18
 Press drive flange out of drive flange mounting bracket.

 Remove drive flange seal using extractor lever VW681.

1:45:38 AM Page 19
Installing sealing ring

 Drive in new sealing ring to stop, without canting.
1:45:38 AM Page 20
Fig. 231: Installation Position Of Speedometer Drive Gear On Flange Shaft

 Set drive gear for Speedometer Vehicle Speed Sensor (VSS) G22 on drive flange (arrow).
 Installation position: The carriers at drive wheel must engage in grooves of drive flange
NOTE:  If necessary, coat contact surface with grease to affix drive wheel in
installation position.
 Press mounting bracket with grooved ball bearing onto drive flange.
1:45:38 AM Page 21

 Insert circlip (arrow - A - ).
Installing left drive flange

 Replace sealing ring (arrow B) in mounting bracket for drive flange.
1:45:38 AM Page 22
 Check drive flange for sharp edges on transmission side of flange end (arrow) and if necessary, deburr.
 Insert left drive flange into transmission.
NOTE:  When sliding in, left drive flange must be carefully guided by hand to
prevent damage to the double sealing ring in transmission.
 Secure mounting bracket for drive flange.

 Bolt on harness connector bracket to mounting bracket for drive flange.
 Install speedometer Vehicle Speed Sensor (VSS) G22 --> Speedometer Vehicle Speed Sensor (VSS)
G22 , removing and installing.

 Install left drive axle - 1 -. --> 40 - FRONT SUSPENSION

 Install heat shield for left drive axle (arrows).
1:45:38 AM Page 23
 Install left front wheel. --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT

Tightening torques
Component Nm
transmission
O-ring at cover for final drive, replacing




Removing
1:45:38 AM Page 24

SUSPENSION
 Remove right wheel.
 Remove right drive axle: --> 40 - FRONT SUSPENSION
 Remove right front exhaust pipe. -->

ENGINE CODE(S): BKH
 Remove right transmission support --> Right and left transmission mounts, removing and installing.
1:45:38 AM Page 25

 Remove bolts for final drive cover opposite of shown tightening sequence and remove cover.
Installing
1:45:38 AM Page 26
 Replace sealing ring (arrow).
 Install cover for final drive.

 2. Stage: Tighten bolts - 1 - to - 12 - in specified sequence to tightening torque
1:45:38 AM Page 27

ENGINE CODE(S): BKH
Tightening torques
Component Nm
Final drive sealing ring/transmission housing, replacing
1:45:38 AM Page 28
Fig. 243: Identifying Special Tools - Final Drive Sealing Ring/Transmission Housing, Replacing

 Double sealing ring installer 3383
NOTE:  A faulty sealing ring lets ATF or gear oil escape into the converter housing
via the center vent of the shaft seal (between the two sealing lips).
 In addition, a faulty sealing ring can let ATF escape into the center
differential. It over-fills and oil escapes at the differential vent.
1:45:38 AM Page 29
Removing
 Remove cover for front final drive --> O-ring at cover for final drive, replacing.
 Pull out differential and remove.
 Remove tapered roller bearing outer race of differential - 1 - and shim - 2 - which is behind it from
NOTE:  Shim is pre-determined and must not be exchanged for a shim with
another thickness.
 Remove left drive flange --> Sealing ring and grooved ball bearing for left drive flange, replacing.

 Pull out seal.
NOTE:  Extractor lever must be positioned behind both sealing lips of the sealing
1:45:38 AM Page 30
ring. Do not position at outer circumference of sealing ring, otherwise the

contact surface in transmission housing will be damaged. When levering
out, carefully guide extractor lever.
Installing
 Check seal seat in transmission housing for damage; rework if necessary.

 Coat outer circumference and sealing lip of sealing ring with ATF.
Fig. 246: Placing Seal Onto Press Piece 3383 With Protruding Sealing Lip On Seal Facing Toward Tool
 Slide seal onto double sealing ring installer 3383 so that the projecting sealing lip (arrow) of sealing ring
faces tool.

 Drive in new sealing ring to stop.

 Install left drive flange --> Sealing ring and grooved ball bearing for left drive flange, replacing.
1:45:38 AM Page 31
 Insert adjustment shim - 2 - and tapered roller bearing outer race for differential - 1 - into transmission
housing up to stop by hand.
 Insert differential into transmission housing.
 Install cover for front final drive.
ENGINE CODE(S): BKH
Tightening torques
Component Nm
transmission
1:45:38 AM Page 32

Seal for front final drive, replacing

 Engine/transmission jack VAG1383 with plate VAG1359/2

Removing

ENGINE CODE(S): BKH
1:45:38 AM Page 33
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE


 Remove heat shield for selector lever cable, if installed.
Fig. 250: Seal In Front Final Drive Intermediate Flange, Replacing

 Remove bolts (arrows) at intermediate flange for front final drive.
CAUTION:  Slowly and carefully remove cover for front final drive/intermediate
flange from transmission housing. The spur gears can otherwise fall
out of the transmission.
transmission must be swapped in this case.
 Lift off cover i.e. intermediate flange for front final drive.
NOTE:  Do not remove spur gears for front final drive. Secure spur gears so they
do not fall out.
 If the spur gears for front final drive were removed, the wheel marking
must face outward (away from transmission) for re installation.
Installing
1:45:38 AM Page 34
 Make sure centering sleeve - A - is correctly seated before installing.

 Install gasket
 Set on cover i.e. intermediate flange for front final drive.
1:45:39 AM Page 35
NOTE:  When tightening bolts by hand, make sure the housing gap between cover
and transmission housing decreases evenly around circumference.
 2. Stage: Tighten bolts - 1 - to - 14 - in specified sequence to tightening
torque
Tightening torques
1:45:39 AM Page 36
Component Nm
Intermediate flange for front final drive to 23
transmission housing
Center differential to transmission housing 23
GEAR OIL IN CENTER DIFFERENTIAL, CHECKING AND TOPPING OFF
Gear oil in center differential, checking and topping off


Procedure
1:45:39 AM Page 37

B). -->
ENGINE CODE(S): BKH
Oil level is correct when the final drive is filled up to lower edge of oil filler hole.
 Let excessive gear oil drain or top up gear oil --> Gear oil in center differential, changing or topping
up after repair.
 Secure or reinstall exhaust system free of stress. -->
1:45:39 AM Page 38

ENGINE CODE(S): BKH
GEAR OIL IN CENTER DIFFERENTIAL, CHANGING OR TOPPING UP AFTER REPAIR
Gear oil in center differential, changing or topping up after repair


Procedure
1:45:39 AM Page 39
Drain gear oil

 Removing drain plug (arrow A) and draining gear oil.

 Always replace drain plug.
 Thread in new drain plug (arrow A) again and tighten to 20 Nm.
Filling up gear oil

B). -->
1:45:39 AM Page 40

ENGINE CODE(S): BKH
NOTE:  There is a distinction made between two cases:

 A - Center differential was not removed.
 B - Center differential was removed
A - Center differential was not removed (e.g. after removing and installing drive flange/drive shaft)


 Top up transmission fluid to lower edge of oil filler hole. Specification and capacity Center differential.
 Thread in old oil filler plug and tighten to 35 Nm.
NOTE:  If it was necessary to loosen or remove the exhaust system, this must be
re-secured or reinstalled for the road test. It must be removed and
installed again for the final oil level check.
 Road test vehicle (15 minutes pure driving).
NOTE:  During road test, gear oil enters output cover and Torsen differential; oil
1:45:39 AM Page 41
level in center differential housing will drop.
 Fill transfer housing with gear oil and check oil level --> Gear oil in center differential, checking and
topping off.
B - Center differential was removed and disassembled
 Add 200 ml. gear oil to output cover.

 Center differential, assembling and installing.


 Add 600 ml. gear oil to center differential housing.
NOTE:  Oil level does not need to be re-checked.
All:
 Secure or re-install exhaust system free of stress. -->

ENGINE CODE(S): BKH
1:45:39 AM Page 42

CENTER DIFFERENTIAL, SERVICING
Center differential, servicing
Transmission installed

1:45:39 AM Page 43
 Punch VW412
 Thrust tube VW454
 Punch VW407
 Sleeve 3021

 Sleeve 40-20
 Press support 3118
 Item 3 Kukko 17/2 separating tool
1:45:39 AM Page 44
CAUTION: Do not run engine with the center differential removed or without gear oil
and do not tow vehicle.

The parts listed in the following illustration can be removed with the transmission installed.
Fig. 262: Center Differential Remove/Install Components

2 - Output flange/driveshaft
1:45:39 AM Page 45
3 - Seal
 Always replace --> O-ring for output flange/driveshaft, replacing
4 - Bolt - 23 Nm
 4x
5 - Housing cover
 With dampener
6 - O-ring
7 - Snap ring
9 - Spur gear 1
10 - Snap ring
11 - Needle bearing

 To replace, heat up transfer gear housing to approx. 100 ° C and drive out needle bearing toward rear
using drift (Warning! Wear protective gloves)
 Drive in to stop using 30-21 sleeve
12 - Bolt - 23 Nm
 Loosen or tighten in stages and in diagonal sequence
13 - Center differential housing
14 - Tension nut
15 - Needle bearing
1:45:39 AM Page 46

 Always replace --> Needle bearing for spur gear 2, replacing
16 - Snap ring
17 - Spur gear 2
19 - Snap ring
20 - Washer
21 - Alignment plate
22 - Bolt - 10 Nm
23 - Snap ring
24 - Gasket
 Always replace --> Center differential, removing and installing
 If damaged replace as complete unit

26 - Seal
 Always replace --> Sealing ring in intermediate flange for front final drive, replacing
27 - Magnet
28 - Bushing
 2x
1:45:39 AM Page 47
29 - Breather
 For transfer gear

 With cap installed
 Installation position: Without cover, breather must project 10 - 11 mm out of housing
30 - Bolt - 23 Nm
32 - Gasket
33 - Bushing
34 - Drive pinion

 Removing and installing --> Sealing ring in drive pinion, replacing

36 - Output pinion

37 - Seal
 Always replace --> Sealing ring in drive pinion, replacing
1:45:39 AM Page 48

1:45:39 AM Page 49

Center differential, removing and installing

 Engine/transmission lifter VAG1383A with universal transmission holder VAG1359/2
1:45:39 AM Page 50



Removing

ENGINE CODE(S): BKH

1:45:39 AM Page 51

repair.

 Loosen mounting bolts - A - and - C - for transfer housing - 2 - in diagonal sequence and remove.
 Do not remove bolts - B -.
1:45:39 AM Page 52
CAUTION: Carefully pull center differential housing off of transmission toward rear.
The Torsen differential could otherwise fall out of the transmission.

 Pull Torsen differential off output shaft toward rear.
Installing
Fig. 272: Location Of Alignment Pins -A/B-, Magnet and Seal Surface
 Check for presence of dowel sleeves (arrows - A - and - B - ).
1:45:39 AM Page 53
 Install gasket
NOTE:  Lightly coat sealing surface -D- with gear oil to prevent the seal from
slipping.
 Slide cleaned magnets into cast holding pocket - 1 - in intermediate flange.

 Add 200 ml. gear oil to output housing (comparable to gear oil, topping up on removed and disassembled
center differential).

 Install Torsen differential onto splines of output shaft and bottom spur gear while turning slowly.
 Check whether installed Torsen differential can be turned by hand.
1:45:40 AM Page 54
 Install fully assembled transfer housing with installed spur gears and drive flange/drive shaft onto
transmission flange.
 Insert bolts - A - and - C - for transfer housing - 2 - and tighten to final tightening torque in diagonal
sequence in several stages.

ENGINE CODE(S): BKH
Tightening torques
Component Nm
Center differential housing to transmission housing 23
O-ring for output flange/driveshaft, replacing
1:45:40 AM Page 55
Fig. 275: Pressure Piece 3402

 Pressure piece 3402

 Engine/transmission lifter VAG1383A with Universal transmission holder VAG1359/2



1:45:40 AM Page 56
Removing

ENGINE CODE(S): BKH

1:45:40 AM Page 57
repair.
Fig. 279: Removing/Installing Flanged Shaft

 Unbolt output flange driveshaft while securing output flange/driveshaft against turning using a drift.
 Pull out output flange/driveshaft.
1:45:40 AM Page 58
Fig. 280: Removing O-Ring Using Appropriate Screwdriver

 Remove O-ring using appropriate screwdriver.
Installing
Fig. 281: Driving In Sealing Ring To Stop Using Pressure Piece 3402
 Drive O-ring in to stop using pressure piece 3402.

 Secure output flange/driveshaft with socket-head bolt.
1:45:40 AM Page 59


ENGINE CODE(S): BKH
Tightening torques
Component Nm
Socket-head bolt for output flange/driveshaft, rear 25
Sealing ring in intermediate flange for front final drive, replacing
1:45:40 AM Page 60

Flange

 If oil escapes at this oil leak inspection opening, this double sealing ring
must be replaced.
Removing


1:45:40 AM Page 61
 Drive out sealing ring (arrow) in direction of transfer gear using a mandrel.
Installing
 Check seal seat in intermediate flange for damage; rework if necessary.


 Slide sealing ring onto thrust piece 3404 so that the larger and projecting outer ring (arrow) of sealing
ring faces tool.
 Drive in sealing ring up to thrust piece 3404 stop.
sealing lip of the sealing ring can be damaged.
Sealing ring in drive pinion, replacing
1:45:40 AM Page 62

Flange

 If oil escapes at this inspection opening, this sealing ring must be
replaced.
Removing

1:45:40 AM Page 63
 Remove intermediate pinion - 2 - for front final drive from transfer housing.
 Pull drive pinion - 3 - from output shaft.
CAUTION: Do not reinstall spur gears that have fallen to the ground. The
Output pinion - 1 - remains on the drive pinion.
 Drive out sealing ring using drift.
Installing
1:45:40 AM Page 64

 Slide sealing ring onto thrust piece 3403.

 Drive sealing ring in up to thrust piece 3403 stop.
Contact surface - A - of thrust piece must lie against drive pinion - B -.

 Completely cover splines on end of shaft (arrow) with insulating tape without creasing or overlapping the
tape, to prevent damage to sealing ring when sliding on drive pinion.
 Install drive pinion on center of output shaft. (Installation position )
1:45:40 AM Page 65
NOTE:  If installing the intermediate flange on the output shaft carelessly, the
 Slide drive pinion - 3 - together with the intermediate pinion - 2 - into final drive housing up to stop
(tapered roller bearing).
Observe installation position of spur gears (pinion):
Wheel identification (arrows) point outward, away from final drive.
1:45:40 AM Page 66
Fig. 292: Identifying Special Tools - Needle Bearing For Spur Gear 2, Replacing

 Punch VW408A
 Press sleeve for sleeve 2080A
 Item 1 Kukko 21/4 extractor
 Item 3 Kukko 22/1 support

 Hot air blower VAG1416
Removing
1:45:40 AM Page 67
Fig. 293: Unbolting Rear Flanged Shaft

 Unbolt rear output flange/driveshaft while securing output flange/driveshaft against turning.
Fig. 294: Identifying Tension Nut, Guide Plate And Shim

 Pull tension nut - A - out of spur gear shaft.

 Remove bolts (arrows).
 Remove guide plate - B - and shim - C -.
 Remove securing ring for securing grooved ball bearing in center differential housing
1:45:40 AM Page 68
Fig. 295: Needle Bearing For Spur Gear -2, Removing (As Shown)
 Attach support - A - at internal extractor - B - as shown and insert spur gear shaft - 2 -.
 Pull out spur gear and carefully remove upward.
 Remove needle bearing securing ring.

1:45:40 AM Page 69
NOTE:  The upper part of the illustration shows how the pulling hooks of extractor
- B - must be inserted into needle bearing.
 Slide centering sleeve - 2 - of extractor - B - approx. 4 mm into direction of arrow in order to be able to
open pulling hooks of extractor far enough.

 Install retainer - A - on extractor - B - as illustrated.
 Quickly pull out needle bearing.
Installing
1:45:41 AM Page 70
 Check needle bearing seat in transfer housing for damage, rework if necessary.
Fig. 298: Inserting New Needle Bearing And Set Sleeve 2080A Onto New Needle Bearing
 Insert new needle bearing and set sleeve 2080A onto new needle bearing - 1 -.
Sleeve 2080A must be centered when set onto sleeve.
 Drive needle bearing into transfer housing up to stop using punch VW408A.
DRIVESHAFT, SERVICING
Driveshaft, servicing
-->

Driveshaft, removing and installing
1:45:41 AM Page 71
-->

1:45:41 AM Page 72
TRANSMISSION 6 Spd. Automatic Transmission 09L All Wheel Drive
TRANSMISSION
6 Spd. Automatic Transmission 09L All Wheel Drive
00 TECHNICAL DATA
Transmission identification
The "6-speed automatic transmission 09L" is installed in the Audi A4 2002 --> in combination with various
engine versions. Allocation --> Code letters, transmission allocation, ratios, equipment.
Location of code letters on transmission
Fig. 1: Locating Type Plate

The transmission code letters are given on the type plate at the bottom of the transmission - arrow A -.
1:51:46 AM
1:52:14 Page 1
Fig. 2: Identifying Type Plate

The type plate lists the following information:
1. Serial number of transmission

2. Part number
3. Transmission designation, in this example 6HP19
4. Code letters, in this example GZV
Additional data are production-related.
NOTE:  The code letters for the transmission are also given on the vehicle data
stickers.
NOTES ON THE AUTOMATIC 6-SPEED TRANSMISSION 09L
Notes on the automatic 6-speed transmission 09L
Transmission
The 6-speed automatic transmission 09L (all wheel drive) has six hydraulically activated forward gears. When
the lock-up clutch is closed these forward gears become mechanically driven gears by cutting out the torque
converter slip.
Torque converter
The torque converter is equipped with a slip-controlled lock-up clutch.
Mechatronics unit
The mechatronics unit incorporates the hydraulic control system, the electronic Transmission Control Module
(TCM) J217, the Multi-Function Transmission Range (TR) switch F125 and the sensors and actuators as a
complete unit. The mechatronics unit is installed in the transmission within the oil pan.
1:51:46 AM Page 2
Transmission Control Module (TCM) J217
The control module is part of the mechatronics unit in the transmission.
The switching point is calculated automatically (depends on driving situation and driving resistance).
Advantages:
 Gear changes are timed for maximum fuel economy.

 Maximum engine output is always available
 Individual adaptation of gear change points in all driving situations
 Gear change points are infinitely variable
Self-diagnosis
Before performing repairs to the automatic transmission, determine the cause of the fault as precisely as
possible using "Guided fault finding".
"Guided fault finding" is performed using the vehicle diagnostic, testing and information system VAS 5051 A.
Gear shift point variations for hills
An additional gear change map automatically selects gear changes for hills depending on accelerator pedal
position and driving speed.
 Gear change map for extreme uphill stretches is matched to engine output
 Gear change map for extreme downhill stretches is matched to the braking effect of the engine
 The engine braking effect can also be fully exploited via a specific gear, e.g. on hills when towing a
trailer, by directly selecting a gear with the Tiptronic.
CODE LETTERS, TRANSMISSION ALLOCATION, RATIOS, EQUIPMENT
Code letters, transmission allocation, ratios, equipment
Automatic transmission 09L.D 09L.D

Transmission Code letters GUR GUR
Manufactured from 06.03 01.04
to 05.04 05.04
Torque Code letters D76 D76
converter
Mechatronics Allocation according to transmission code letters
unit
Application Model Audi A4 2002 --> Audi A4 Cabriolet 2003 -->
Engine 4.2 ltr. 5V - 250 kW 4.2 ltr. 5V - 250 kW
1:51:46 AM Page 3
Primary drive 33:29 1.138 33:29 1.138

Front axle Spur gear 31:29 1.069 31:29 1.069
drive
Bevel gear 32:11 2.909 32:11 2.909
drive
Ratio 3.539 3.539
Rear axle Bevel gear 31:10 3.100 31:10 3.100
drive
Ratio 3.528 3.528
Automatic transmission 09L.D 09L.D 09L.D

Transmission Code letters HHL HHM HHU
Manufactured from 11.04 11.04 05.04
to
Torque Code letters Z80 H77 D76
converter
unit
Application Model Audi A4 2002 --> Audi A4 2002 --> Audi A4 2002 -->
USA
Engine 2.0 ltr. TFSI - 147 3.2 ltr. FSI - 188 kW 4.2 ltr. 5V - 250 kW
kW
Primary 33:29 1.138 33:29 1.138 33:29 1.138
drive
Front axle Spur gear 31:29 1.069 31:29 1.069 31:29 1.069
drive
Bevel gear 32:11 2.909 32:11 2.909 32:11 2.909
drive
Ratio 3.539 3.539 3.539
Rear axle Bevel gear 31:10 3.100 31:10 3.100 31:10 3.100
drive
Ratio 3.528 3.528 3.528
Automatic transmission 09L.D 09L.D

Transmission Code letters HHU HLB
to
Torque Code letters D76 D76
converter
unit
Application Model Audi A4 Cabriolet Audi A4 2002 -->
2004 -->
1:51:46 AM Page 4
Engine 4.2 ltr. 5V - 250 kW 4.2 ltr. 5V - 250 kW

Primary 33:29 1.138 33:29 1.138
drive
Front axle Spur gear 31:29 1.069 31:29 1.069
drive
Bevel gear 32:11 2.909 32:11 2.909
drive
Ratio 3.539 3.539
Rear axle Bevel gear 31:10 3.100 31:10 3.100
drive
Ratio 3.528 3.528
REAR FINAL DRIVE IDENTIFICATION
Rear final drive identification
The final drive 01R is allocated to the automatic transmission 09L all wheel drive
Assembly allocation -->


Location on final drive
Code letters and date of manufacture - arrow 1 -
Final drive 01R - arrow 2 -
1:51:46 AM Page 5

Final drive 01R - arrow 2 -
Fig. 5: Rear Final Drive Identification

Final drive code letters and date of manufacture - arrow 1 -
Example: EXZ 26 11 02
I I I I
I I I I
Code letters Day Month Year of manufacture
(2002)
Code letters, ratios, capacities -->

1:51:46 AM Page 6
CAPACITIES
Planetary transmission
Capacities Planetary transmission Automatic transmission

Initial filling 9.8 ltr. 09L
Changing interval no change required * See note
Lubricant ATF(Shell ATF M-1375.4)
*Lifetime filling: change only after repair, approx. 8 ltrs. if oil pan has been removed.
ATF is obtainable as a replacement part.
Container size 1.0 ltr. - ATF (automatic transmission fluid) G 055 005 A2
Use only the correct type of ATF (available as a replacement part) for the planetary gearing in automatic
transmission 09L. Other oils may cause faults and/or failure of the transmission.
 Checking ATF level in planetary transmission --> ATF level, checking and correcting.
Front final drive
Capacities Front final drive Automatic transmission

Changing no change required * See note
Lubricant Gear oil SAE 75 W 90 (synthetic
oil)
*Lifetime filling: change only after repairs, up to 1.1 ltrs. if differential cover has been removed.
Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part in following container sizes:
 0.5 ltr. - gear oil G 052 145 A1

 1.0 ltr. - gear oil G 052 145 S2
 Checking oil level in front final drive --> Front final drive gear oil.
Transfer gear
Capacities Transfer gear Automatic transmission

Changing interval no change required * See note
1:51:46 AM Page 7
Lubricant Gear oil SAE 75 W 90 (synthetic

oil)
*Lifetime filling: change only after repairs, up to 0.55 ltrs. if Torsen differential cover has been removed.
Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part in following container sizes:
 0.5 ltr. - gear oil G 052 145 A1

 1.0 ltr. - gear oil G 052 145 S2
 Checking transfer gear oil level--> Transfer gear oil.
Rear final drive
 Checking gear oil level -->

Capacities and specifications -->

NOTES ON TOW-STARTING AND TOWING
Notes on tow-starting and towing
CAUTION: When vehicle is being towed, selector lever must be set to position "N"
and vehicle must not to be towed for more than 50 km or at a speed in
excess of 50 km/h, as the transmission would otherwise be destroyed.
NOTE:  It is not possible to start the engine by means of tow-starting, for instance
in the case of insufficient battery charge or if starter is not working.
REPAIR INSTRUCTIONS
General repair instructions
The maximum possible care and cleanliness and proper tools are essential for satisfactory and successful
transmission repairs. The usual basic safety precautions also naturally apply when performing vehicle repairs.
1:51:46 AM Page 8
A number of generally applicable instructions for the various repair procedures - which were previously
repeated at numerous places in the article - are summarized here. They apply to the work described in this
article.
Special tools
For a complete list of special tools used in this article "Special tools".
Transmission
 Read the rules for cleanliness when working on the automatic transmission --> Rules for cleanliness.
 Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.
 If the transmission has been removed from vehicle, secure torque converter to prevent it from falling out.
 Thoroughly clean all joints and surrounding areas before disassembling.
 Before installing transmission check position of torque converter.

 When installing transmission make sure dowel sleeves are correctly seated.
 Carefully cover or seal open components if repairs cannot be carried out immediately.
 When installing a new automatic transmission, check the following fluid levels and top off if necessary:
ATF in the planetary gearbox --> ATF level, checking and correcting, the gear oil in the front final
drive --> Front final drive gear oil, the transfer gear oil --> Transfer gear oil. Capacities and
specifications --> Capacities
 When installing a new rear final drive, check the oil level in the rear final drive and top off if necessary.
Capacities and specifications -->
O-rings, oil seals, gaskets
 Always install new O-rings, oil seals and gaskets.

 After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs
1:51:46 AM Page 9

 Before installing oil seals, fill the space between the sealing lips - arrow - half full with sealing grease G
052 128 A1 .
 The open side of the oil seals faces toward the side with fluid filling.
 Before installing, lightly lubricate outer circumference of seal and sealing lips with ATF or gear oil,
depending on location.
 Lightly lubricate O-rings with ATF before installation to prevent them from getting crushed during
assembly.
 Use only ATF in ATF area. Other lubricants will cause the transmission hydraulics to malfunction.
 When installing a new oil seal, position the seal in the housing so that sealing lip does not contact the
shaft in the same place as the old seal (make use of insertion depth tolerances).
 Replace paper gaskets, clean all sealing surfaces thoroughly and remove previous gaskets completely.
 After installing, check the relevant fluid levels and top off if necessary: ATF in planetary gearbox -->
ATF level, checking and correcting, gear oil in front final drive --> Front final drive gear oil, transfer
gear oil --> Transfer gear oil, gear oil in rear final drive -->
. Capacities and specifications --> Capacities
Nuts, bolts
 Loosen bolts in reverse sequence to the specified tightening sequence.

 Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence
and in stages if no tightening sequence is specified.
 Always replace self-locking bolts and nuts.
 Clean threads of bolts which are secured by a locking compound with a wire brush. Then apply locking
fluid AMV 185 101 A1 to bolts again before installing.
1:51:46 AM Page 10
 Threaded holes which take self-locking bolts or bolts coated with locking compound must be cleaned
(using a tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being
removed.
Locking elements

 Retaining rings/circlips must be properly seated in the base of the groove.
Bearings
 Lubricate bearings with gear oil or ATF, depending on location.
Mechatronics unit
CAUTION:  Before touching or removing the mechatronics unit, always

discharge any static electricity by touching vehicle ground or other
grounded object by hand.
 Never touch the 16 contacts in connector - B - with your hands, as
static discharge would damage the control module and mechatronics
unit.
 Replace the transmission if any of the shift elements are scorched.

 Allocate mechatronics unit according to transmission code letters .
Fig. 7: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051 A
Guided fault finding, vehicle self-diagnosis and testing system
 Before servicing the automatic transmission, the exact cause of the failure must be determined as
precisely as possible via the vehicle diagnostic, testing and information system VAS 5051 A in the modes
1:51:46 AM Page 11
"Guided Fault Finding", "vehicle self-diagnosis" and "testing system".
RULES FOR CLEANLINESS
Rules for cleanliness
 Observe the general repair instructions --> General repair instructions.

 Place removed parts on a clean surface and cover them with sheeting and paper or use lint-free cloths.
 Carefully cover or seal open components if repairs cannot be carried out immediately.
 Only install clean components: do not remove replacement parts from packaging until just before
installation.
32 TORQUE CONVERTER
TORQUE CONVERTER
Torque converter
CAUTION: Before installing transmission check position of torque converter.
NOTE:  Read the rules for cleanliness when working on the automatic
transmission --> Rules for cleanliness.
 General repair instructions --> General repair instructions.
 Apply thin coat of ATF to seals. Other types of lubricant will cause the
transmission hydraulics to malfunction.

1:51:46 AM Page 12
There are various types of torque converter. They are marked with code letters - arrow -.
Torque converter/transmission allocation --> Code letters, transmission allocation, ratios, equipment.

 Oil extractor V.A.G 1358 A

 Oil extractor probe V.A.G 1358 A/1
Fig. 10: Extracting ATF From Torque Converter Using Oil Extractor V.A.G 1358 A And Oil Extractor
Probe V.A.G 1358 A/1
If the ATF has become fouled by abrasion or when performing a major transmission overhaul, drain the torque
converter as follows:
 Extract ATF from torque converter using oil extractor V.A.G 1358 A and oil extractor probe V.A.G 1358
A/1.
1:51:46 AM Page 13

 Extractor lever VW 681
Fig. 12: Thrust Piece T10137

 Thrust piece T10137
Procedure
 Remove transmission: --> Transmission, removing (vehicles with 2.0 ltr. TFSI engine), -->
Transmission, removing (vehicles with 3.2 ltr. FSI engine), --> Transmission, removing (vehicles
with 4.2 ltr. MPI engine).
 Mount transmission on assembly stand --> Transmission, securing to assembly stand.
 Carefully pull out torque converter.
1:51:46 AM Page 14
 Remove oil seal for torque converter using oil seal extractor VW 681.
 Lightly lubricate outer circumference and sealing lips of oil seal with ATF.
 Installation position: open side of oil seal points toward transmission
Fig. 14: Driving In Torque Converter Oil Seal With Thrust Piece T10137 Until Thrust Piece Reaches
Stop
 Drive in torque converter oil seal with thrust piece T10137 until thrust piece reaches stop.
1:51:46 AM Page 15

 Check hub - arrow - of torque converter for scoring.
NOTE:  The torque converter is a welded assembly and must be replaced as a

complete unit in the event of any damage or malfunctions.
 Depth gauge
Installing
 Press torque converter hub through oil seal as far as first stop.
 Lightly press torque converter inward and turn until slots on torque converter hub engage in drive lugs on
ATF pump gear and torque converter slides in a noticeable distance.

1:51:46 AM Page 16
Installed depth
If the torque converter is correctly installed, the depth between the contact surfaces at the tapped holes on the
torque converter and the contact surface of the torque converter bell housing is at least 19 mm.
CAUTION: If the torque converter is not installed correctly, the torque converter drive
lugs or the ATF pump will be seriously damaged when the transmission is
joined to the engine.
 Use new ribbed bolts to secure torque converter to drive plate.
When installing the transmission, observe the following instructions.
CAUTION: Before and while you are tightening the bolts on the engine/transmission
flange keep checking that the torque converter can still be rotated behind
the drive plate. If the converter cannot be turned, it must be assumed that
it has not been installed correctly and the drive lugs on the converter or
the ATF pump will be damaged when the bolts are fully tightened.
37 CONTROLS, HOUSING
ELECTRICAL/ELECTRONIC COMPONENTS AND LOCATIONS
Fig. 17: Connecting Data Link Connector (DLC)

1:51:46 AM Page 17
Location: below knee padding on left side of steering wheel
The following components can be tested in the "Guided fault finding" using vehicle diagnostic, testing and
information system VAS 5051 A.
Fig. 18: Removing/Installing Securing Bolts For Mechatronics Unit In Sequence

Mechatronics unit, Transmission Control Module (TCM) J217, Multi-function transmission range (TR)
switch F125, Transmission input speed (RPM) sensor G182 and Transmission output speed (RPM) sensor
G195
Location: the mechatronics unit is bolted to the underside of the transmission housing and covered by the
The mechatronics unit incorporates the hydraulic control system, the electronic control module and the sensors
and actuators as a complete synchronized unit. This includes:
 Transmission Control Module (TCM) J217

 Multi-Function Transmission Range (TR) Switch F125
 Transmission Input Speed (RPM) Sensor G182
 Transmission Output Speed (RPM) Sensor G195
The "mechatronics" unit can only be replaced as a complete unit.
NOTE:  All components mentioned are tested via Self-diagnosis.
1:51:46 AM Page 18
 Removing and installing mechatronics unit --> Mechatronics unit, removing and installing
Fig. 19: Locating Wiring Harness With Connector Is Attached To The Mechatronics Unit
Internal wiring harness in transmission
Location: the wiring harness - A - with connector - C - is attached to the mechatronics unit - B -.
 Removing and installing wiring harness --> Wiring harness in transmission, removing and installing.
Fig. 20: Transmission Range (TR) Selector Lever Display -Y6-

Transmission Range (TR) Display Y6
Location: integrated into instrument cluster
1:51:46 AM Page 19
NOTE:  The Transmission Range (TR) Display Y6 can only be replaced together
with instrument cluster.
Fig. 21: Selector Mechanism Consists Of 3 Hall Senders, And

Tiptronic switch F189
 Location: The Tiptronic switch F189 is integrated in the printed circuit of the symbol panel, which is
located in the selector mechanism cover.
 Comprises 3 Hall sensors actuated by a magnet on transverse slide of the sliding cover.
A - Tip-down sensor
B - Sensor for Tiptronic recognition
C - Tip-up sensor

NOTE:  In the event of faults, first check that magnet is properly secured on the
1:51:46 AM Page 20
transverse slide - C - of the sliding cover. Replace sliding cover if

necessary. Always check wiring before replacing symbol insert with
integrated printed circuit. On vehicles with multi-function steering wheel
the buttons on the steering wheel and their wiring connections must also
be checked.
 Ignore - item A - and - item B -.
 Removing and installing Tiptronic switch F189 --> Tiptronic switch F189, removing and installing
SELECTOR MECHANISM, SERVICING
Selector mechanism, servicing
CAUTION: Before working on vehicle when engine is running, shift the selector lever
into position "P" and apply the parking brake.
 Turn ignition key to "ignition on" position.

 Press and hold brake pedal.
 When button in selector lever handle is pressed, it should be possible to move selector lever out of
position "P" without "catching".
 It should not be possible to remove the ignition key when the selector lever is in any position other than
"P".
 Shift selector lever to position "P".
 It should be possible to move ignition key to removal position without "sticking".
 Pull out ignition key.
 It should only be possible to remove ignition key in selector lever position "P".
 Selector lever cannot be shifted out of "P" position with button pressed and foot brake depressed.
If ignition key removal lock does not function as described, locking cable has to be adjusted --> Locking
cable, adjusting.
Selector mechanism, checking
 It should not be possible to operate the starter while the selector lever is in position "S", "D", "R" or in the
"Tiptronic gate".
 When travelling at speeds above 5 km/h and shifting into selector lever position "N", the solenoid for the
selector lever lock must not engage and block the selector lever. The selector lever can be shifted into a
driving gear.
1:51:46 AM Page 21
 When travelling at speeds below 2 km/h (almost stationary) and shifting into selector lever position "N",
the solenoid for the selector lever lock should only engage after about 1 second. Selector lever cannot be
shifted out of "N" position until brake pedal is depressed.
Selector lever in "P" position and ignition switched on:
 Do not depress brake pedal.
 Selector lever is locked and cannot be shifted out of "P" position. Solenoid for selector lever lock blocks
selector lever.
 Solenoid for selector lever lock releases selector lever. It is possible to shift into a driving gear. Shift
selector lever slowly from "P" position through "R, N, D and S" and check whether the display in the
instrument cluster shows the correct selector lever position in each case.
Selector lever in "N" position and ignition switched on:
 After a short waiting time: Selector lever is locked and cannot be shifted out of "N" position. Solenoid for
selector lever lock blocks selector lever.
 Depress brake pedal.
 Solenoid for selector lever lock releases selector lever. It is possible to shift into a driving gear.
Selector lever in "D" position, ignition and lights switched on:
 Shift selector lever into "Tiptronic gate".
 The illuminated "D" symbol in the selector lever position indicator should go out and the "+" and "-"
symbols should light up.
 The selector lever position indicator in the instrument cluster should switch from "PRNDS" to "654321"
when the selector lever is shifted into the "Tiptronic gate".
If ignition key removal lock does not function as described, selector lever cable has to be checked and
possibly adjusted --> Selector lever cable, checking and adjusting.
Selector mechanism cover, selector lever handle, component overview
NOTE:  Lubricate all bearings and moving surfaces with polycarbamide grease G
052 142 A2 .
1:51:46 AM Page 22
Fig. 23: Selector Mechanism Cover, Selector Lever Handle, Component Overview
1 - Selector lever
2 - Sleeve for selector lever
4 - Cover
 With position indicator and Tiptronic gate and display for selector lever lock
1:51:46 AM Page 23
 Removing and installing --> Selector mechanism cover, removing and installing
5 - Symbol insert
 Clipped onto cover
 With integrated Tiptronic switch F189

 Removing and installing --> Tiptronic switch F189, removing and installing
7 - Sliding cover
 With integrated magnet for Tiptronic switch F189 on transverse slide.

8 - Guide for sliding cover
 Carefully pry apart two halves
Removing
 Shift selector lever to position "D".

 Turn sleeve - 1 - counter-clockwise and push down onto stop.

 Pull button - 2 - out of selector lever handle - 3 - carefully, just far enough to be able to insert a cable tie
NOTE:  Under no circumstances pull button out further, as selector lever handle
1:51:46 AM Page 24
would then become damaged.
 Use cable tie to secure the button in its pulled position - arrow - , as shown in illustration.
 Remove selector lever handle by pulling it off.
Installing
Installation is performed in reverse sequence. Note the following:

NOTE:  To install the selector lever handle - 3 - the button - 2 - has to be pulled out
to the stop and must be secured with either a cable tie - arrow - or with the
assembly aid supplied together with the new handle.
 If, by mistake, the button has not been secured, it must not be pulled out
of the selector lever handle using mechanical tools. Position a
compressed air gun at the bottom of the handle and carefully press the
button out with compressed air.
 Install selector lever handle - 3 - fully onto selector lever; button - 2 - points toward the driver. The
handle must engage in annular groove of selector lever.
 Remove cable tie - arrow - or assembly aid; the button mechanism will then engage in the vertical groove
on the selector lever. If necessary, press button into selector lever handle.
 Pull sleeve - 1 - upward and engage by turning in clockwise direction.
Selector mechanism cover, removing and installing
Removing
 Remove selector lever handle --> Selector lever handle, removing and installing.
1:51:47 AM Page 25

 Open ashtray on center console and remove trim - arrows -.
 Release 4 retainers - arrows - and lift off cover - 1 - including guide.

 Disconnect electrical connector from side of guide.
Installing
 Install selector lever handle --> Transmission, installing (vehicles with 4.2 ltr. MPI engine).
Tiptronic switch F189, removing and installing
 Comprises 3 Hall sensors actuated by a magnet on the transverse slide of sliding cover.
 Also check that magnet is properly secured on transverse slide of sliding cover, replace sliding cover with
guide if necessary.
1:51:47 AM Page 26
Removing
 Remove selector mechanism cover --> Selector mechanism cover, removing and installing.
 Press 4 locking hooks - arrows - inward and pull cover - 2 - off guide - 1 -.
 Take printed circuit with integrated Tiptronic switch F189 out of cover.
NOTE:  If necessary, the sliding cover with the magnet for the Tiptronic switch
F189 can be removed as described below. However, as a replacement part
the sliding cover is only available together with the guide.
1:51:47 AM Page 27
 Carefully separate two halves of guide by levering them apart - arrows -.

 Remove sliding cover with magnet for Tiptronic switch F189.
Installing
 Install selector mechanism cover --> Selector mechanism cover, removing and installing.
Selector mechanism, component overview
052 142 A2 .
1:51:47 AM Page 28
Fig. 30: Selector Mechanism, Component Overview

1 - Selector mechanism cover (bottom)
2 - Retaining clip for selector lever
3 - Bearing bushing
5 - Pivot pin
6 - Selector lever
 Removing and installing --> Shift lock solenoid N110, removing and installing
8 - Actuating lever for locking cable
9 - Lock for locking cable
10 - Lever for locking cable
11 - Locking lever
12 - Selector gate
13 - 10 Nm
17 - Retaining clip
 Replace
19 - Pivot pin
20 - 10 Nm
1:51:47 AM Page 29
Selector mechanism, removing and installing
NOTE:  The following procedure describes how to remove and install the selector
mechanism without the selector lever cable, i.e. the selector lever cable
remains in the vehicle.
Removing


 Remove air conditioning control console --> 87 AIR CONDITIONING .
 Remove ashtray from center console -->
1:51:47 AM Page 30

 Disconnect electrical connector from Shift lock solenoid Shift lock solenoid N110.

 Unhook locking cable - arrows -.

 Shift selector lever to position "S".
Fig. 34: Loosening Clamping Sleeves

Vehicles with 4.2 ltr. MPI engine:
NOTE:  To prevent damage, the flexible couplings in the front exhaust pipes must
not be bent further than 10°.
 Disconnect exhaust system at clamps - arrows -.

 Disengage rear section of exhaust system at rubber mountings and remove.
1:51:47 AM Page 31
NOTE:  A second technician is required for removing the rear section of the
exhaust system.
Fig. 35: Removing/Installing Heat Shield For Driveshaft

 Disconnect exhaust system at clamp - arrow -.

 Remove heat shield - A - for driveshaft - arrows -.
Fig. 36: Driveshaft Heat Shield Bolts

 Remove heat shield - 1 - for exhaust system below selector mechanism - arrows -.
 Remove bolts at transmission/driveshaft flange.
 Push driveshaft - 2 - together toward rear final drive. The constant velocity joints can be moved axially.
1:51:47 AM Page 32
Fig. 37: Drive Shaft Tied To Side, Onto Heat Shield

 Tie driveshaft to side, onto heat shield - arrow -.
Fig. 38: Removing/Installing Lower Cover From/To Shift Mechanism

 Remove cover on underside of selector mechanism - arrows -.

 Remove selector lever cable sleeve from selector mechanism cover (bottom) and slide back.
1:51:47 AM Page 33
 Remove retaining clip - 1 - for selector lever cable by pulling it off downward at the selector mechanism.
 Pull plastic securing spring - 2 - slightly forward and press pin - 3 - upward, but only as far as is
necessary - arrow -.
NOTE:  Make sure that pin is not pressed out completely.
 Pull selector lever cable - 4 - out of selector mechanism.
NOTE:  Do not bend or kink the selector lever cable.

 Remove nuts - arrows -.
NOTE:  A second technician is required to detach the selector mechanism under

the vehicle.
 Push retaining clips - 1 - and - 2 - inward, at the same time pushing the selector mechanism downward.
Installing
 Install selector lever cable --> Selector lever cable, removing and installing (vehicles with 2.0 ltr.
TFSI engine), --> Selector lever cable, removing and installing (vehicles with 3.2 ltr. FSI engine), -->
Selector lever cable, removing and installing (vehicles with 4.2 ltr. MPI engine).
1:51:47 AM Page 34
 Install new retaining clip - 1 - for selector lever cable on selector mechanism.
 Installation position: The angled end of the retaining clip faces to the inside of selector mechanism.
 Install locking cable --> Locking cable, removing and installing.

 Bolt driveshaft onto transmission -->
 Install exhaust system free of stress -->

 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO
 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL,
ENGINE CODE(S): BKH
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE
.
Tightening torques
1:51:47 AM Page 35
Component Nm
Selector mechanism to body 10
Cover (bottom) to selector mechanism 10
Selector mechanism, disassembling and assembling
NOTE:  Removing and installing securing spring for locking cable Removing and
installing securing spring for locking cable.
 If selector gate or selector housing are faulty the entire selector
mechanism has to be replaced. The two components cannot be adjusted
using workshop tools.
Fig. 42: Selector Mechanism, Disassembling And Assembling Overview

1:51:47 AM Page 36
Disassembling

 Remove Shift lock solenoid N110 - item 7 - --> Shift lock solenoid N110, removing and installing.
 Unbolt and then unclip selector gate - 12 - from selector housing - 14 -.
 Release pivot pins - 5 - and - 19 - and pull them out sideways.
 Unclip retaining clips - 2 - and - 16 -.

 Pull off retaining clip - 17 -.
 Swivel locking lever - 11 - upward as far as it will go.
 Pull selector lever - 6 - together with bushings - 3 - and - 15 - and Tiptronic locking levers - 4 - and - 18 -
downward out of selector housing - 14 -.
Assembling
 Make sure that selector lever is still in position "S".

 Insert selector lever - 6 - into selector lever housing - 14 - from below.
 Install Tiptronic locking levers - 4 - and - 18 - , and bushings - 3 - and - 15 - onto selector lever.
 Push selector lever - 6 - together with bushings into selector lever housing - 14 - and position with
retaining clip - 17 -.
 Engage retaining clips - 2 - and - 16 - on selector lever housing.
 Press pivot pins - 5 - and - 19 - into selector lever - 6 - until they engage.
 Check that the pivot pins are engaged in the Tiptronic locking lever.
 Install Shift lock solenoid N110 - item 7 - --> Shift lock solenoid N110, removing and installing.
 Clip selector gate - 12 - onto selector housing - 14 - and tighten to 0.4 Nm.
Removing and installing securing spring for locking cable
Fig. 43: Removing And Installing Securing Spring For Locking Cable
1:51:47 AM Page 37
Removing
 To remove locking cable lift spring slightly at top - arrow B -.

 Disengage spring from retainer lug - arrow C - and lift out.
Installing
 Insert spring from above - arrow B - and engage under retainer lug - arrow C -.
 Align spring so that it lies level in groove - arrow A -.
 To install locking cable, lift spring slightly at the top - arrow B -.
Shift lock solenoid N110, removing and installing
Removing
 Disconnect electrical connector at Shift lock solenoid N110.

 Release retainer and pull out Shift lock solenoid N110 from front - arrows -.
1:51:47 AM Page 38
Installing
 Press Shift lock solenoid into guide until it engages. Actuating lever - 2 - for solenoid must engage in
locking lever - 1 - on selector mechanism.
Selector lever cable and locking cable, components overview

 Before installing, lightly lubricate cable eye and ball socket with
polycarbamide grease G 052 142 A2 .
1:51:47 AM Page 39

 Removing and installing: --> Selector lever cable, removing and installing (vehicles with 2.0 ltr. TFSI
engine), --> Selector lever cable, removing and installing (vehicles with 3.2 ltr. FSI engine), -->
Selector lever cable, removing and installing (vehicles with 4.2 ltr. MPI engine)
2 - Lock nuts, 12 Nm
3 - Sleeve for selector lever cable
 Press into selector mechanism cover (bottom).
1:51:47 AM Page 40
4 - Circlip
5 - Starter switch
6 - Locking cable for ignition key removal lock

7 - Hex bolt, 9 Nm
8 - Clamping bolt for selector lever cable, 13 Nm
 Loosen 1 turn for adjusting, do NOT remove completely
9 - Pin for selector lever cable
 To remove selector lever cable pull plastic locking spring on selector mechanism forward slightly and
push up pin just far enough to release cable.
10 - Retaining clip for selector lever cable
 Replace
11 - Support bracket
 For securing selector lever cable to transmission
12 - Hex bolt, 10 Nm
Selector lever cable, removing and installing (vehicles with 2.0 ltr. TFSI engine)
Removing
1:51:47 AM Page 41
Fig. 47: Identifying Quick-Release Fasteners And Noise Insulation

 Open quick release fasteners - 2 - and - 3 - and remove rear sound insulation.
Fig. 48: Pressing Ball Socket Of Selector Lever Cable From Selector Shaft Lever & Removing Bracket
On Transmission
 Pry ball socket - 1 - of selector lever cable off selector shaft lever.
 Remove support bracket from transmission - arrows -.
NOTE:  Shown in illustration with transmission support removed.
1:51:47 AM Page 42


1:51:47 AM Page 43

 Tie driveshaft up to side onto heat shield - arrow -.

 Remove retaining clip - 1 - for selector lever cable by pulling it off downward at selector mechanism.
1:51:47 AM Page 44
Installing
 Installation position: The angled end of the retaining clip faces to the inside of the selector mechanism.
 Insert end of selector lever cable - 4 - in joint on selector lever.

 Push pin - 3 - down - arrow -.
 Check that plastic securing spring - 2 - has locked the pin.

 Secure cover to underside of selector mechanism - arrows -.

 Attach sleeve for selector lever cable to selector mechanism cover (bottom).
1:51:47 AM Page 45
 Shift selector lever from position "P" to "S".
 Selector mechanism and selector lever cable must move freely. If necessary replace selector lever cable or
service selector mechanism.
 Push selector shaft lever - 2 - on transmission toward rear as far as possible (in illustration: as far as
possible to the right) until parking lock engages.
NOTE:  When the parking lock has engaged it should no longer be possible to
rotate both front wheels in one direction.
 Make sure that the selector lever cable - 1 - has not been bent or kinked and that it is not under tension.
Fig. 57: Pressing Selector Lever Cable Onto Ball Head Of Selector Shaft Lever
1:51:48 AM Page 46
 Carefully press selector lever cable - 1 - onto ball head of selector shaft lever - 3 -.
NOTE:  Make sure you do not bend the selector shaft lever when pressing on the
ball socket, as this would make it impossible to obtain an accurate
adjustment of the selector mechanism.
Fig. 58: Identifying Cable Support Bracket To Transmission

 Bolt on support bracket for selector lever cable - arrows -.

.
ENGINE CODE(S): BKH
.
Tightening torques
1:51:48 AM Page 47
Component Nm
Selector lever cable to support bracket 12
Support bracket to transmission 10
Selector lever cable, removing and installing (vehicles with 3.2 ltr. FSI engine)

 Engine/transmission jack V.A.G 1383 A
Fig. 60: Identifying Exhaust Pipe Fasteners

Removing

 On vehicles equipped with auxiliary heater, remove screws - arrows - securing exhaust pipe of auxiliary
heater to sound insulation.
1:51:48 AM Page 48



exhaust system.
1:51:48 AM Page 49


1:51:48 AM Page 50

Fig. 66: Placing Lifting Surface Of Engine/Transmission Jack V.A.G 1383 A Centrally On Lower
Housing Base
 Remove universal support V.A.G 1359/2 from engine/transmission jack V.A.G 1383 A.
 Place telescopic arm of engine/transmission jack V.A.G 1383 A centrally below cast lug on transmission
housing - arrow - and support transmission from below.
Fig. 67: Removing/Installing Bolts And Mounting Bolts Of Subframe

 Remove bolts - 2 - and - 3 - and then subframe securing bolts - 1 - and - 4 -.
1:51:48 AM Page 51
Fig. 68: Lowering Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx.
By Dimension
 Slowly lower transmission and subframe using engine/transmission jack V.A.G 1383 A until distance - a
- is as specified.
 Dimension - a - = 50 mm
On Transmission

 Do not bend or kink the selector lever cable.
1:51:48 AM Page 52

1:51:48 AM Page 53
Installing
 Installation position: The angled end of retaining clip faces to the inside of selector mechanism.



1:51:48 AM Page 54
 Press selector shaft lever - 2 - on transmission as far as it will go toward the rear (in direction of - arrow -
) until parking lock engages.
On Transmission
 Carefully press selector lever cable - 1 - onto ball head of selector shaft lever.
1:51:48 AM Page 55
cable, as this would make it impossible to obtain an accurate adjustment
of the selector mechanism.

 Install subframe, observing the correct tightening sequence --> 40 - FRONT SUSPENSION .

ENGINE CODE(S): BKH
.
Tightening torques
Component Nm
1:51:48 AM Page 56

Removing


exhaust system.
1:51:48 AM Page 57


1:51:48 AM Page 58

Housing Base
 Detach universal mounting bracket V.A.G 1359/2 from engine/transmission jack V.A.G 1383 A.
Fig. 82: Remove Bolts 2- And At Front And Rear Of Subframe On Both Sides Of Vehicle
 Remove bolts - 1 - and - 2 - and lower subframe at rear.

 Remove transmission support (left-side) --> Transmission support and transmission mounting,
removing and installing (left and right).
1:51:48 AM Page 59

 Remove support bracket for selector lever cable - arrows -.
Fig. 84: Using Pry Lever - RMV Outside Mirror 80-200 To Pry Ball Socket On Selector Lever Cable Off
Selector Shaft Lever
 Use pry lever - RMV outside mirror 80-200 to pry ball socket - 1 - on selector lever cable off selector
shaft lever.

 - Item 2 - can be disregarded.
1:51:48 AM Page 60

1:51:48 AM Page 61
Installing



1:51:48 AM Page 62
1:51:49 AM Page 63
 Install transmission supports --> Transmission support and transmission mounting, removing and
installing (left and right).


.
ENGINE CODE(S): BKH
.
1:51:49 AM Page 64
Tightening torques
Component Nm
Fig. 92: Socket And Key T40031

 Socket and key T40031
Procedure
Fig. 93: Inserting Socket And Key T40031 Through Access Hole In Selector Mechanism To Loosen
Clamping Bolt At Rear Of Selector Lever Cable
1:51:49 AM Page 65
 Insert socket and key T40031 through access hole in selector mechanism to loosen clamping bolt at rear
of selector lever cable approx. 1 turn.
NOTE:  Only loosen clamping bolt 1 turn - do not remove.

 Clamping bolt can only be accessed with selector lever in position "S".
 The selector lever must remain in "S" position when clamping bolt is
loosened; otherwise, adjustment will not be correct.
 Carefully move selector lever slightly forward and backward, without shifting lever into a different
selector lever position.
 Pull selector lever once more to rear as far as possible into "S" position and release the selector lever.
NOTE:  Do not touch selector lever again during adjustment process.
 Tighten clamping bolt in this position using socket and key T40031.
 Check selector mechanism --> Selector mechanism, checking.

NOTE:  Use the vehicle diagnostic, testing and information system VAS 5051 A
(Self-diagnosis, 02 - Automatic transmission, 08 - Read measured value
block, Display group 4 in display field - 3 - to compare the position of the
Multi-Function Transmission Range (TR) Switch F125 with the position on
the selector lever.
If selector mechanism is not functioning correctly after adjusting selector lever cable, proceed as follows:
 Adjust selector lever cable to basic setting --> Adjusting selector lever cable to basic setting.
1:51:49 AM Page 66
Tightening torque
Component Nm
Clamping bolt to selector lever cable 13
Adjusting selector lever cable to basic setting

Procedure
1:51:49 AM Page 67
NOTE:  Before adjusting the selector lever cable to basic setting make sure that
clamping bolt has been tightened. The clamping bolt can be accessed via
the hole in the selector mechanism, when in position "S". Use socket and
key T40031 to tighten clamping bolt.
 Tighten clamping bolt to 13 Nm in this position, using socket and key T40031.

NOTE:  Make sure the selector lever is in position "P".
NOTE:
1:51:49 AM Page 68
 When the parking lock has engaged it should no longer be possible to



Tightening torque
Component Nm
Removing
NOTE:  The locking cable must not be bent or kinked.
CAUTION: Follow steps required when disconnecting battery -->
 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for
 With ignition switched off, disconnect battery Ground (GND) strap.
1:51:49 AM Page 69

.
 Remove steering column cover -->
.
 Remove A/C control console --> 87 AIR CONDITIONING .

.
1:51:49 AM Page 70

1 - Locking cable
 Lift up retaining clip - 2 - on locking device and pull locking rod - 1 - off starter switch.
 Lift up locking cable securing spring - 4 -. Pull locking cable support bracket - 5 - sideways off selector
mechanism, then disengage locking cable eye.
Installing
1:51:49 AM Page 71

1 - Locking cable
 Route locking cable behind instrument panel brace - arrow - without kinking.
 Insert locking cable - 1 - into starter switch.
 Check that locking device - 2 - engages.
 Turn starter switch to locked position (ignition off).

 Make sure that selector lever is in position "P".
 Hook eye of locking cable onto pin - 3 -.
1:51:49 AM Page 72
 Lift up securing spring - 4 - slightly.
 Insert locking cable support bracket - 5 - into selector mechanism from the right. Push it in so that
securing spring - 4 - engages.
 Install ashtray in center console -->
 Install air conditioning operating unit --> 87 AIR CONDITIONING .

 Install steering column cover -->
.
 Install storage compartment on drivers side -->
.
 Follow steps required after connecting battery -->
 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL

.
1:51:49 AM Page 73
 Adjustment pin for shift lock 3 3352 A

 Angle grinder
 Safety goggles

Preparation
NOTE:  If the procedure described below is followed the center console does not
have to be removed.
 Using an angle grinder or similar, cut off Adjustment pin for shift lock 3 3352 A at rear end of flat section
- arrow -.
CAUTION: Wear safety goggles.
 Order a new Adjustment pin for shift lock 3 3352 A as a replacement for subsequent use.
Requirements for adjustment
 Locking cable must be in installation position.

 Selector lever is in position "P"
 Ignition key is in removal position.
Procedure
 Remove trim panel from center console --> Selector mechanism cover, removing and installing.
1:51:49 AM Page 74
NOTE:  The selector lever handle and cover can remain installed.


 It should be possible to move support bracket - 2 - for locking cable by hand.
 Insert modified Adjustment pin for shift lock 3 3352 A between pin on locking cable lever and locking
cable eye.
 Pull locking cable in direction of - arrow - as far as it will go and tighten bolt.
 In this position it should be easy to remove and insert Adjustment pin for shift lock 3 3352 A.
 Remove adjustment gauge.

.
 Always test ignition key removal lock after adjusting locking cable --> Ignition key removal lock,
checking.
Tightening torque
Component Nm
1:51:49 AM Page 75
Overview:
 --> Transmission, removing (vehicles with 2.0 ltr. TFSI engine)

 --> Transmission, installing (vehicles with 2.0 ltr. TFSI engine)
 --> Transmission, removing (vehicles with 3.2 ltr. FSI engine)
 --> Transmission, installing (vehicles with 3.2 ltr. FSI engine)
 --> Transmission, removing (vehicles with 4.2 ltr. MPI engine)

 --> Transmission, installing (vehicles with 4.2 ltr. MPI engine)
Transmission, removing (vehicles with 2.0 ltr. TFSI engine)
1:51:49 AM Page 76
Fig. 105: Identifying Special Tools - Transmission, Removing (Vehicles With 2.0 ltr. TFSI Engine)
 Engine support bridge 10-222 A

 Used oil collection and extraction unit V.A.G 1782
 Adapter 3282/48
 Pin 3282/50
Fig. 106: Bracket 30-211 A

Fig. 107: Insert Pad For Front Fender T40045

1:51:50 AM Page 77
 Insert pad for front fender T40045

 Bolt M10x20
Removing
NOTE:  General repair instructions --> General repair instructions.

 Read the rules for cleanliness when working on the automatic
 All cable ties which are released or cut open during removal must be
installed in the same position when installing.
 Shift selector lever to position "N".
CAUTION: Follow the steps required when disconnecting battery -->

Fig. 108: Disconnecting Battery Ground (GND) Strap

 With ignition switched off, disconnect Ground (GND) wire - arrow - at battery.
1:51:50 AM Page 78
Fig. 109: Removing Engine Cover

 Remove engine cover - arrows -.
Fig. 110: Unbolting Coolant Expansion Tank

 Unbolt coolant expansion tank - arrow -.

 Disconnect electrical connector for Engine Coolant Level (ECL) Warning Switch F66 at bottom of
coolant expansion tank.
 Place coolant expansion tank to one side, leaving coolant hoses - 1 - and - 2 - connected.
1:51:50 AM Page 79
Fig. 111: Identifying Engine/Transmission Threaded Connections

 Remove engine/transmission securing bolts - 4 - , - 5 - and - 6 - (accessible from above).
Fig. 112: Inserting Insert Pad For Front Fender T40045 On Both Sides Between Fender Mounting Flange
And Body Panel Underneath
 Remove rubber seal from edges of fender mounting flanges.

 To avoid damaging edges of fender panels using engine support bridge 10-222 A, insert pad for front
fender T40045 on both sides between fender mounting flange and body panel underneath.
1:51:50 AM Page 80
Fig. 113: Engine Support Bridge 10-222 A Set Up With Adapters 10-222/3 On Fender Mounting Flanges
 Set up engine support bridge 10-222 A with adapters 10-222/3 on fender mounting flanges.
 Engage spindles on engine lifting eyes as illustrated.
 Take up weight of engine using spindles.
 Remove both front wheels.

1:51:50 AM Page 81

 Open quick-release fasteners - 1 to 3 - and remove front and rear sound insulation.
Fig. 116: Removing Bracket For Sound Insulation

 Remove bracket for sound insulation - arrows -.
Fig. 117: Removing Left/Right Heat Shields For Drive Axles

1:51:50 AM Page 82
 Remove heat shield - 1 - for drive axle (left-side).

 Unbolt drive axles (left and right) from transmission flange shafts.
Fig. 118: Loosening Clamping Sleeve

NOTE:  The flexible pipe connection (de-coupling element) on the front exhaust
pipe must not be bent more than 10° - otherwise it can be damaged.
 Loosen nuts on front clamp - arrows -.

 Push clamp toward rear of vehicle to disconnect exhaust system.
Fig. 119: Separating Front Exhaust Pipe/Catalytic Converter

 Remove bolts - arrows - at connection between front exhaust pipe and catalytic converter.
 Remove nut - 1 - at bracket for front exhaust pipe and remove front exhaust pipe.
1:51:50 AM Page 83

 Unbolt heat shield - A - for driveshaft - arrows -.

 Slide driveshaft together toward rear final drive. The constant velocity joints can be moved axially.
 Tie up driveshaft to body.
On Transmission
NOTE:  Mark installation position of support bracket for selector lever cable with a
felt-tip pen.

 Move selector lever cable clear.
1:51:50 AM Page 84
Fig. 122: Disconnecting Electrical Connector At Transmission By Turning Fastener Cap Counter-
Clockwise
 Disconnect electrical connector at transmission by turning fastener cap counter-clockwise - arrow -.
Fig. 123: Disconnecting ATF Pipes & Removing Bracket For ATF Lines
NOTE:  Read the rules for cleanliness when working on automatic transmission --
> Rules for cleanliness.
 Place used oil collection and extraction unit V.A.G 1782 below engine.
 Unscrew union nuts - 1 - and - 2 - and disconnect ATF pipes.
 Remove bracket for ATF lines - arrow -.
1:51:50 AM Page 85
Fig. 124: Disconnecting ATF Lines At Connection Points On Right Side Of Transmission
 Disconnect ATF lines - 1 - and - 2 - at connection points on right side of transmission.

 Remove ATF lines going to ATF cooler.
 Detach bracket - 3 - for ATF lines at bottom of transmission.
Fig. 125: Removing Bolt & Disconnecting ATF Lines From Transmission
 Remove bolt - arrow -.

 Detach ATF lines from transmission.
1:51:50 AM Page 86
Fig. 126: Removing Stabilizer Bar Mountings

 Remove stabilizer bar mountings on both sides - 1 - and - 2 -.

 Remove engine/transmission securing bolts - 1 to 3 - and - 8 to 11 -.
NOTE:  Bolt - 7 - should remain screwed in hand-tight.
1:51:50 AM Page 87
Fig. 128: Identifying Starter, Electrical Connector & Nuts

 Detach starter and swivel to one side.

 Disconnect electrical connector - 3 -.
 Remove nut - 1 - for clamp.
 Remove nut - 2 - and detach electrical wiring.
 Remove starter.

 Remove 3 torque converter bolts - arrows - through opening for removed starter (turning crankshaft 1 /3
turn each time).
1:51:50 AM Page 88
Fig. 130: Placing Adapter 3282/48 On Transmission Support 3282

 Set up transmission support 3282 on engine/transmission jack V.A.G 1383 A.

 Place Adapter 3282/48 on transmission support 3282 as shown in illustration.
 Align arms of transmission support according to holes in adjustment plate.
 Attach support elements as illustrated on adjustment plate.
 Pin 3282/50 has to be screwed in at right rear.

 Place engine/transmission jack V.A.G 1383 A with transmission support 3282 underneath transmission.
NOTE:  The arrow symbol on the adjustment plate points in the direction of travel.
 Align adjustment plate parallel with transmission.
Fig. 131: Bolting Support To Left Rear Tapped Hole On Transmission
1:51:51 AM Page 89
 Bolt support to left rear tapped hole on transmission - 1 - using one bolt M10x20.
 Insert flattened pin 3282/50 into mounting hole at right rear of transmission housing - arrow 2 -.
CAUTION:  The flattened side of the pin must face toward the transmission oil
pan to prevent the oil pan from being bent or damaged.
 Replace the transmission oil pan if damaged.
Fig. 132: Inserting Pin Into Mounting Hole At Left Front Of Transmission Housing & Recess In Housing
At Right Front Of Differential Housing
 Insert pin into mounting hole at left front of transmission housing - arrow 2 -.
 Insert pin into recess in housing at right front of differential housing - arrow 1 -.
 Raise transmission slightly.
Fig. 133: Removing Bolts For Transmission Mountings

 Remove bolts - arrows - for transmission mountings (left and right).
1:51:51 AM Page 90
Fig. 134: Removing Heat Shield For Left Transmission Support

 Remove heat shield for transmission support (left-side).

 Remove transmission supports (left and right) together with transmission mountings - arrows -.
 Remove last engine/transmission securing bolt.
 Push transmission off engine and at the same time pry torque converter off drive plate using a
screwdriver.
 Carefully lower transmission using engine/transmission jack V.A.G 1383 A.
NOTE:  When lowering transmission, make sure there is sufficient clearance from
drive axles.

 Secure torque converter in transmission with support bridge 30-211 A to prevent it from dropping out.
Transmission, installing (vehicles with 2.0 ltr. TFSI engine)
NOTE:  Use thread tap to remove any remaining locking fluid from all threaded
1:51:51 AM Page 91
holes which will accommodate self-locking bolts.

 Replace self-locking nuts and bolts when performing assembly work.
 Re-attach all cable ties at the same locations when re-installing.

 Before installing transmission, you must ensure that the torque converter is properly fitted in the
transmission.
 If the torque converter is correctly installed, the depth between the contact surfaces at tapped holes on
torque converter and contact surface of the torque converter bell housing is at least 19 mm.

 Before installing transmission, check for correct positioning of dowel sleeves - A - at cylinder block.
Install new dowel sleeves if necessary.
1:51:51 AM Page 92
 Install intermediate plate between engine and transmission in the original position.
 Before joining engine and transmission, turn torque converter and drive plate (on engine) until one hole
and one tapped hole are in line with the opening for the removed starter.
 When pushing the engine and transmission together, make sure that no wiring or lines etc. can become
trapped.
Install the transmission, adhere to the following instructions.
CAUTION: Before and while tightening the bolts on the engine/transmission flange
keep checking that the torque converter can still be rotated behind the
drive plate. If the converter cannot be turned, it must be assumed that it
has not been installed correctly and the drive lugs on the converter or the
ATF pump will be damaged when the bolts are fully tightened.

 Screw in bolt - 7 - hand-tight.

 Install transmission support with transmission mounting --> Transmission support and transmission
mounting, removing and installing (left and right).
 Counterhold crankshaft to tighten torque converter bolts.
1:51:51 AM Page 93

 Use new ribbed bolts to secure torque converter to drive plate. Use only the correct bolts (same as
original equipment) .
 Install 3 bolts - arrow - for torque converter hand-tight into opening of removed starter (turning
crankshaft 1 /3 turn each time).
 Bolt transmission onto engine.
NOTE:  Tightening torques only apply to lightly greased, oiled, phosphated or

blackened nuts and bolts.
 Lubricants such as engine or transmission oil may be used, but do not use
graphite lubricant.
 Do not use parts which have been degreased.
 Tolerance for tightening torques ±15%.

Engine/transmission securing bolts
Item Bolt Nm
1 M12x67 65
2 M10x60 65 * See note
3, 4, 5 M12x75 65
6 M12x100 65
7 M12x90 65
8 M10x60 45
9 to 11 M10x45 45
A Dowel sleeves for centralizing
1:51:51 AM Page 94
*Bolt strength 10.9
The remaining installation steps are in reverse sequence. Note the following:
 Install starter -->


.
 Install stabilizer bar --> 40 - FRONT SUSPENSION .
 Clean ATF lines and ATF cooler --> ATF cooling lines and ATF cooler, cleaning.
 Secure ATF lines to transmission and engine --> ATF cooling lines.
 Install driveshaft -->
.
 Install front exhaust pipe with main catalytic converter -->
ENGINE CODE(S): BKH
.
 Align exhaust system free of stress -->
ENGINE CODE(S): BKH
1:51:51 AM Page 95

.
 Install drive axles --> 40 - FRONT SUSPENSION .


.
 Check ATF level --> ATF level, checking and correcting.
Component Nm
Drive plate to torque converter 85 * See note
Heat shield for drive axle to transmission 23
Bracket for sound insulation to subframe 10
*Replace bolts.
Transmission, removing (vehicles with 3.2 ltr. FSI engine)
1:51:51 AM Page 96
Fig. 141: Identifying Special Tools - Transmission, Removing (Vehicles With 3.2 ltr. FSI Engine) (1 Of 2)

 Support bridge 30-211 A
 Adapter 3282/48
 Pin 3282/50
1:51:51 AM Page 97

 Adapter T40058
 Bolt M10x20
Removing

1:51:51 AM Page 98


 Remove front exhaust pipe with catalytic converter (left and right) -->
ENGINE CODE(S): BKH
.
1:51:51 AM Page 99
NOTE:  After removal of the front exhaust pipes the subframe is detached at the
rear and the transmission support (left-side) is removed.
Housing Base
 The transmission is supported centrally at the connection on the housing - arrow - with
engine/transmission jack V.A.G 1383 A.
 Use engine/transmission jack V.A.G 1383 A to lift transmission up slightly.

 Install bolts - 1 - and - 4 - hand-tight.
NOTE:  - Item 2 - and - item 3 - can be disregarded.
 Lower transmission and remove engine/transmission jack V.A.G 1383 A from under vehicle.
1:51:52 AM Page 100



 Rest driveshaft on exhaust system (right-side).
On Transmission
felt-tip pen.
1:51:52 AM Page 101


Fig. 149: Removing Union Nuts And Disconnect ATF Lines

 Unscrew union nuts - 3 - and disconnect ATF lines.
 Remove bracket - 2 - securing ATF lines.
NOTE:  - Item 1 - can be disregarded.
1:51:52 AM Page 102

Fig. 150: Removing Bracket For ATF Lines At Bottom On Transmission

 Remove bracket - arrow - for ATF lines at bottom section of transmission.
NOTE:  Place a cloth below the ATF line to catch escaping ATF.

 Pull ATF lines out of transmission.
1:51:52 AM Page 103

Fig. 152: Disconnecting Electrical Connector On Engine Speed (RPM) Sensor G28
 Disconnect electrical connector - arrow - for engine speed (RPM) sensor G28.
Clockwise
CAUTION: Check once again to make sure that the rear subframe mountings are
secured hand-tight.
1:51:52 AM Page 104

Fig. 154: Removing/Installing Bolts At Torque Support Stop

 Unscrew bolts - arrows - two turns at stop for torque reaction support.
Fig. 155: Removing Nuts At Bottom On Left/Right Engine Mounts

 Unscrew nuts - A - below left and right engine mountings until nuts are flush with bottom end of studs.
Fig. 156: Identifying Front Engine Cover

1:51:52 AM Page 105

 Remove front engine cover - arrows -.

 To avoid damaging edges of fender panels with engine support bridge 10-222 A, insert pad for front
fender T40045 on both sides between the fender mounting flange and body panel underneath.
1:51:52 AM Page 106

Fig. 158: Setting Up Engine Support Bridge 10-222 A With Adapters 10-222 A/3 On Fender Mounting
Flanges
 Set up engine support bridge 10-222 A with adapters 10-222 A/3 on fender mounting flanges.
 Take up weight of engine with spindles until bottom engine/transmission securing bolts are accessible.

 Unbolt stabilizer bar mountings on both sides - 1 - and - 2 -.

 Swivel stabilizer bar downward.
Fig. 160: Removing Bottom Engine/Transmission Connecting Bolts

 Remove bottom engine/transmission securing bolts - arrows -.
1:51:52 AM Page 107

Fig. 161: Disconnecting Electrical Wires On Starter, Removing Bolts & Starter
 Disconnect wires - 2 - and - 3 - at starter.

 Remove bolts - 1 - and - 4 - and remove starter.
 Guide starter toward the rear through wheel housing on right side of vehicle.
Fig. 162: Inserting Guide Pin Of Adapter T40058

 Insert guide pin of adapter T40058 so that the large diameter - arrow 1 - faces engine. The smaller
diameter - arrow 2 - faces adapter.
1:51:52 AM Page 108

Fig. 163: Loosening Torque Converter Bolts Using Adapter T40058

 Counter-hold crankshaft using adapter T40058 to loosen torque converter bolts.
NOTE:  - Arrow - can be disregarded.

 Remove 3 torque converter bolts - arrows - through the opening for removed starter (turning crankshaft
1 / turn each time).
3
1:51:52 AM Page 109


 Remove engine/transmission securing bolts - 4 to 6 -.
NOTE:  Bolts - 3 - and - 7 - remain screwed in hand-tight.

1:51:53 AM Page 110


 pin 3282/50 has to be screwed in at right rear.


 Insert flattened pin 3282/50 into mounting hole at rear right of transmission housing - arrow 2 -.
1:51:53 AM Page 111

Fig. 169: Removing/Installing Bolts, Heat Shield, Transmission Support

 Remove bolts - 2 - at transmission support (right-side) and detach heat shield - B -.

 Remove bolts - 1 -.
 Detach transmission support - A - together with transmission mounting from transmission.
Fig. 170: Pressing Transmission Off Engine, While Pressing Torque Converter Off Of Drive Plate
1:51:53 AM Page 112

 Remove last engine/transmission securing bolts.

screwdriver.
drive axles.

 Secure torque converter in transmission using support bridge 30-211 A to prevent it from dropping out.
Transmission, installing (vehicles with 3.2 ltr. FSI engine)
 Replace O-rings
1:51:53 AM Page 113


 Before installing transmission, make sure that the torque converter is properly installed in the
transmission.
 If the torque converter is correctly installed, the depth between the contact surfaces at the tapped holes on
the torque converter and contact surface of torque converter bell housing is at least 19 mm.

1:51:53 AM Page 114

and one tapped hole are in line with the opening for removed starter.
 When pushing engine and transmission together, make sure that no wiring or lines etc. can become
trapped.
Install transmission, adhere to the following instructions.


 Install transmission support (right-side) with transmission mounting --> Transmission support and
transmission mounting, removing and installing (left and right).
1:51:53 AM Page 115



 Counter-hold crankshaft using adapter T40058 to secure torque converter bolts.
1:51:53 AM Page 116


 Use new ribbed bolts to secure torque converter to drive plate. Use only correct bolts (same as original
equipment) .

graphite lubricant.
1:51:53 AM Page 117


Item Bolt Nm
1 M10x115 65 * See note
2, 6 M12x125 65
3, 5 M12x110 65
4 M12x115 65
7 M12x140 65
8, 9, 10 M10x80 45
*Bolt strength 10.9


.
 Clean ATF pipes and ATF cooler --> ATF cooling lines and ATF cooler, cleaning.
 Secure ATF pipes to transmission and engine --> ATF cooling lines.
 Install selector lever cable --> Selector lever cable, removing and installing (vehicles with 3.2 ltr. FSI
engine).
.
 Install front exhaust pipes -->
1:51:53 AM Page 118


ENGINE CODE(S): BKH
.

ENGINE CODE(S): BKH
.
 Install drive shafts --> 40 - FRONT SUSPENSION .

 Allow stop for torque reaction support to settle under its own weight on rubber buffer for torque reaction
support and tighten bolts - arrows -.
1:51:53 AM Page 119

.
Component Nm
Engine mounting to support 23
Heat shield for drive shaft to transmission 23
Stop for torque reaction support to lock carrier 28
*Replace bolts.
Transmission, removing (vehicles with 4.2 ltr. MPI engine)
1:51:54 AM Page 120

Fig. 180: Identifying Special Tools - Transmission, Removing (Vehicles With 4.2 ltr. MPI Engine) (1 Of 2)

 Shackle 10-222 A/12
 Hose clamps, up to 25 mm dia. 3094
 Adapter 3282/48
1:51:54 AM Page 121

 Pin 3282/50
 Adapter T40058
 Bolt M10x20
Removing

 Heat insulation sleeves removed during removal of transmission must be

Fig. 182: Sliding Battery Cover Toward Right Side Of Vehicle And Remove
1:51:54 AM Page 122

 Slide battery cover toward right side of vehicle - arrow 1 - and remove - arrow 2 -.
Fig. 183: Disconnecting Ground (GND) Wire At Battery


 Remove rear engine cover - arrows -.
1:51:54 AM Page 123

Fig. 185: Removing Front Engine Cover


 Remove cover - 1 - on left side of engine compartment.
Fig. 187: Removing Coolant Hoses & Coolant Expansion Tank

 Disconnect coolant hose - 2 - with hose clamp 3094 and detach at coolant expansion tank.
 Disconnect electrical wire leading to Engine Coolant Level (ECL) warning switch F66 at expansion tank
(bottom) and move coolant expansion tank (with coolant hose - 1 - attached) clear to one side.
 If necessary, close off connection with a suitable plug.
1:51:54 AM Page 124

Fig. 188: Removing Bracket For Electrical Harness Connectors At Left From Bulkhead
 Disconnect electrical connectors - 1 to 4 - from retainer at left of bulkhead.

 Disconnect electrical connectors - 1 - , - 3 - and - 4 -.
 Detach retainer at bulkhead.
 Detach heat insulation sleeve at wiring harness and move wiring harness clear.
 Move Lambda probe wires clear (downward).

 Remove cover - 1 - on right side of engine compartment.
1:51:54 AM Page 125

Fig. 190: Removing Air Guide Hose

 Remove air intake hose - arrows -.
Fig. 191: Removing Bracket For Electrical Harness Connectors At Right From Bulkhead
 Disconnect connectors - 1 to 4 - from retainer at right of bulkhead.

 Disconnect electrical connectors - 2 - and - 4 -.
NOTE:  Mark the attachment points for the Lambda probe wires, to make sure they
are attached in the same place during installation.
1:51:54 AM Page 126

Fig. 192: Installing Shackle 10-222 A/12 To Engine Lifting Eye (Right Rear)
 Install shackle 10-222 A/12 to engine lifting eye (right rear).
 Detach rubber seal from edges of fender mounting flanges.

1:51:54 AM Page 127

Fig. 194: Placing Engine Support Bridge 10-222 A With Adapters 10-222 A/3 Onto Fender Panel Flange
 Place engine support bridge 10-222 A with adapters 10-222 A/3 onto fender panel flange, as shown in
illustration.
 Engage spindles of engine support bridge 10-222 A in engine lifting eye (front) and in shackle 10-222
A/21 (rear).
 Take up weight of engine on spindles of support bar, but do not lift.


 On vehicles equipped with auxiliary heater remove screws - arrows - securing exhaust pipe of auxiliary
1:51:54 AM Page 128

Fig. 196: Removing Quick-Release Fasteners, Screws And Noise Insulation

 Release quick release fasteners - 1 - , remove bolts - 2 - and remove sound insulation.

Fig. 198: Removing Wiring Harness Bracket At Right Engine Plate

1:51:55 AM Page 129

 Remove bracket for wiring harness at engine support (right-side) - arrows -.
Fig. 199: Unclipping Operating Rod For Vehicle Levelling Sensor At Lower Transverse Link
 If installed, unclip operating rod for vehicle level sensor from lower transverse link - arrow - or detach
connector at operating rod (top).
Fig. 200: Removing Bolt (On Left And Right)

 Remove bolt - 2 - (on left and right).
NOTE:  Ignore - item 1 - and - items 3 to 5 -.
1:51:55 AM Page 130

Fig. 201: Removing Nuts For Left/Right Stabilizer Mounts

 Remove nuts (left and right) - 1 to 4 - for stabilizer bar mounting and remove stabilizer bar.
Fig. 202: Removing/Installing Securing Bolts (Left/Right) For Transmission Mounting At Subframe
 Remove securing bolts (left and right) - 3 - for transmission mounting - B - at subframe - C -.
1:51:55 AM Page 131


 Before loosening subframe, use locating pin 3393 to check whether holes - 1 - and - 2 - are aligned.
If this is not the case, wheel alignment has to be performed after installing subframe.
 Remove bolts - 1 to 4 - and lower subframe.
NOTE:  The subframe may be allowed to rest on the transverse links. It does not
have to be removed completely.
1:51:55 AM Page 132




1:51:55 AM Page 133


Fig. 208: Disconnecting 16-Pin Electrical Connector At Transmission By Folding Out Release Tab And
Turning Fastener Cap Counter-Clockwise
 Disconnect 16-pin electrical connector - 2 - at transmission by folding out the release tab and turning
fastener cap counter-clockwise.
1:51:55 AM Page 134

Fig. 209: Drive Axle Heat Shield

 Remove heat shields - arrow - for drive axles (left and right).
 Remove drive axles (left and right) from flange on transmission.
NOTE:  Make sure you do not damage surface coating on drive axles.
Fig. 210: Removing Refrigerant Line On Bracket

 Remove bracket (right-side) - arrow - for refrigerant line.
1:51:55 AM Page 135

Fig. 211: Disconnecting Electrical Harness Connector At Right Engine Mount


 Remove bolts - arrows - and remove engine support together with engine mounting.
Fig. 212: Identifying Ground (GND) Wire, Wires, Nuts, Bolts & Starter
 Remove Ground (GND) wire - 5 -.

 Disconnect wires - 3 - and - 4 -.
 Remove nut - 1 - and bolt - 2 -.
 Remove starter.
1:51:55 AM Page 136


Fig. 214: Removing Bolts From Torque Converter Through Opening For Starter
 Remove 3 bolts from torque converter through opening for starter (turn crankshaft 1 /3 of a turn to access
one bolt after another).
1:51:56 AM Page 137


 Remove lower engine/transmission securing bolts - arrows -.

 Mark position of mounting bracket for selector lever cable relative to transmission housing to simplify
reassembly. Unbolt mounting bracket - arrows -.
 Loosen clips securing ATF lines to transmission and engine --> ATF cooling lines.
 Lower engine/transmission assembly as far as possible, using spindles of support bracket.
CAUTION: When lowering the engine/transmission assembly, make sure none of the
lines or wires are stretched or pinched and also avoid causing damage to
any other components.
1:51:56 AM Page 138

Fig. 217: Removing Bolt At Strap For Left Front Exhaust Pipe
 Remove bolt - arrow - at bracket for front exhaust pipe (left-side).
Fig. 218: Removing Nuts For Left Front Exhaust Pipe/Exhaust Manifold
 Remove nuts - 1 to 3 - connecting front exhaust pipe (left-side) to exhaust manifold.
NOTE:  In the illustration the engine has been removed.
 Detach front exhaust pipe from exhaust manifold (left-side).

 Remove front exhaust pipe.
1:51:56 AM Page 139

Fig. 219: Identifying Bolt, Heat Shield, Bolt & Engine Speed (RPM) Sensor G28
 Remove heat shield - B -.
 Pull engine speed (RPM) sensor G28 - item A - out of transmission.
NOTE:  The engine speed (RPM) sensor G28 is inserted in bell housing (top left).
Fig. 220: Removing Bolt At Strap For Right Front Exhaust Pipe
 Remove bolt - arrow - at bracket for front exhaust pipe (right-side).
1:51:56 AM Page 140

Fig. 221: Removing Nuts For Right Front Exhaust Pipe/Exhaust Manifold
 Remove nuts - 1 to 3 - connecting front exhaust pipe (right-side) with exhaust manifold.

 Remove bolts - 2 - at transmission supports (right and left) and detach heat shields - B -.
1:51:56 AM Page 141

 Use removal lever 80-200 to pry ball socket - 1 - on selector lever cable off selector shaft lever.



1:51:56 AM Page 142

 pin 3282/50 has to be screwed in at rear right.
NOTE:  The pin 3282/50 is flattened at the side - arrow - , the flattened side should
face the oil pan when inserting pin into transmission.

1:51:56 AM Page 143

 Place drip tray in position.

 Pull ATF cooling lines off transmission.
 Seal lines and transmission connections with clean sealing plugs to prevent ATF from escaping.
1:51:56 AM Page 144


 Remove all remaining securing bolts between engine and transmission.

 If necessary, lower engine slightly again via spindles.
Fig. 229: Using Assembly Lever To Press Torque Converter Off Drive Plate Of Engine
 Use assembly lever to press torque converter off drive plate of engine - arrow -.
 Press transmission off engine.
1:51:57 AM Page 145

Fig. 230: Lowering Rear Edge Of Transmission By Adjusting Transmission Support 3282 Accordingly
 Lower rear edge of transmission by adjusting transmission support 3282 accordingly.

 Guide transmission out diagonally downward/to rear.
NOTE:  When lowering transmission, make sure there is sufficient clearance to

drive axles.

 Secure torque converter in transmission using Bracket 30-211 A to prevent it from dropping out.
Transmission, installing (vehicles with 4.2 ltr. MPI engine)
NOTE:  Re-attach all cable ties at the same locations when re-installing.
 Secure all hose connections with the correct hose clips (as original
equipment) .
 Re-attach heat shield sleeves at the same locations when re-installing.
 Replace self-locking nuts.
1:51:57 AM Page 146


 Before installing transmission, make sure that the torque converter is properly installed in transmission.
 If torque converter is correctly installed, the depth between contact surfaces at tapped holes on torque
converter and contact surface of torque converter bell housing is at least 19 mm.

 If an intermediate plate was installed between engine and transmission, reinstall plate in same position.
 When pushing engine and transmission together, make sure that no cables, lines, etc. can become trapped.
 Bolt transmission onto engine Illustration of transmission flange.

equipment) .
1:51:57 AM Page 147


 Install 3 torque converter bolts through opening for starter (finger-tight). Turn crankshaft 1 /3 of a turn to
access one bolt after another.
 Tighten torque converter bolts to torque (turning crankshaft 1 /3 turn each time).
1:51:57 AM Page 148

 Insert engine speed (RPM) sensor G28 - item A - into bell housing (top left) and tighten bolt - 1 -.
 Install heat shield - B - and tighten bolt - 2 - (transmission/engine bolt connection Illustration of
transmission flange)

 Insert ATF cooling lines - A - and - B - into transmission as far as possible and tighten bolt - 2 -.
1:51:57 AM Page 149

 Press selector lever cable - 1 - onto selector shaft lever - 3 -.


.
ENGINE CODE(S): BKH
.

If measurement performed with locating pin 3393 during removal showed that holes - 1 - and - 2 - were aligned:
 Install subframe, observing tightening sequence --> 40 - FRONT SUSPENSION .
1:51:57 AM Page 150

If measurement performed with locating pin 3393 during removal showed that holes - 1 - and - 2 - were NOT
aligned:
 Only tighten bolts for subframe to tightening torque setting, do not yet turn further (wait until wheel
alignment has been carried out).
CAUTION: The vehicle must not be driven.


 Secure driveshaft to transmission -->
1:51:57 AM Page 151

 Secure heat shield - A - for driveshaft - arrows -.

ENGINE CODE(S): BKH
.
 Bolt drive axles to flange shafts --> 40 - FRONT SUSPENSION .

 Install heat shields - arrow - for drive axles (left and right).
 Check oil level in final drive (front) --> Front final drive gear oil.
 Check oil level in transfer gear--> Transfer gear oil.
1:51:57 AM Page 152



.
 If necessary, carry out wheel alignment --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .
CAUTION: After wheel alignment tighten subframe bolts to their final torque setting.
Tightening torques

graphite lubricant.
Drive plate to torque converter Nm

Ribbed bolts, M10x1x21.5 (3x) * See note* See
note
4.2 ltr. MPI engine 85
*Replace bolts.
*Use new bolts (same as original equipment) .
Illustration of transmission flange
1:51:58 AM Page 153

A: dowel sleeves for centralizing
Securing engine to transmission:
Item Bolt Nm
8 M10x60 45
9 M10x60 45
10 M10x60 45
*Also secures starter.
Securing transmission to engine:
Item Bolt Nm
2 M12x105 65
3 M12x110 65
4 M12x105 65
5 M12x105 65
6 M12x130 65 * See note
7 M12x170 65
*Also secures a heat shield.
Component Nm
Engine speed (RPM) sensor G28 to transmission 10
Bracket for ATF lines to transmission 21
Bracket for exhaust pipe lug. 23
Heat shields above drive axles to transmission 23
Heat shield for driveshaft to transmission cover 25
Transmission support and transmission mounting, removing and installing (left and right)
1:51:58 AM Page 154


Removing
 Remove front exhaust pipe on relevant side of transmission -->

ENGINE CODE(S): BKH
.
1:51:58 AM Page 155

Housing Base
NOTE:  Always remove both transmission mountings from the subframe.
1:51:58 AM Page 156


 Lower transmission slightly with engine/transmission jack V.A.G 1383 A to make bolts - 1 - and - 2 -
more accessible.
1:51:58 AM Page 157

Removing transmission mounting - B -
 Detach transmission mounting - B -.

1:51:58 AM Page 158

Removing transmission support
 Remove transmission support - A - with transmission mounting.
Installing
 Install transmission supports.

NOTE:  Do not tighten transmission mountings to subframe to specified torque

until re-installation of subframe has been completed.
 To avoid tension you may have to re-align transmission mounting and transmission support.
 Tighten all bolts to specified torque.

Tightening torques for transmission support and heat shield (left and right)
1. Bolt (3x) for securing transmission support to transmission, 23 Nm

2. Bolt (3x) for securing heat shield to transmission support, 10 Nm
1:51:58 AM Page 159

Tightening torques for transmission mountings (left and right)
1. Bolt (1x) for securing transmission mounting to transmission support, 50 Nm

2. Washer
3. Bolt (2x) for securing transmission mounting to subframe, 23 Nm
 Install front exhaust pipe -->

ENGINE CODE(S): BKH
.
1:51:59 AM Page 160


 Attachment and holding rig. 3457
Procedure
Attachment and holding rig. 3457 can be used to transport automatic transmission and also when setting up

 Install attachment and holding rig. 3457 to attachment points on transmission housing and secure in place.
Transmission, securing to assembly stand
1:51:59 AM Page 161

Fig. 255: Identifying Special Tools - Transmission, Securing To Assembly Stand


 Support clamp VW 313
 Support plate VW 309
 Workshop crane V.A.G 1202 A or workshop crane VAS 6100
 Transmission is removed
1:51:59 AM Page 162


 Bolt transportation tool onto support plate VW 309 and install into support clamp VW 313 with the aid of
workshop crane.
CAUTION: The center of gravity of the transmission is outside the pivot center of the
support clamp. A second technician has to hold the transmission housing
when it is being turned to prevent it from swinging round.
NOTE:  If the installed transmission with oil pan is to be turned upside down on
assembly stand, seal the transmission housing and final drive breathers.
PLANETARY GEARBOX AUTOMATIC TRANSMISSION FLUID (ATF)
Planetary gearbox Automatic Transmission Fluid (ATF)
ATF level, checking and correcting
1:51:59 AM Page 163

Fig. 257: Identifying Special Tools - ATF Level, Checking And Correcting
 Vehicle diagnostic, testing and information system VAS 5051 A

 Drip tray V.A.G 1306
 ATF charging device V.A.G 1924
 Safety goggles
Conditions
 Transmission must not be in emergency running (backup) mode.

 Vehicle must be level (horizontal).
 Selector lever in position "P", engine idling.
1:51:59 AM Page 164

 Air conditioner and heating system switched off.
 Vehicle diagnostic, testing and information system VAS 5051 A connected; vehicle self-diagnosis and
vehicle system "02 - gearbox electronics" selected.
 The ATF temperature at the beginning of the test must not be higher than 30° C. If necessary, first allow
the transmission to cool down.
NOTE:  The ATF temperature is taken from the reading on the vehicle diagnostic,
testing and information system VAS 5051 A.
 The ATF level will vary according to the ATF temperature.
 If the ATF level is checked when the ATF temperature is too low, this will
result in overfilling.
 If the level is checked when the ATF temperature is too high, this will
result in underfilling.
 Both overfilling and underfilling have a detrimental effect on the
functioning of the transmission.
 Use only correct type of ATF (available as a replacement part) for the
planetary gearing in automatic transmission 09L. Other oils cause faults
and/or failure of the transmission; for ATF specification refer to -->
Capacities .
ATF temperature reading
Display on VAS 5051 A:

 From list - 1 - select diagnostic function "08 - Read data block (measured value block)".
1:51:59 AM Page 165


 Use keypad - 2 - to enter "4" for "Display group number 4" and confirm by touching Q key.

 Reading for ATF temperature is shown in display zone - 1 -.
NOTE:  The ATF level is checked at the ATF inspection plug.

 The ATF level is correct if a small amount of fluid comes out at the ATF
inspection plug when ATF temperature is between 35° C and 45° C, or 50°
C in hot climates (the fluid level rises due to expansion as it warms up).
1:51:59 AM Page 166

 Drive vehicle onto a four-column hoist or over an inspection pit so that it is absolutely horizontal.
 Fill container of ATF charging device V.A.G 1924 with ATF for automatic transmission 09L; ATF
specification --> Capacities .
CAUTION: The ATF charging device must be clean and the ATF must not be mixed
with other types of ATF!
 Secure reservoir for ATF charging device V.A.G 1924 as high as possible on vehicle.
 Start engine and let it idle.
 Place drip tray V.A.G 1306 under transmission.
Fig. 262: Identifying ATF Inspection Plug

 When an ATF temperature of 35° C is reached, remove ATF inspection plug - arrow B - and drain off
1:52:00 AM Page 167

any surplus ATF.
Fig. 263: Filler Plug Seal

 Replace seal - arrow - for ATF inspection plug.

If ATF comes out of inspection hole before ATF has reached 40° C the ATF level - arrow - is OK.
NOTE:  The ATF inspection plug must be screwed in again at the latest when ATF
reaches a temperature of 45° C (or 50° C in hot climates).
If no ATF emerges from ATF inspection hole when ATF has reached 45° C, top off with ATF.
 Install new seal on ATF inspection plug and tighten to 80 Nm. The ATF check is now completed.
 End function "08 - Read data block (measured value block)" by touching <-- key.
 Press "06 - End output".
1:52:00 AM Page 168

Filling up ATF
temperature reaches 45° C (or 50° C in hot climates). If necessary, switch
off the engine, allow transmission to cool down and repeat the test.

 Guide filler nozzle of ATF charging device V.A.G 1924 in from below through an opening in deflector
cap - arrow - , taking care not to push deflector cap upward out of position.
 Fill with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole.
NOTE:  The ATF level must not be too low or too high, otherwise this would impair
the function of the transmission.
 Install new seal on ATF inspection plug and tighten to 80 Nm.

Draining ATF or filling after repairs
1:52:00 AM Page 169




 Safety goggles
Procedure
 Engine not running.
1:52:00 AM Page 170


Draining ATF
 Remove ATF drain plug - arrow A -.

 Drain ATF.
NOTE:  Observe relevant disposal regulations.

 The engine must not be started and vehicle must not be towed without
ATF in transmission.
1:52:00 AM Page 171

 The drain plug with seal must be replaced.
 Tighten new drain plug - arrow A - to 12 Nm.
Filling with ATF
 Remove ATF inspection plug - arrow B -.

 Continue filling with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection
hole again.
 Tighten ATF inspection plug.
 With engine idling, press brake pedal and shift selector lever through all selector lever positions leaving
selector lever at least 10 seconds in each position.
 Increase engine speed to 2000 rpm and maintain for at least 60 seconds.
NOTE:  Observe all notes and test requirements for "Checking and correcting ATF
level".
ATF COOLING LINES
1:52:00 AM Page 172

ATF cooling lines
ATF cooling lines, component overview (vehicles with 2.0 ltr. TFSI engine)
Fig. 271: ATF Cooling Lines, Component Overview (Vehicles With 2.0 ltr. TFSI Engine)
1 - Nut, 8 Nm
2 - Clip
3 - Bolt, 42 Nm
4 - ATF lines
1:52:01 AM Page 173

5 - Union nuts, 29 Nm
6 - Bolt, 21 Nm
 Before tightening bolt, push in ATF lines onto stop by hand
7 - ATF lines
8 - O-rings
 Replace
 Lubricate with ATF when installing
9 - Clip
10 - Bolt, 5 Nm
 Secures ATF lines to transmission
12 - Bolt, 5 Nm
 Secures ATF line at ATF cooler (top)

 Before tightening bolt, push in ATF line onto stop by hand
13 - O-ring
 Replace
14 - ATF line
 Inserted into ATF cooler (top)

15 - ATF lines
 Inserted into ATF cooler (bottom)

16 - O-ring
1:52:01 AM Page 174

 Replace
17 - Bolt, 5 Nm

ATF cooling lines, component overview (vehicles with 4.2 ltr. MPI engine)
Fig. 272: ATF Cooling Lines, Component Overview (Vehicles With 4.2 ltr. MPI Engine)
1 - Bolt, 21 Nm
 Before tightening bolt, push in line onto stop by hand
1:52:01 AM Page 175

2 - O-ring
 Replace
3 - O-ring
 Replace
4 - Bolt -5 Nm-
 For securing ATF lines to transmission
5 - Union nut, 29 Nm
7 - Nut, 5 Nm
 For securing ATF lines to bracket
8 - Nut, 5 Nm
 For securing bracket to transmission
11 - Plug connector
12 - Bolt, 5 Nm
 For securing ATF lines at front end
13 - Bolt, 5 Nm

 For securing ATF line to bracket at ATF cooler (bottom)
14 - ATF line

1:52:01 AM Page 176

15 - O-ring
 Replace
16 - Bolt, 5 Nm
 For securing ATF line at ATF cooler (top)

17 - ATF line

18 - O-ring
 Replace
ATF cooling lines, removing and installing
 Drip tray
 Safety goggles
Removing
 Mark position of all ATF cooling lines in relation to one another with different colors to avoid confusion.
 Place drip tray V.A.G 1306 underneath.
 Disconnect ATF cooling lines.

 Seal opened cooling lines with clean sealing plugs.
Installing
1:52:01 AM Page 177

 Clean ATF lines --> ATF cooling lines and ATF cooler, cleaning.
 Lightly lubricate O-rings with ATF.
 First press ATF lines onto transmission or cooler by hand until they engage, then secure lines --> ATF
cooling lines, component overview (vehicles with 4.2 ltr. MPI engine).
ATF cooling lines and ATF cooler, cleaning
 Compressed air gun (commercially available)

 Hose, approx. 18 mm dia.
 Drip tray
NOTE:  Always clean ATF cooling lines and ATF cooler before installing a
replacement transmission.

Procedure
 Place drip tray underneath.

 Connect a hose approx. 18 mm dia. to ATF line - A - and secure with a hose clamp. Place other end of
hose in drip tray.
1:52:01 AM Page 178

 Blow through ATF line - B - using a compressed air line (max. 10 bar).
 Change hose from ATF line - A - over to ATF line - B - and repeat sequence.
 Press ATF cooling lines onto transmission or cooler by hand until they engage, then tighten --> ATF
38 GEARS, CONTROL
OIL PAN, ATF STRAINER AND MECHATRONICS UNIT, REMOVING AND INSTALLING
Oil pan, ATF strainer and mechatronics unit, removing and installing
CAUTION: Do not run engine or tow vehicle with oil pan removed or when there is no
ATF in the transmission.

 Always replace mechatronics unit if contaminated or faulty.
 Lightly lubricate O-rings and seals with ATF. Other types of lubricant will
cause the transmission hydraulics to malfunction.

1:52:01 AM Page 179


 Safety goggles
Removing


 Remove ATF drain plug - 1 -.

 Drain ATF.

 Loosen 23 bolts on oil pan in diagonal sequence and remove oil pan.
1:52:02 AM Page 180

Installing
NOTE:  Replace seals and gaskets.

 Clean all magnets in recesses on oil pan. Make sure that magnets make full contact with oil pan.
 Clean sealing surface thoroughly; remaining material from the previous gasket must be removed
completely.

 Tighten oil pan bolts in several stages and in diagonal sequence.

 Tighten new drain plug - 1 -.
 Fill with ATF --> Draining ATF or filling after repairs.
Tightening torques
Component Nm
Drain plug to oil pan 12 * See note
Oil pan to transmission housing 12 * See note
*Replace plug.
*Tighten diagonally in stages.
1:52:02 AM Page 181

ATF strainer, removing and installing
Removing

 Remove oil pan --> Oil pan, removing and installing.
Fig. 277: Identifying Intake Line Of ATF Strainer

 Carefully remove ATF strainer - A - from transmission.
NOTE:  The ATF strainer only has to be replaced if it has been damaged.
1:52:02 AM Page 182

Fig. 278: Removing/Installing Oil Seal For ATF Strainer From Transmission
If replacing ATF strainer:
 If installed, carefully remove oil seal for ATF strainer - A - from transmission using a screwdriver or
similar.
NOTE:  Take care not to damage sealing surface.

 For illustration purposes the oil seal is shown with mechatronics unit
removed.
 The new ATF strainer is supplied with oil seal installed.
Continuation for new and old ATF strainer:
1:52:02 AM Page 183

 Press intake line of ATF strainer - A - carefully onto stop into mounting hole in transmission.
NOTE:  A new ATF strainer is pressed into transmission with oil seal installed.
 Install oil pan --> Oil pan, removing and installing.

Mechatronics unit, removing and installing
NOTE:  Always replace mechatronics unit if contaminated or faulty.

Removing


 Remove ATF strainer --> ATF strainer, removing and installing.
1:52:02 AM Page 184

 Disconnect 16-pin electrical connector - 2 - at transmission by folding out release tab and turning fastener
cap counter-clockwise.
 Touch vehicle Ground (GND) with your hand (without gloves) to discharge any static electricity.

discharge any static electricity by touching vehicle Ground (GND) or
other Ground (GND) object with your hand.
 Never touch contacts in 16-pin connector by hand, as static
discharge would damage the control module and mechatronics unit.

 Unfasten retaining clip - arrow - for wiring harness connector on outside of transmission housing.
1:52:02 AM Page 185


 Remove securing bolts for mechatronics unit in sequence - 11 to 1 -.
NOTE:  Only remove securing bolts marked - 1 to 11 -.

 If other bolts are loosened, this may affect the operation of the
mechatronics unit or the mechatronics unit could come apart.
 Remove mechatronics unit together with wiring harness from transmission, at the same time guide out
connector for wiring harness.
Installing
1:52:03 AM Page 186

 Make sure that seal - B - is properly inserted and secured.

 Replace O-rings on connector for wiring harness and lightly lubricate with ATF.
 Clip wiring harness - A - onto mechatronics unit - B - by first attaching tab - arrow - on reverse side of
wiring harness to mechatronics unit.
NOTE:  If the tab on the reverse side of the wiring harness breaks off, the wiring
harness must be replaced --> Wiring harness in transmission, removing
and installing.
 Install wiring harness connector in transmission housing.
 Installation position: flat part of rear shoulder faces downward, the lugs at shoulder are horizontal
1:52:03 AM Page 187

Fig. 285: Inserting Transmission Selector Lever Stud Into Groove On Selector Slide
 While installing mechatronics unit without force, insert transmission selector lever stud - arrow - into
groove on selector slide - A - (move selector slide backward and forward if necessary).

 Tighten securing bolts - 1 - and - 2 - for mechatronics unit to 2 Nm.

 Then tighten securing bolts in specified sequence - 1 to 11 - to 8 Nm.
1:52:03 AM Page 188


 Push retainer clip - arrow - onto wiring harness connector.

 Install ATF strainer --> ATF strainer, removing and installing.

.
Removing
 Remove mechatronics unit --> Mechatronics unit, removing and installing


1:52:03 AM Page 189

 Carefully disconnect wiring harness - A - from mechatronics unit - B -. Make sure you detach tab - arrow
- on reverse side of wiring harness from mechatronics unit.
and installing.
 Carefully disconnect connector - C - from socket - D - of mechatronics unit.
Installing
 Carefully connect connector - C - to socket - D - on mechatronics unit.

 Install mechatronics unit --> Mechatronics unit, removing and installing.
39 FINAL DRIVE - FRONT DIFFERENTIAL

FRONT FINAL DRIVE GEAR OIL
Front final drive gear oil
1:52:03 AM Page 190


Front final drive gear oil level, checking


 Safety goggles
Condition
 Gear oil about 20° C (room temperature)
Work sequence
 Drive vehicle onto a four-column lifting platform or over an inspection pit in order for it to be absolutely
horizontal.
 Place drip tray V.A.G 1306 under the transmission.
1:52:03 AM Page 191


 Remove plug - arrow -.
 Oil level must be up to lower edge of filler hole.
 Drain off any excess oil or top off to proper level; specification --> Capacities .
NOTE:  The plug with seal must be replaced.
 Tighten new plug to 35 Nm.
Front final drive gear oil, topping up gear oil level after repairs


 Safety goggles
1:52:04 AM Page 192

Requirements:
Topping off



 Fill front final drive slowly and at a constant rate for a period of at least 5 minutes until gear oil (capacity
and specification --> Capacities ) comes out at lower edge of oil filler hole.
NOTE:  The top off period of at least 5 minutes is necessary so that the internal oil
level can be balanced out between differential and baffle chamber.
 The plug with seal must be replaced.
NOTE:  The oil level does not need to be re-checked.
1:52:04 AM Page 193


Front final drive, assembly overview
Fig. 293: Front Final Drive, Assembly Overview

1 - Oil seal

 Replacing --> Final drive/transmission housing oil seal, replacing
2 - Shim
1:52:04 AM Page 194

3 - Outer race for tapered roller bearing
4 - O-ring
 Replace
5 - Plug, 35 Nm
 Replace
6 - Flange shaft (right-side)
 Removing and installing --> Flanged shaft (right side), removing and installing
7 - Retaining ring
 Replace
8 - Flange shaft oil seal (right-side)
 Replacing --> Flanged shaft oil seal (right side), replacing
9 - Bolt, 23 Nm
 Follow correct tightening sequence --> Final drive cover O-ring, replacing
11 - Shim
13 - O-ring for final drive cover
 Replacing --> Final drive cover O-ring, replacing
14 - Differential
15 - Spring pin
16 - Selector shaft lever
1:52:04 AM Page 195

17 - Oil seal for selector shaft
 Replacing --> Selector shaft oil seal, replacing
18 - Bolt, 23 Nm
19 - Flange shaft (left-side)
 Removing and installing --> Flange shaft (left-side), removing and installing
Flange shaft (left-side), removing and installing

Fig. 295: Puller T10037

 Puller T10037
1:52:04 AM Page 196

Removing

 Unbolt heat shield - arrow - from transmission above drive axle (left-side).
 Unbolt drive axle (left-side) from flange on transmission and tie up.
Fig. 297: Removing Bolts On Retaining Bracket For Left-Side Flange Shaft
 Remove bolts - arrows - on retaining bracket for left-side flange shaft.
1:52:04 AM Page 197

Fig. 298: Screwing Puller T10037 Onto Differential Cover

 Screw puller T10037 onto differential cover - arrow -.

 Pull out left flange shaft using puller T10037 only until bearing on shaft is removed from transmission
housing.
CAUTION: If the shaft is not kept centered, the splines of the shaft will fall against the
inner seal between the final drive and transmission housing. The seal will
be damaged and require replacement --> Final drive/transmission housing
oil seal, replacing.
Fig. 299: Removing/Inserting Flange Shaft Into Transmission And Guide Shaft Into Seal On Differential
 Pull left flange shaft - A - out of transmission making sure that the shaft remains centered in the opening
on differential - arrow -.
1:52:05 AM Page 198

Installing
 Clean flange shaft.
 Insert flange shaft - A - into transmission and guide shaft into seal on differential - arrow - , keeping it
centered.
NOTE:  If the shaft is not kept centered, the splines of the shaft will damage the
seal between the final drive and transmission housing. The seal will
require replacement--> Final drive/transmission housing oil seal,
replacing.
 Bolt left drive axle to flange shaft --> 40 - FRONT SUSPENSION .

 Check oil level in front final drive --> Front final drive gear oil.
Tightening torques
Component Nm
Retaining bracket for left flange shaft to 23
transmission
Flanged shaft (right side), removing and installing
1:52:05 AM Page 199


Removing

 Unbolt heat shield - arrow - from transmission above drive axle (right-side).
 Unbolt drive axle (right-side) from flange on transmission and tie up.
1:52:05 AM Page 200

Fig. 303: Placing Chisel Or Suitable Spacer Under Flange Shaft And Pulling Flange Shaft Out By
Turning Bolt

 Remove flange shaft: Place a chisel or suitable spacer - A - under flange shaft and pull flange shaft out by
turning bolt - B -.
NOTE:  If the flange shaft does not come out easily, turn the shaft and screw the
bolt into the opposite hole to assist removal.
1:52:05 AM Page 201

Fig. 304: Removing And Installing Securing Ring

 Replace circlip for flange shaft

 Clamp flange shaft in vise, using jaw protectors. Use new retaining ring - A - to press old retaining ring
out of groove in flange shaft.
Installing
 Clean flange shaft and seal.

 If seal is damaged, it must be replaced --> Flanged shaft oil seal (right side), replacing.
 Pack space between sealing lip and dust lip half full with sealing grease G 052 128 A1 .
 Insert flange shaft by hand into splines of differential until splines lock properly into place.
 Press flange shaft in by hand or with mandrel VW 295 as far as stop.
NOTE:  The circlip on the flange shaft should click into place.
 Bolt right drive axle to flange shaft --> 40 - FRONT SUSPENSION .

Tightening torque
Component Nm
1:52:05 AM Page 202

Flanged shaft oil seal (right side), replacing
Fig. 305: Identifying Special Tools - Flanged Shaft Oil Seal (Right Side), Replacing

Procedure
1:52:05 AM Page 203



 Remove flange shaft (right-side) --> Flanged shaft (right side), removing and installing.

 Pull out flange shaft oil seal.
Fig. 307: Driving New Seal In Onto Stop

 Lubricate outer circumference of seal with gear oil

 Drive new seal in onto stop (take care to keep seal straight).
 Installation position: open side of seal faces transmission.
 Install flange shaft (right-side) --> Flanged shaft (right side), removing and installing.
1:52:06 AM Page 204

Final drive cover O-ring, replacing

Procedure

 Remove transmission support (right-side) --> Transmission support and transmission mounting,
1:52:06 AM Page 205

Fig. 309: Removing/Installing Bolts On Final Drive Cover In Sequence

 Remove bolts on final drive cover in sequence - 11 to 1 - and remove cover together with outer race for
tapered roller bearing and shim.
NOTE:  Thickness of shim has been measured to fit; the shim must not be
replaced with another shim of different thickness.
 Replace O-ring - arrow -.
Note the following if the outer race for tapered roller bearing and the shim have dropped out of the final drive
cover:
 Lubricate shim and outer race for tapered roller bearing with gear oil and insert in final drive cover as far
1:52:06 AM Page 206

as stop.

 Tighten bolts of final drive cover as follows.
Step Tightening sequence

I  Tighten bolts - 1 - and - 2 - to 3 Nm.
II  Tighten bolts - 1 to 11 - to 23 Nm in sequence
indicated.
 Install transmission support (right-side) --> Transmission support and transmission mounting,
Final drive/transmission housing oil seal, replacing
1:52:06 AM Page 207

Fig. 312: Identifying Special Tools - Final Drive/Transmission Housing Oil Seal, Replacing

Requirements
 Transmission mounted on assembly stand --> Transmission, securing to assembly stand.
CAUTION: Do not place transmission down on the oil pan.
1:52:06 AM Page 208

Procedure
NOTE:  A faulty seal allows gear oil to enter the torque converter bell housing.

1:52:07 AM Page 209

 Remove differential.
 Remove tapered roller bearing outer race - 1 - for differential and shim - 2 - (behind outer race) from

 Remove flange shaft (left-side) --> Flange shaft (left-side), removing and installing.
 Remove seal.
NOTE:  The oil seal extractor lever VW 681 must be applied behind the two sealing
lips of the oil seal. Do not apply the lever to the outer circumference of the
seal, as this would damage the sealing surface in the transmission. Guide
the lever carefully when removing the seal.
 Examine oil seal seat in transmission housing for damage; reface surface if necessary.
1:52:07 AM Page 210

 Lightly lubricate outer circumference and sealing lip of oil seal with gear oil.
NOTE:  Push the seal onto the thrust piece with the protruding sealing lip of the
seal facing the tool.
Fig. 316: Driving In New Oil Seal As Far As Stop Using Thrust Piece T10139
 Drive in new oil seal as far as stop using thrust piece T10139.
 Insert shim - 2 - and tapered roller bearing outer race - 1 - for differential onto stop in transmission
housing by hand.
NOTE:  Make sure that shim and outer race are kept straight when inserting.
1:52:07 AM Page 211


 Install differential in transmission housing.
cover:
as the stop.

 Tighten bolts of cover for final drive as follows.
1:52:07 AM Page 212


II  Tighten bolts - 1 to 11 - to 23 Nm in the
sequence indicated.
 Install flange shaft (left-side) --> Flange shaft (left-side), removing and installing.
Selector shaft oil seal, replacing

 Removal lever 80-200

1:52:07 AM Page 213

Procedure



1:52:07 AM Page 214

 Drive out roll pin - 1 - at selector shaft lever - 2 - - arrow - until it is possible to detach selector shaft
lever from selector shaft.

 Push a small screwdriver through seal and pull it out.

 Lubricate outer circumference and the space between sealing lips of seal with ATF.
 Install new seal onto selector shaft.
Fig. 325: Pressing On New Oil Seal Using Thrust Piece T10135 And Assembly Lever As Far As Stop
 Press on new oil seal using thrust piece T10135 and assembly lever - A - as far as stop; make sure that oil
seal remains straight.
NOTE:  To prevent slippage when pressing in oil seal, place something as a base
(e.g. piece of rubber) between assembly lever and subframe - arrow -.
1:52:08 AM Page 215

 Before installing, drive roll pin in selector shaft lever back through lever in opposite direction.
 Push selector shaft lever onto selector shaft and drive in roll pin.
NOTE:  Do not bend the selector shaft lever when pressing on the ball socket, as
otherwise it will no longer be possible to precisely adjust the gear selector
mechanism
TRANSFER GEAR OIL
Transfer gear oil

Transfer gear oil level, checking
1:52:08 AM Page 216



 Safety goggles
Condition
Work sequence
Fig. 328: Removing Plug

1:52:08 AM Page 217

 The oil level must be up to lower edge of filler hole.
 Top off with gear oil if necessary; specification --> Transfer gear.
Transfer gear oil, topping off after repairs


 Safety goggles
Conditions

 The cover was removed from transfer gear and all gear oil was thereby drained.
Work sequence
1:52:08 AM Page 218


NOTE:  The engine must not be started and vehicle must not be towed without
gear oil in transmission.
 Fill transfer gear slowly and evenly over a period of at least 5 minutes with gear oil (capacity and
specification --> Transfer gear).
level can be balanced out between Torsen differential and baffle chamber.
NOTE:  The level does not need to be re-checked.
TRANSFER GEAR, SERVICING
Transfer gear, servicing
CAUTION: Do not run the engine or tow the vehicle if the Torsen differential is
removed or if the gear oil has been drained from the transmission.
Torsen differential cover, removing and installing
1:52:08 AM Page 219



 Safety goggles
Removing
CAUTION: The engine must not run and the vehicle must not be towed without gear
oil.


Vehicles with 2.0 ltr. TFSI engine
1:52:09 AM Page 220

NOTE:  The flexible line connection (de-coupling element) on the front exhaust
line must not be bent more than 10° - otherwise it can be damaged.


NOTE:  To prevent damage, the flexible couplings in the front exhaust lines must

exhaust system.
1:52:09 AM Page 221



Fig. 336: Loosening/Tightening Securing Bolts For Cover For Torsen Differential In Sequence
1:52:09 AM Page 222

 Loosen securing bolts for cover for Torsen differential in sequence - 6 to 1 - and remove; allow gear oil to
drain out.
NOTE:  The cover is not equipped with a drain plug; drain gear oil by removing the
cover.
CAUTION: Pull the Torsen differential cover backward from the transmission housing
slowly and carefully. The Torsen differential may otherwise fall out of the
transmission.
Fig. 337: Securing Torsen Differential And Baffle Plate To Prevent Them From Dropping Out
 Secure Torsen differential - B - and baffle plate - A - to prevent them from dropping out, or pull them off
output shaft toward the rear.
1:52:09 AM Page 223

Fig. 338: Identifying If Torsen Differential And Baffle Plate Have Been Removed
Installing
NOTE:  Replace O-ring on cover for transfer gear.
Note the following if the Torsen differential - B - and the baffle plate - A - have been removed:
 Clean baffle plate, lubricate with gear oil and insert in transmission.
 Installation position: tongue on baffle plate should be positioned on the transmission so that the side lugs
are located above opening - B - - arrow -.
1:52:09 AM Page 224

 Install Torsen differential - B - onto splines of output shaft (turn slightly at the same time).
NOTE:  Check installation position of tongue on baffle plate - arrow - again.
 Check whether the attached Torsen differential can be turned manually.

 Check whether tongue - arrow - on baffle plate is still located properly.
 Place cover for Torsen differential with shaft installed onto Torsen differential, turn slightly if necessary.
 Tighten bolts of cover for Torsen differential as follows.

sequence indicated.

.
1:52:10 AM Page 225


ENGINE CODE(S): BKH
.
 Top off transfer gear oil--> Transfer gear oil, topping off after repairs
Tightening torques
Component Nm
Cross member to body 23
Flanged shaft oil seal (rear), replacing
1:52:10 AM Page 226

Fig. 341: Identifying Special Tools - Flanged Shaft Oil Seal (Rear), Replacing

 Thrust pad VW 447 i
 Punch VW 409
 Pressure application device T10136
Procedure
 Remove Torsen differential cover --> Torsen differential cover, removing and installing.
1:52:10 AM Page 227

Fig. 342: Removing/Installing Circlip On Inner Side Of Cover

 Remove circlip - arrow - on inner side of cover.
NOTE:  The circlip locates the flange shaft on the bearing in the cover.
Fig. 343: Using Punch VW 409 To Press Flange Shaft Out Of Torsen Differential Cover By Placing Cover
On Thrust Plate VW 401 And Thrust Plate VW 402
 Using punch VW 409, press flange shaft out of Torsen differential cover by placing cover on thrust plate
VW 401 and thrust plate VW 402.
NOTE:  Hold flange shaft - A - with one hand to prevent it from falling.
1:52:10 AM Page 228

Fig. 344: Prying Out Oil Seal

 Pry out oil seal.
NOTE:  To prevent damage to the housing, place something underneath (e.g.

metal bar - A - ).
Fig. 345: Placing Torsen Differential Cover On Pressure Application Device T10136
 Place Torsen differential cover - A - on pressure application device T10136.
NOTE:  The peg in the middle of the tool is centered and faces upward in the
cover. It serves as a guide and stop for pressure application device
T10136/1.

 Push new seal onto pressure application device T10136/1.
 Installation position: open side of seal faces cover.
1:52:10 AM Page 229

Fig. 346: Inserting Pressure Application Device T10136/1 With Seal Into Cover From Above
 Insert pressure application device T10136/1 with seal into cover from above.
NOTE:  The peg of the pressure application device T10136 serves as a guide from
below and also as a stop for press tool T10136/1.
1:52:10 AM Page 230

Fig. 347: Pressing Flange Shaft Using Punch VW 409 And Thrust Pad VW 447 I Into Torsen Differential
Cover By Placing Cover On Thrust Plate VW 401 And Thrust Plate VW 402
 Press flange shaft using punch VW 409 and thrust pad VW 447 i into Torsen differential cover by placing
cover on thrust plate VW 401 and thrust plate VW 402.
NOTE:  Only insert flange shaft as far as necessary to install circlip.

 Install circlip - arrow - in groove of flange shaft on inner side of cover.

 Install Torsen differential cover --> Torsen differential cover, removing and installing.
 Top off transfer gear oil --> Transfer gear oil, topping off after repairs
1:52:11 AM Page 231

...
32 TORQUE CONVERTER
TORQUE CONVERTER
Torque converter
CAUTION: Before installing transmission check position of torque converter.
 Apply thin coat of ATF to seals. Other types of lubricant will cause the
transmission hydraulics to malfunction.

There are various types of torque converter. They are marked with code letters - arrow -.
Torque converter/transmission allocation --> Code letters, transmission allocation, ratios, equipment.
1:53:16 AM
1:53:19 Page 1

 Oil extractor V.A.G 1358 A

 Oil extractor probe V.A.G 1358 A/1
Fig. 10: Extracting ATF From Torque Converter Using Oil Extractor V.A.G 1358 A And Oil Extractor
Probe V.A.G 1358 A/1
If the ATF has become fouled by abrasion or when performing a major transmission overhaul, drain the torque
converter as follows:
 Extract ATF from torque converter using oil extractor V.A.G 1358 A and oil extractor probe V.A.G 1358
A/1.
1:53:16 AM Page 2


Procedure
 Remove transmission: --> Transmission, removing (vehicles with 2.0 ltr. TFSI engine), -->
Transmission, removing (vehicles with 3.2 ltr. FSI engine), --> Transmission, removing (vehicles
with 4.2 ltr. MPI engine).
 Mount transmission on assembly stand --> Transmission, securing to assembly stand.
 Carefully pull out torque converter.
1:53:16 AM Page 3
 Remove oil seal for torque converter using oil seal extractor VW 681.
 Lightly lubricate outer circumference and sealing lips of oil seal with ATF.
 Installation position: open side of oil seal points toward transmission
Fig. 14: Driving In Torque Converter Oil Seal With Thrust Piece T10137 Until Thrust Piece Reaches
Stop
 Drive in torque converter oil seal with thrust piece T10137 until thrust piece reaches stop.
1:53:16 AM Page 4

 Check hub - arrow - of torque converter for scoring.
NOTE:  The torque converter is a welded assembly and must be replaced as a

complete unit in the event of any damage or malfunctions.
 Depth gauge
Installing
 Press torque converter hub through oil seal as far as first stop.
 Lightly press torque converter inward and turn until slots on torque converter hub engage in drive lugs on
ATF pump gear and torque converter slides in a noticeable distance.

1:53:16 AM Page 5
Installed depth
If the torque converter is correctly installed, the depth between the contact surfaces at the tapped holes on the
torque converter and the contact surface of the torque converter bell housing is at least 19 mm.
 Use new ribbed bolts to secure torque converter to drive plate.
When installing the transmission, observe the following instructions.
CAUTION: Before and while you are tightening the bolts on the engine/transmission
flange keep checking that the torque converter can still be rotated behind
the drive plate. If the converter cannot be turned, it must be assumed that
it has not been installed correctly and the drive lugs on the converter or
the ATF pump will be damaged when the bolts are fully tightened.
1:53:16 AM Page 6
...

Location: below knee padding on left side of steering wheel
The following components can be tested in the "Guided fault finding" using vehicle diagnostic, testing and
information system VAS 5051 A.
1:54:13 AM
1:54:29 Page 1

Mechatronics unit, Transmission Control Module (TCM) J217, Multi-function transmission range (TR)
switch F125, Transmission input speed (RPM) sensor G182 and Transmission output speed (RPM) sensor
G195
Location: the mechatronics unit is bolted to the underside of the transmission housing and covered by the
The mechatronics unit incorporates the hydraulic control system, the electronic control module and the sensors
and actuators as a complete synchronized unit. This includes:
 Transmission Control Module (TCM) J217

 Multi-Function Transmission Range (TR) Switch F125
 Transmission Input Speed (RPM) Sensor G182
 Transmission Output Speed (RPM) Sensor G195
The "mechatronics" unit can only be replaced as a complete unit.
NOTE:  All components mentioned are tested via Self-diagnosis.
 Removing and installing mechatronics unit --> Mechatronics unit, removing and installing
1:54:13 AM Page 2
Internal wiring harness in transmission
Location: the wiring harness - A - with connector - C - is attached to the mechatronics unit - B -.
 Removing and installing wiring harness --> Wiring harness in transmission, removing and installing.

Location: integrated into instrument cluster
NOTE:  The Transmission Range (TR) Display Y6 can only be replaced together
1:54:13 AM Page 3
with instrument cluster.
Fig. 21: Selector Mechanism Consists Of 3 Hall Senders, And

Tiptronic switch F189
 Location: The Tiptronic switch F189 is integrated in the printed circuit of the symbol panel, which is
located in the selector mechanism cover.
 Comprises 3 Hall sensors actuated by a magnet on transverse slide of the sliding cover.
A - Tip-down sensor
B - Sensor for Tiptronic recognition
C - Tip-up sensor

NOTE:  In the event of faults, first check that magnet is properly secured on the
transverse slide - C - of the sliding cover. Replace sliding cover if
1:54:13 AM Page 4
necessary. Always check wiring before replacing symbol insert with

integrated printed circuit. On vehicles with multi-function steering wheel
the buttons on the steering wheel and their wiring connections must also
be checked.
 Ignore - item A - and - item B -.
 Removing and installing Tiptronic switch F189 --> Tiptronic switch F189, removing and installing
Selector mechanism, servicing
CAUTION: Before working on vehicle when engine is running, shift the selector lever
into position "P" and apply the parking brake.

 When button in selector lever handle is pressed, it should be possible to move selector lever out of
position "P" without "catching".
 It should not be possible to remove the ignition key when the selector lever is in any position other than
"P".
 It should be possible to move ignition key to removal position without "sticking".
 Pull out ignition key.
 It should only be possible to remove ignition key in selector lever position "P".
 Selector lever cannot be shifted out of "P" position with button pressed and foot brake depressed.
If ignition key removal lock does not function as described, locking cable has to be adjusted --> Locking
cable, adjusting.
Selector mechanism, checking
 It should not be possible to operate the starter while the selector lever is in position "S", "D", "R" or in the
"Tiptronic gate".
 When travelling at speeds above 5 km/h and shifting into selector lever position "N", the solenoid for the
selector lever lock must not engage and block the selector lever. The selector lever can be shifted into a
driving gear.
 When travelling at speeds below 2 km/h (almost stationary) and shifting into selector lever position "N",
1:54:13 AM Page 5
the solenoid for the selector lever lock should only engage after about 1 second. Selector lever cannot be
shifted out of "N" position until brake pedal is depressed.
 Selector lever is locked and cannot be shifted out of "P" position. Solenoid for selector lever lock blocks
selector lever.
 Solenoid for selector lever lock releases selector lever. It is possible to shift into a driving gear. Shift
selector lever slowly from "P" position through "R, N, D and S" and check whether the display in the
instrument cluster shows the correct selector lever position in each case.
 After a short waiting time: Selector lever is locked and cannot be shifted out of "N" position. Solenoid for
selector lever lock blocks selector lever.
 Depress brake pedal.
 Solenoid for selector lever lock releases selector lever. It is possible to shift into a driving gear.
Selector lever in "D" position, ignition and lights switched on:
 The illuminated "D" symbol in the selector lever position indicator should go out and the "+" and "-"
symbols should light up.
 The selector lever position indicator in the instrument cluster should switch from "PRNDS" to "654321"
when the selector lever is shifted into the "Tiptronic gate".
If ignition key removal lock does not function as described, selector lever cable has to be checked and
possibly adjusted --> Selector lever cable, checking and adjusting.
Selector mechanism cover, selector lever handle, component overview
052 142 A2 .
1:54:13 AM Page 6
1 - Selector lever
2 - Sleeve for selector lever
4 - Cover
 With position indicator and Tiptronic gate and display for selector lever lock
1:54:13 AM Page 7
 Removing and installing --> Selector mechanism cover, removing and installing
5 - Symbol insert
 Clipped onto cover
 With integrated Tiptronic switch F189

7 - Sliding cover
 With integrated magnet for Tiptronic switch F189 on transverse slide.

8 - Guide for sliding cover
 Carefully pry apart two halves
Removing

 Turn sleeve - 1 - counter-clockwise and push down onto stop.

 Pull button - 2 - out of selector lever handle - 3 - carefully, just far enough to be able to insert a cable tie
NOTE:  Under no circumstances pull button out further, as selector lever handle
1:54:13 AM Page 8
would then become damaged.
 Use cable tie to secure the button in its pulled position - arrow - , as shown in illustration.
 Remove selector lever handle by pulling it off.
Installing

NOTE:  To install the selector lever handle - 3 - the button - 2 - has to be pulled out
to the stop and must be secured with either a cable tie - arrow - or with the
assembly aid supplied together with the new handle.
 If, by mistake, the button has not been secured, it must not be pulled out
of the selector lever handle using mechanical tools. Position a
compressed air gun at the bottom of the handle and carefully press the
button out with compressed air.
 Install selector lever handle - 3 - fully onto selector lever; button - 2 - points toward the driver. The
handle must engage in annular groove of selector lever.
 Remove cable tie - arrow - or assembly aid; the button mechanism will then engage in the vertical groove
on the selector lever. If necessary, press button into selector lever handle.
 Pull sleeve - 1 - upward and engage by turning in clockwise direction.
Selector mechanism cover, removing and installing
Removing
1:54:13 AM Page 9


Installing
Tiptronic switch F189, removing and installing
 Comprises 3 Hall sensors actuated by a magnet on the transverse slide of sliding cover.
 Also check that magnet is properly secured on transverse slide of sliding cover, replace sliding cover with
guide if necessary.
1:54:13 AM Page 10
Removing
 Press 4 locking hooks - arrows - inward and pull cover - 2 - off guide - 1 -.
 Take printed circuit with integrated Tiptronic switch F189 out of cover.
NOTE:  If necessary, the sliding cover with the magnet for the Tiptronic switch
F189 can be removed as described below. However, as a replacement part
the sliding cover is only available together with the guide.
1:54:13 AM Page 11
 Carefully separate two halves of guide by levering them apart - arrows -.

 Remove sliding cover with magnet for Tiptronic switch F189.
Installing
Selector mechanism, component overview
052 142 A2 .
1:54:13 AM Page 12
Fig. 30: Selector Mechanism, Component Overview

1 - Selector mechanism cover (bottom)
3 - Bearing bushing
5 - Pivot pin
6 - Selector lever
 Removing and installing --> Shift lock solenoid N110, removing and installing
8 - Actuating lever for locking cable
11 - Locking lever
12 - Selector gate
13 - 10 Nm
17 - Retaining clip
 Replace
19 - Pivot pin
20 - 10 Nm
1:54:13 AM Page 13
NOTE:  The following procedure describes how to remove and install the selector
mechanism without the selector lever cable, i.e. the selector lever cable
remains in the vehicle.
Removing


 Remove air conditioning control console --> 87 AIR CONDITIONING .
1:54:13 AM Page 14

 Disconnect electrical connector from Shift lock solenoid Shift lock solenoid N110.

 Unhook locking cable - arrows -.



1:54:13 AM Page 15
exhaust system.

 Disconnect exhaust system at clamp - arrow -.


1:54:13 AM Page 16



1:54:13 AM Page 17
 Remove retaining clip - 1 - for selector lever cable by pulling it off downward at the selector mechanism.

NOTE:  A second technician is required to detach the selector mechanism under

the vehicle.
 Push retaining clips - 1 - and - 2 - inward, at the same time pushing the selector mechanism downward.
Installing
 Install selector lever cable --> Selector lever cable, removing and installing (vehicles with 2.0 ltr.
TFSI engine), --> Selector lever cable, removing and installing (vehicles with 3.2 ltr. FSI engine), -->
Selector lever cable, removing and installing (vehicles with 4.2 ltr. MPI engine).
1:54:13 AM Page 18
 Installation position: The angled end of the retaining clip faces to the inside of selector mechanism.
 Install locking cable --> Locking cable, removing and installing.


ENGINE CODE(S): BKH
.
Tightening torques
1:54:13 AM Page 19
Component Nm
Selector mechanism, disassembling and assembling
NOTE:  Removing and installing securing spring for locking cable Removing and
installing securing spring for locking cable.
 If selector gate or selector housing are faulty the entire selector
mechanism has to be replaced. The two components cannot be adjusted
using workshop tools.
Fig. 42: Selector Mechanism, Disassembling And Assembling Overview

1:54:13 AM Page 20
Disassembling

 Remove Shift lock solenoid N110 - item 7 - --> Shift lock solenoid N110, removing and installing.
 Unbolt and then unclip selector gate - 12 - from selector housing - 14 -.
 Release pivot pins - 5 - and - 19 - and pull them out sideways.
 Unclip retaining clips - 2 - and - 16 -.

 Pull selector lever - 6 - together with bushings - 3 - and - 15 - and Tiptronic locking levers - 4 - and - 18 -
downward out of selector housing - 14 -.
Assembling
 Make sure that selector lever is still in position "S".

 Insert selector lever - 6 - into selector lever housing - 14 - from below.
 Install Tiptronic locking levers - 4 - and - 18 - , and bushings - 3 - and - 15 - onto selector lever.
 Push selector lever - 6 - together with bushings into selector lever housing - 14 - and position with
retaining clip - 17 -.
 Engage retaining clips - 2 - and - 16 - on selector lever housing.
 Press pivot pins - 5 - and - 19 - into selector lever - 6 - until they engage.
 Check that the pivot pins are engaged in the Tiptronic locking lever.
 Install Shift lock solenoid N110 - item 7 - --> Shift lock solenoid N110, removing and installing.
 Clip selector gate - 12 - onto selector housing - 14 - and tighten to 0.4 Nm.
Removing and installing securing spring for locking cable
Fig. 43: Removing And Installing Securing Spring For Locking Cable
1:54:13 AM Page 21
Removing
 To remove locking cable lift spring slightly at top - arrow B -.

 Disengage spring from retainer lug - arrow C - and lift out.
Installing
 Insert spring from above - arrow B - and engage under retainer lug - arrow C -.
 Align spring so that it lies level in groove - arrow A -.
 To install locking cable, lift spring slightly at the top - arrow B -.
Shift lock solenoid N110, removing and installing
Removing
 Disconnect electrical connector at Shift lock solenoid N110.

 Release retainer and pull out Shift lock solenoid N110 from front - arrows -.
1:54:13 AM Page 22
Installing
 Press Shift lock solenoid into guide until it engages. Actuating lever - 2 - for solenoid must engage in
locking lever - 1 - on selector mechanism.
Selector lever cable and locking cable, components overview

 Before installing, lightly lubricate cable eye and ball socket with
polycarbamide grease G 052 142 A2 .
1:54:13 AM Page 23

 Removing and installing: --> Selector lever cable, removing and installing (vehicles with 2.0 ltr. TFSI
engine), --> Selector lever cable, removing and installing (vehicles with 3.2 ltr. FSI engine), -->
2 - Lock nuts, 12 Nm
3 - Sleeve for selector lever cable
 Press into selector mechanism cover (bottom).
1:54:13 AM Page 24
4 - Circlip
5 - Starter switch
6 - Locking cable for ignition key removal lock

7 - Hex bolt, 9 Nm
8 - Clamping bolt for selector lever cable, 13 Nm
9 - Pin for selector lever cable
 To remove selector lever cable pull plastic locking spring on selector mechanism forward slightly and
push up pin just far enough to release cable.
 Replace
11 - Support bracket
 For securing selector lever cable to transmission
12 - Hex bolt, 10 Nm
Selector lever cable, removing and installing (vehicles with 2.0 ltr. TFSI engine)
Removing
1:54:13 AM Page 25

On Transmission
1:54:13 AM Page 26


1:54:14 AM Page 27


1:54:14 AM Page 28
Installing



1:54:14 AM Page 29
1:54:14 AM Page 30


.
ENGINE CODE(S): BKH
.
Tightening torques
1:54:14 AM Page 31
Component Nm
Selector lever cable, removing and installing (vehicles with 3.2 ltr. FSI engine)


Removing

1:54:14 AM Page 32



exhaust system.
1:54:14 AM Page 33


1:54:14 AM Page 34

Housing Base
 Remove universal support V.A.G 1359/2 from engine/transmission jack V.A.G 1383 A.

 Remove bolts - 2 - and - 3 - and then subframe securing bolts - 1 - and - 4 -.
1:54:14 AM Page 35
Fig. 68: Lowering Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx.
By Dimension
 Slowly lower transmission and subframe using engine/transmission jack V.A.G 1383 A until distance - a
- is as specified.
On Transmission

 Do not bend or kink the selector lever cable.
1:54:14 AM Page 36

1:54:14 AM Page 37
Installing
 Installation position: The angled end of retaining clip faces to the inside of selector mechanism.



1:54:14 AM Page 38
 Press selector shaft lever - 2 - on transmission as far as it will go toward the rear (in direction of - arrow -
) until parking lock engages.
On Transmission
 Carefully press selector lever cable - 1 - onto ball head of selector shaft lever.
1:54:14 AM Page 39
cable, as this would make it impossible to obtain an accurate adjustment
of the selector mechanism.


ENGINE CODE(S): BKH
.
Tightening torques
Component Nm
1:54:14 AM Page 40

Removing


exhaust system.
1:54:14 AM Page 41


1:54:14 AM Page 42

Housing Base

1:54:14 AM Page 43

 Use pry lever - RMV outside mirror 80-200 to pry ball socket - 1 - on selector lever cable off selector
shaft lever.

1:54:14 AM Page 44

1:54:14 AM Page 45
Installing



1:54:14 AM Page 46
1:54:14 AM Page 47
 Install transmission supports --> Transmission support and transmission mounting, removing and
installing (left and right).


.
ENGINE CODE(S): BKH
.
1:54:15 AM Page 48
Tightening torques
Component Nm

Procedure
1:54:15 AM Page 49
 Insert socket and key T40031 through access hole in selector mechanism to loosen clamping bolt at rear
of selector lever cable approx. 1 turn.
NOTE:  Only loosen clamping bolt 1 turn - do not remove.

 Clamping bolt can only be accessed with selector lever in position "S".
 The selector lever must remain in "S" position when clamping bolt is
loosened; otherwise, adjustment will not be correct.
 Carefully move selector lever slightly forward and backward, without shifting lever into a different
selector lever position.
 Pull selector lever once more to rear as far as possible into "S" position and release the selector lever.
NOTE:  Do not touch selector lever again during adjustment process.
 Tighten clamping bolt in this position using socket and key T40031.
 Check selector mechanism --> Selector mechanism, checking.

NOTE:  Use the vehicle diagnostic, testing and information system VAS 5051 A
(Self-diagnosis, 02 - Automatic transmission, 08 - Read measured value
block, Display group 4 in display field - 3 - to compare the position of the
Multi-Function Transmission Range (TR) Switch F125 with the position on
the selector lever.
If selector mechanism is not functioning correctly after adjusting selector lever cable, proceed as follows:
 Adjust selector lever cable to basic setting --> Adjusting selector lever cable to basic setting.
1:54:15 AM Page 50
Tightening torque
Component Nm
Clamping bolt to selector lever cable 13
Adjusting selector lever cable to basic setting

Procedure
1:54:15 AM Page 51
NOTE:  Before adjusting the selector lever cable to basic setting make sure that
clamping bolt has been tightened. The clamping bolt can be accessed via
the hole in the selector mechanism, when in position "S". Use socket and
key T40031 to tighten clamping bolt.
 Tighten clamping bolt to 13 Nm in this position, using socket and key T40031.

NOTE:  Make sure the selector lever is in position "P".
NOTE:
1:54:15 AM Page 52
 When the parking lock has engaged it should no longer be possible to



Tightening torque
Component Nm
Removing
NOTE:  The locking cable must not be bent or kinked.

1:54:15 AM Page 53

.
 Remove steering column cover -->
.
 Remove A/C control console --> 87 AIR CONDITIONING .

.
1:54:15 AM Page 54

1 - Locking cable
 Lift up retaining clip - 2 - on locking device and pull locking rod - 1 - off starter switch.
 Lift up locking cable securing spring - 4 -. Pull locking cable support bracket - 5 - sideways off selector
mechanism, then disengage locking cable eye.
Installing
1:54:15 AM Page 55

1 - Locking cable
 Route locking cable behind instrument panel brace - arrow - without kinking.
 Insert locking cable - 1 - into starter switch.
 Check that locking device - 2 - engages.
 Turn starter switch to locked position (ignition off).

 Make sure that selector lever is in position "P".
 Hook eye of locking cable onto pin - 3 -.
1:54:15 AM Page 56
 Lift up securing spring - 4 - slightly.
 Insert locking cable support bracket - 5 - into selector mechanism from the right. Push it in so that
securing spring - 4 - engages.
 Install air conditioning operating unit --> 87 AIR CONDITIONING .

 Install steering column cover -->
.
.

.
1:54:15 AM Page 57

 Angle grinder
 Safety goggles

Preparation
NOTE:  If the procedure described below is followed the center console does not
have to be removed.
 Using an angle grinder or similar, cut off Adjustment pin for shift lock 3 3352 A at rear end of flat section
- arrow -.
 Order a new Adjustment pin for shift lock 3 3352 A as a replacement for subsequent use.
Requirements for adjustment
 Locking cable must be in installation position.

 Selector lever is in position "P"
 Ignition key is in removal position.
Procedure
 Remove trim panel from center console --> Selector mechanism cover, removing and installing.
1:54:15 AM Page 58
NOTE:  The selector lever handle and cover can remain installed.


 It should be possible to move support bracket - 2 - for locking cable by hand.
 Insert modified Adjustment pin for shift lock 3 3352 A between pin on locking cable lever and locking
cable eye.
 Pull locking cable in direction of - arrow - as far as it will go and tighten bolt.
 In this position it should be easy to remove and insert Adjustment pin for shift lock 3 3352 A.
 Remove adjustment gauge.

.
 Always test ignition key removal lock after adjusting locking cable --> Ignition key removal lock,
checking.
Tightening torque
Component Nm
1:54:15 AM Page 59
Overview:
 --> Transmission, removing (vehicles with 2.0 ltr. TFSI engine)

 --> Transmission, installing (vehicles with 2.0 ltr. TFSI engine)
 --> Transmission, removing (vehicles with 3.2 ltr. FSI engine)
 --> Transmission, installing (vehicles with 3.2 ltr. FSI engine)
 --> Transmission, removing (vehicles with 4.2 ltr. MPI engine)

 --> Transmission, installing (vehicles with 4.2 ltr. MPI engine)
Transmission, removing (vehicles with 2.0 ltr. TFSI engine)
1:54:15 AM Page 60
Fig. 105: Identifying Special Tools - Transmission, Removing (Vehicles With 2.0 ltr. TFSI Engine)

 Adapter 3282/48
 Pin 3282/50
Fig. 106: Bracket 30-211 A


1:54:15 AM Page 61

 Bolt M10x20
Removing

CAUTION: Follow the steps required when disconnecting battery -->


1:54:15 AM Page 62

Fig. 110: Unbolting Coolant Expansion Tank


coolant expansion tank.
 Place coolant expansion tank to one side, leaving coolant hoses - 1 - and - 2 - connected.
1:54:15 AM Page 63

 Remove engine/transmission securing bolts - 4 - , - 5 - and - 6 - (accessible from above).

 To avoid damaging edges of fender panels using engine support bridge 10-222 A, insert pad for front
fender T40045 on both sides between fender mounting flange and body panel underneath.
1:54:16 AM Page 64

1:54:16 AM Page 65

 Open quick-release fasteners - 1 to 3 - and remove front and rear sound insulation.


1:54:16 AM Page 66
 Remove heat shield - 1 - for drive axle (left-side).




 Remove bolts - arrows - at connection between front exhaust pipe and catalytic converter.
 Remove nut - 1 - at bracket for front exhaust pipe and remove front exhaust pipe.
1:54:16 AM Page 67

 Unbolt heat shield - A - for driveshaft - arrows -.

 Tie up driveshaft to body.
On Transmission
felt-tip pen.

 Move selector lever cable clear.
1:54:16 AM Page 68
Clockwise
 Unscrew union nuts - 1 - and - 2 - and disconnect ATF pipes.
 Remove bracket for ATF lines - arrow -.
1:54:16 AM Page 69
Fig. 124: Disconnecting ATF Lines At Connection Points On Right Side Of Transmission
 Disconnect ATF lines - 1 - and - 2 - at connection points on right side of transmission.

 Remove ATF lines going to ATF cooler.
 Detach bracket - 3 - for ATF lines at bottom of transmission.

 Detach ATF lines from transmission.
1:54:16 AM Page 70

 Remove stabilizer bar mountings on both sides - 1 - and - 2 -.

 Remove engine/transmission securing bolts - 1 to 3 - and - 8 to 11 -.
NOTE:  Bolt - 7 - should remain screwed in hand-tight.
1:54:16 AM Page 71
Fig. 128: Identifying Starter, Electrical Connector & Nuts

 Detach starter and swivel to one side.

 Remove nut - 1 - for clamp.
 Remove nut - 2 - and detach electrical wiring.
 Remove starter.

 Remove 3 torque converter bolts - arrows - through opening for removed starter (turning crankshaft 1 /3
turn each time).
1:54:16 AM Page 72


 Pin 3282/50 has to be screwed in at right rear.

1:54:16 AM Page 73
Fig. 133: Removing Bolts For Transmission Mountings

 Remove bolts - arrows - for transmission mountings (left and right).
1:54:16 AM Page 74
Fig. 134: Removing Heat Shield For Left Transmission Support

 Remove heat shield for transmission support (left-side).

 Remove transmission supports (left and right) together with transmission mountings - arrows -.
 Remove last engine/transmission securing bolt.
screwdriver.
drive axles.

 Secure torque converter in transmission with support bridge 30-211 A to prevent it from dropping out.
Transmission, installing (vehicles with 2.0 ltr. TFSI engine)
1:54:16 AM Page 75


 Before installing transmission, you must ensure that the torque converter is properly fitted in the
transmission.
 If the torque converter is correctly installed, the depth between the contact surfaces at tapped holes on
torque converter and contact surface of the torque converter bell housing is at least 19 mm.

1:54:16 AM Page 76
and one tapped hole are in line with the opening for the removed starter.
 When pushing the engine and transmission together, make sure that no wiring or lines etc. can become
trapped.
Install the transmission, adhere to the following instructions.

 Screw in bolt - 7 - hand-tight.

 Counterhold crankshaft to tighten torque converter bolts.
1:54:16 AM Page 77

 Use new ribbed bolts to secure torque converter to drive plate. Use only the correct bolts (same as
original equipment) .

graphite lubricant.

Item Bolt Nm
1 M12x67 65
3, 4, 5 M12x75 65
6 M12x100 65
7 M12x90 65
8 M10x60 45
9 to 11 M10x45 45
1:54:17 AM Page 78
*Bolt strength 10.9


.
.
 Install front exhaust pipe with main catalytic converter -->
ENGINE CODE(S): BKH
.
ENGINE CODE(S): BKH
1:54:17 AM Page 79

.


.
Component Nm
*Replace bolts.
Transmission, removing (vehicles with 3.2 ltr. FSI engine)
1:54:17 AM Page 80

 Support bridge 30-211 A
 Adapter 3282/48
 Pin 3282/50
1:54:17 AM Page 81

 Adapter T40058
 Bolt M10x20
Removing

1:54:17 AM Page 82


 Remove front exhaust pipe with catalytic converter (left and right) -->
ENGINE CODE(S): BKH
.
1:54:17 AM Page 83
NOTE:  After removal of the front exhaust pipes the subframe is detached at the
rear and the transmission support (left-side) is removed.
Housing Base
 The transmission is supported centrally at the connection on the housing - arrow - with
engine/transmission jack V.A.G 1383 A.
 Use engine/transmission jack V.A.G 1383 A to lift transmission up slightly.

NOTE:  - Item 2 - and - item 3 - can be disregarded.
 Lower transmission and remove engine/transmission jack V.A.G 1383 A from under vehicle.
1:54:17 AM Page 84


 Rest driveshaft on exhaust system (right-side).
On Transmission
felt-tip pen.
1:54:17 AM Page 85

Fig. 149: Removing Union Nuts And Disconnect ATF Lines

 Unscrew union nuts - 3 - and disconnect ATF lines.
 Remove bracket - 2 - securing ATF lines.
1:54:17 AM Page 86
Fig. 150: Removing Bracket For ATF Lines At Bottom On Transmission

 Remove bracket - arrow - for ATF lines at bottom section of transmission.
NOTE:  Place a cloth below the ATF line to catch escaping ATF.

 Pull ATF lines out of transmission.
1:54:17 AM Page 87
Fig. 152: Disconnecting Electrical Connector On Engine Speed (RPM) Sensor G28
 Disconnect electrical connector - arrow - for engine speed (RPM) sensor G28.
Clockwise
CAUTION: Check once again to make sure that the rear subframe mountings are
secured hand-tight.
1:54:17 AM Page 88

 Unscrew bolts - arrows - two turns at stop for torque reaction support.
Fig. 155: Removing Nuts At Bottom On Left/Right Engine Mounts

 Unscrew nuts - A - below left and right engine mountings until nuts are flush with bottom end of studs.

1:54:17 AM Page 89

1:54:18 AM Page 90
Flanges
 Set up engine support bridge 10-222 A with adapters 10-222 A/3 on fender mounting flanges.
 Take up weight of engine with spindles until bottom engine/transmission securing bolts are accessible.

 Unbolt stabilizer bar mountings on both sides - 1 - and - 2 -.

 Swivel stabilizer bar downward.

 Remove bottom engine/transmission securing bolts - arrows -.
1:54:18 AM Page 91
Fig. 161: Disconnecting Electrical Wires On Starter, Removing Bolts & Starter
 Disconnect wires - 2 - and - 3 - at starter.

 Remove bolts - 1 - and - 4 - and remove starter.
 Guide starter toward the rear through wheel housing on right side of vehicle.

1:54:18 AM Page 92


 Remove 3 torque converter bolts - arrows - through the opening for removed starter (turning crankshaft
1 / turn each time).
3
1:54:18 AM Page 93

 Remove engine/transmission securing bolts - 4 to 6 -.
NOTE:  Bolts - 3 - and - 7 - remain screwed in hand-tight.

1:54:18 AM Page 94

 pin 3282/50 has to be screwed in at right rear.


 Insert flattened pin 3282/50 into mounting hole at rear right of transmission housing - arrow 2 -.
1:54:18 AM Page 95

 Remove bolts - 2 - at transmission support (right-side) and detach heat shield - B -.

Fig. 170: Pressing Transmission Off Engine, While Pressing Torque Converter Off Of Drive Plate
1:54:18 AM Page 96
 Remove last engine/transmission securing bolts.

screwdriver.
drive axles.

 Secure torque converter in transmission using support bridge 30-211 A to prevent it from dropping out.
Transmission, installing (vehicles with 3.2 ltr. FSI engine)
 Replace O-rings
1:54:18 AM Page 97

 Before installing transmission, make sure that the torque converter is properly installed in the
transmission.
 If the torque converter is correctly installed, the depth between the contact surfaces at the tapped holes on
the torque converter and contact surface of torque converter bell housing is at least 19 mm.

1:54:18 AM Page 98
and one tapped hole are in line with the opening for removed starter.
 When pushing engine and transmission together, make sure that no wiring or lines etc. can become
trapped.
Install transmission, adhere to the following instructions.


 Install transmission support (right-side) with transmission mounting --> Transmission support and
transmission mounting, removing and installing (left and right).
1:54:18 AM Page 99


1:54:18 AM Page 100


equipment) .

graphite lubricant.
1:54:19 AM Page 101


Item Bolt Nm
1 M10x115 65 * See note
2, 6 M12x125 65
3, 5 M12x110 65
4 M12x115 65
7 M12x140 65
8, 9, 10 M10x80 45
*Bolt strength 10.9


.
 Clean ATF pipes and ATF cooler --> ATF cooling lines and ATF cooler, cleaning.
 Secure ATF pipes to transmission and engine --> ATF cooling lines.
 Install selector lever cable --> Selector lever cable, removing and installing (vehicles with 3.2 ltr. FSI
engine).
.
1:54:19 AM Page 102


ENGINE CODE(S): BKH
.

ENGINE CODE(S): BKH
.
 Install drive shafts --> 40 - FRONT SUSPENSION .

 Allow stop for torque reaction support to settle under its own weight on rubber buffer for torque reaction
support and tighten bolts - arrows -.
1:54:19 AM Page 103

.
Component Nm
Engine mounting to support 23
Stop for torque reaction support to lock carrier 28
*Replace bolts.
Transmission, removing (vehicles with 4.2 ltr. MPI engine)
1:54:19 AM Page 104


 Shackle 10-222 A/12
 Hose clamps, up to 25 mm dia. 3094
 Adapter 3282/48
1:54:19 AM Page 105

 Pin 3282/50
 Adapter T40058
 Bolt M10x20
Removing


Fig. 182: Sliding Battery Cover Toward Right Side Of Vehicle And Remove
1:54:19 AM Page 106

 Slide battery cover toward right side of vehicle - arrow 1 - and remove - arrow 2 -.
Fig. 183: Disconnecting Ground (GND) Wire At Battery


1:54:19 AM Page 107



Fig. 187: Removing Coolant Hoses & Coolant Expansion Tank

 Disconnect coolant hose - 2 - with hose clamp 3094 and detach at coolant expansion tank.
 Disconnect electrical wire leading to Engine Coolant Level (ECL) warning switch F66 at expansion tank
 If necessary, close off connection with a suitable plug.
1:54:19 AM Page 108


 Detach retainer at bulkhead.
 Detach heat insulation sleeve at wiring harness and move wiring harness clear.

1:54:19 AM Page 109



1:54:19 AM Page 110

Fig. 192: Installing Shackle 10-222 A/12 To Engine Lifting Eye (Right Rear)
 Install shackle 10-222 A/12 to engine lifting eye (right rear).
 Detach rubber seal from edges of fender mounting flanges.

1:54:19 AM Page 111

Fig. 194: Placing Engine Support Bridge 10-222 A With Adapters 10-222 A/3 Onto Fender Panel Flange
 Place engine support bridge 10-222 A with adapters 10-222 A/3 onto fender panel flange, as shown in
illustration.
 Engage spindles of engine support bridge 10-222 A in engine lifting eye (front) and in shackle 10-222
A/21 (rear).
 Take up weight of engine on spindles of support bar, but do not lift.


1:54:20 AM Page 112


 Release quick release fasteners - 1 - , remove bolts - 2 - and remove sound insulation.


1:54:20 AM Page 113

 Remove bracket for wiring harness at engine support (right-side) - arrows -.
 If installed, unclip operating rod for vehicle level sensor from lower transverse link - arrow - or detach
connector at operating rod (top).
Fig. 200: Removing Bolt (On Left And Right)

 Remove bolt - 2 - (on left and right).
NOTE:  Ignore - item 1 - and - items 3 to 5 -.
1:54:20 AM Page 114

Fig. 201: Removing Nuts For Left/Right Stabilizer Mounts

 Remove nuts (left and right) - 1 to 4 - for stabilizer bar mounting and remove stabilizer bar.
1:54:20 AM Page 115


 Before loosening subframe, use locating pin 3393 to check whether holes - 1 - and - 2 - are aligned.
If this is not the case, wheel alignment has to be performed after installing subframe.
 Remove bolts - 1 to 4 - and lower subframe.
NOTE:  The subframe may be allowed to rest on the transverse links. It does not
have to be removed completely.
1:54:20 AM Page 116




1:54:20 AM Page 117


 Disconnect 16-pin electrical connector - 2 - at transmission by folding out the release tab and turning
fastener cap counter-clockwise.
1:54:20 AM Page 118


 Remove heat shields - arrow - for drive axles (left and right).
 Remove drive axles (left and right) from flange on transmission.
NOTE:  Make sure you do not damage surface coating on drive axles.
Fig. 210: Removing Refrigerant Line On Bracket

 Remove bracket (right-side) - arrow - for refrigerant line.
1:54:20 AM Page 119

Fig. 211: Disconnecting Electrical Harness Connector At Right Engine Mount


 Remove bolts - arrows - and remove engine support together with engine mounting.
Fig. 212: Identifying Ground (GND) Wire, Wires, Nuts, Bolts & Starter
 Remove Ground (GND) wire - 5 -.

 Disconnect wires - 3 - and - 4 -.
 Remove nut - 1 - and bolt - 2 -.
 Remove starter.
1:54:20 AM Page 120


 Remove 3 bolts from torque converter through opening for starter (turn crankshaft 1 /3 of a turn to access
one bolt after another).
1:54:21 AM Page 121



 Mark position of mounting bracket for selector lever cable relative to transmission housing to simplify
reassembly. Unbolt mounting bracket - arrows -.
 Loosen clips securing ATF lines to transmission and engine --> ATF cooling lines.
 Lower engine/transmission assembly as far as possible, using spindles of support bracket.
CAUTION: When lowering the engine/transmission assembly, make sure none of the
lines or wires are stretched or pinched and also avoid causing damage to
any other components.
1:54:21 AM Page 122

 Remove bolt - arrow - at bracket for front exhaust pipe (left-side).
Fig. 218: Removing Nuts For Left Front Exhaust Pipe/Exhaust Manifold
 Remove nuts - 1 to 3 - connecting front exhaust pipe (left-side) to exhaust manifold.
 Detach front exhaust pipe from exhaust manifold (left-side).

1:54:21 AM Page 123

 Pull engine speed (RPM) sensor G28 - item A - out of transmission.
NOTE:  The engine speed (RPM) sensor G28 is inserted in bell housing (top left).
 Remove bolt - arrow - at bracket for front exhaust pipe (right-side).
1:54:21 AM Page 124

 Remove nuts - 1 to 3 - connecting front exhaust pipe (right-side) with exhaust manifold.

 Remove bolts - 2 - at transmission supports (right and left) and detach heat shields - B -.
1:54:21 AM Page 125




1:54:21 AM Page 126

 pin 3282/50 has to be screwed in at rear right.
NOTE:  The pin 3282/50 is flattened at the side - arrow - , the flattened side should
face the oil pan when inserting pin into transmission.

1:54:21 AM Page 127


 Pull ATF cooling lines off transmission.
 Seal lines and transmission connections with clean sealing plugs to prevent ATF from escaping.
1:54:21 AM Page 128


 Remove all remaining securing bolts between engine and transmission.

 If necessary, lower engine slightly again via spindles.
Fig. 229: Using Assembly Lever To Press Torque Converter Off Drive Plate Of Engine
 Use assembly lever to press torque converter off drive plate of engine - arrow -.
 Press transmission off engine.
1:54:21 AM Page 129

Fig. 230: Lowering Rear Edge Of Transmission By Adjusting Transmission Support 3282 Accordingly
 Lower rear edge of transmission by adjusting transmission support 3282 accordingly.

 Guide transmission out diagonally downward/to rear.

drive axles.

 Secure torque converter in transmission using Bracket 30-211 A to prevent it from dropping out.
Transmission, installing (vehicles with 4.2 ltr. MPI engine)
equipment) .
1:54:22 AM Page 130


 Before installing transmission, make sure that the torque converter is properly installed in transmission.
 If torque converter is correctly installed, the depth between contact surfaces at tapped holes on torque
converter and contact surface of torque converter bell housing is at least 19 mm.

 If an intermediate plate was installed between engine and transmission, reinstall plate in same position.
 When pushing engine and transmission together, make sure that no cables, lines, etc. can become trapped.
 Bolt transmission onto engine Illustration of transmission flange.

equipment) .
1:54:22 AM Page 131


 Install 3 torque converter bolts through opening for starter (finger-tight). Turn crankshaft 1 /3 of a turn to
access one bolt after another.
 Tighten torque converter bolts to torque (turning crankshaft 1 /3 turn each time).
1:54:22 AM Page 132

 Insert engine speed (RPM) sensor G28 - item A - into bell housing (top left) and tighten bolt - 1 -.
 Install heat shield - B - and tighten bolt - 2 - (transmission/engine bolt connection Illustration of
transmission flange)

 Insert ATF cooling lines - A - and - B - into transmission as far as possible and tighten bolt - 2 -.
1:54:22 AM Page 133



.
ENGINE CODE(S): BKH
.

If measurement performed with locating pin 3393 during removal showed that holes - 1 - and - 2 - were aligned:
1:54:22 AM Page 134

If measurement performed with locating pin 3393 during removal showed that holes - 1 - and - 2 - were NOT
aligned:
 Only tighten bolts for subframe to tightening torque setting, do not yet turn further (wait until wheel
alignment has been carried out).
CAUTION: The vehicle must not be driven.


 Secure driveshaft to transmission -->
1:54:22 AM Page 135

 Secure heat shield - A - for driveshaft - arrows -.

ENGINE CODE(S): BKH
.
 Bolt drive axles to flange shafts --> 40 - FRONT SUSPENSION .

 Install heat shields - arrow - for drive axles (left and right).
 Check oil level in final drive (front) --> Front final drive gear oil.
 Check oil level in transfer gear--> Transfer gear oil.
1:54:22 AM Page 136



.
CAUTION: After wheel alignment tighten subframe bolts to their final torque setting.
Tightening torques

graphite lubricant.
Drive plate to torque converter Nm

Ribbed bolts, M10x1x21.5 (3x) * See note* See
note
4.2 ltr. MPI engine 85
*Replace bolts.
*Use new bolts (same as original equipment) .
Illustration of transmission flange
1:54:22 AM Page 137

A: dowel sleeves for centralizing
Securing engine to transmission:
Item Bolt Nm
8 M10x60 45
9 M10x60 45
10 M10x60 45
*Also secures starter.
Securing transmission to engine:
Item Bolt Nm
2 M12x105 65
3 M12x110 65
4 M12x105 65
5 M12x105 65
6 M12x130 65 * See note
7 M12x170 65
*Also secures a heat shield.
Component Nm
Engine speed (RPM) sensor G28 to transmission 10
Bracket for ATF lines to transmission 21
Transmission support and transmission mounting, removing and installing (left and right)
1:54:23 AM Page 138


Removing
 Remove front exhaust pipe on relevant side of transmission -->

ENGINE CODE(S): BKH
.
1:54:23 AM Page 139

Housing Base
NOTE:  Always remove both transmission mountings from the subframe.
1:54:23 AM Page 140


 Lower transmission slightly with engine/transmission jack V.A.G 1383 A to make bolts - 1 - and - 2 -
more accessible.
1:54:23 AM Page 141

Removing transmission mounting - B -
 Detach transmission mounting - B -.

1:54:23 AM Page 142

Removing transmission support
 Remove transmission support - A - with transmission mounting.
Installing
 Install transmission supports.

NOTE:  Do not tighten transmission mountings to subframe to specified torque

until re-installation of subframe has been completed.
 To avoid tension you may have to re-align transmission mounting and transmission support.
 Tighten all bolts to specified torque.

Tightening torques for transmission support and heat shield (left and right)
1. Bolt (3x) for securing transmission support to transmission, 23 Nm

2. Bolt (3x) for securing heat shield to transmission support, 10 Nm
1:54:23 AM Page 143

Tightening torques for transmission mountings (left and right)
1. Bolt (1x) for securing transmission mounting to transmission support, 50 Nm

2. Washer
3. Bolt (2x) for securing transmission mounting to subframe, 23 Nm
 Install front exhaust pipe -->

ENGINE CODE(S): BKH
.
1:54:23 AM Page 144


Procedure
Attachment and holding rig. 3457 can be used to transport automatic transmission and also when setting up

Transmission, securing to assembly stand
1:54:23 AM Page 145

Fig. 255: Identifying Special Tools - Transmission, Securing To Assembly Stand


 Workshop crane V.A.G 1202 A or workshop crane VAS 6100
1:54:24 AM Page 146


 Bolt transportation tool onto support plate VW 309 and install into support clamp VW 313 with the aid of
workshop crane.
CAUTION: The center of gravity of the transmission is outside the pivot center of the
support clamp. A second technician has to hold the transmission housing
when it is being turned to prevent it from swinging round.
NOTE:  If the installed transmission with oil pan is to be turned upside down on
assembly stand, seal the transmission housing and final drive breathers.
PLANETARY GEARBOX AUTOMATIC TRANSMISSION FLUID (ATF)
Planetary gearbox Automatic Transmission Fluid (ATF)
ATF level, checking and correcting
1:54:24 AM Page 147

Fig. 257: Identifying Special Tools - ATF Level, Checking And Correcting
 Vehicle diagnostic, testing and information system VAS 5051 A

 Safety goggles
Conditions
 Transmission must not be in emergency running (backup) mode.

 Vehicle must be level (horizontal).
 Selector lever in position "P", engine idling.
1:54:24 AM Page 148

 Air conditioner and heating system switched off.
 Vehicle diagnostic, testing and information system VAS 5051 A connected; vehicle self-diagnosis and
vehicle system "02 - gearbox electronics" selected.
 The ATF temperature at the beginning of the test must not be higher than 30° C. If necessary, first allow
the transmission to cool down.
NOTE:  The ATF temperature is taken from the reading on the vehicle diagnostic,
testing and information system VAS 5051 A.
 The ATF level will vary according to the ATF temperature.
 If the ATF level is checked when the ATF temperature is too low, this will
result in overfilling.
 If the level is checked when the ATF temperature is too high, this will
result in underfilling.
 Both overfilling and underfilling have a detrimental effect on the
functioning of the transmission.
 Use only correct type of ATF (available as a replacement part) for the
planetary gearing in automatic transmission 09L. Other oils cause faults
and/or failure of the transmission; for ATF specification refer to -->
Capacities .
ATF temperature reading

 From list - 1 - select diagnostic function "08 - Read data block (measured value block)".
1:54:24 AM Page 149


 Use keypad - 2 - to enter "4" for "Display group number 4" and confirm by touching Q key.

 Reading for ATF temperature is shown in display zone - 1 -.
NOTE:  The ATF level is checked at the ATF inspection plug.

 The ATF level is correct if a small amount of fluid comes out at the ATF
inspection plug when ATF temperature is between 35° C and 45° C, or 50°
C in hot climates (the fluid level rises due to expansion as it warms up).
1:54:24 AM Page 150


 When an ATF temperature of 35° C is reached, remove ATF inspection plug - arrow B - and drain off
1:54:24 AM Page 151

any surplus ATF.
Fig. 263: Filler Plug Seal

 Replace seal - arrow - for ATF inspection plug.

If ATF comes out of inspection hole before ATF has reached 40° C the ATF level - arrow - is OK.
reaches a temperature of 45° C (or 50° C in hot climates).
 Install new seal on ATF inspection plug and tighten to 80 Nm. The ATF check is now completed.
1:54:24 AM Page 152

Filling up ATF
temperature reaches 45° C (or 50° C in hot climates). If necessary, switch
off the engine, allow transmission to cool down and repeat the test.

NOTE:  The ATF level must not be too low or too high, otherwise this would impair
the function of the transmission.
 Install new seal on ATF inspection plug and tighten to 80 Nm.

Draining ATF or filling after repairs
1:54:24 AM Page 153




 Safety goggles
Procedure
 Engine not running.
1:54:25 AM Page 154


Draining ATF
 Remove ATF drain plug - arrow A -.

 Drain ATF.

1:54:25 AM Page 155

 Tighten new drain plug - arrow A - to 12 Nm.
Filling with ATF
 Remove ATF inspection plug - arrow B -.

 Continue filling with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection
hole again.
 Tighten ATF inspection plug.
 With engine idling, press brake pedal and shift selector lever through all selector lever positions leaving
selector lever at least 10 seconds in each position.
 Increase engine speed to 2000 rpm and maintain for at least 60 seconds.
NOTE:  Observe all notes and test requirements for "Checking and correcting ATF
level".
ATF COOLING LINES
1:54:25 AM Page 156

ATF cooling lines
ATF cooling lines, component overview (vehicles with 2.0 ltr. TFSI engine)
Fig. 271: ATF Cooling Lines, Component Overview (Vehicles With 2.0 ltr. TFSI Engine)
1 - Nut, 8 Nm
2 - Clip
3 - Bolt, 42 Nm
4 - ATF lines
1:54:25 AM Page 157

6 - Bolt, 21 Nm
7 - ATF lines
8 - O-rings
 Replace
9 - Clip
10 - Bolt, 5 Nm
12 - Bolt, 5 Nm
 Secures ATF line at ATF cooler (top)

13 - O-ring
 Replace
14 - ATF line

15 - ATF lines

16 - O-ring
1:54:25 AM Page 158

 Replace
17 - Bolt, 5 Nm

ATF cooling lines, component overview (vehicles with 4.2 ltr. MPI engine)
Fig. 272: ATF Cooling Lines, Component Overview (Vehicles With 4.2 ltr. MPI Engine)
1 - Bolt, 21 Nm
1:54:25 AM Page 159

2 - O-ring
 Replace
3 - O-ring
 Replace
4 - Bolt -5 Nm-
 For securing ATF lines to transmission
7 - Nut, 5 Nm
 For securing ATF lines to bracket
8 - Nut, 5 Nm
 For securing bracket to transmission
11 - Plug connector
12 - Bolt, 5 Nm
 For securing ATF lines at front end
13 - Bolt, 5 Nm

 For securing ATF line to bracket at ATF cooler (bottom)
14 - ATF line

1:54:25 AM Page 160

15 - O-ring
 Replace
16 - Bolt, 5 Nm
 For securing ATF line at ATF cooler (top)

17 - ATF line

18 - O-ring
 Replace
ATF cooling lines, removing and installing
 Drip tray
 Safety goggles
Removing
 Mark position of all ATF cooling lines in relation to one another with different colors to avoid confusion.
 Place drip tray V.A.G 1306 underneath.
 Disconnect ATF cooling lines.

 Seal opened cooling lines with clean sealing plugs.
Installing
1:54:26 AM Page 161

 Clean ATF lines --> ATF cooling lines and ATF cooler, cleaning.
 Lightly lubricate O-rings with ATF.
 First press ATF lines onto transmission or cooler by hand until they engage, then secure lines --> ATF
ATF cooling lines and ATF cooler, cleaning
 Compressed air gun (commercially available)

 Hose, approx. 18 mm dia.
 Drip tray
NOTE:  Always clean ATF cooling lines and ATF cooler before installing a
replacement transmission.

Procedure

 Connect a hose approx. 18 mm dia. to ATF line - A - and secure with a hose clamp. Place other end of
hose in drip tray.
1:54:26 AM Page 162

 Blow through ATF line - B - using a compressed air line (max. 10 bar).
 Change hose from ATF line - A - over to ATF line - B - and repeat sequence.
 Press ATF cooling lines onto transmission or cooler by hand until they engage, then tighten --> ATF
1:54:26 AM Page 163

...
38 GEARS, CONTROL
OIL PAN, ATF STRAINER AND MECHATRONICS UNIT, REMOVING AND INSTALLING
Oil pan, ATF strainer and mechatronics unit, removing and installing
CAUTION: Do not run engine or tow vehicle with oil pan removed or when there is no
ATF in the transmission.

 Always replace mechatronics unit if contaminated or faulty.
 Lightly lubricate O-rings and seals with ATF. Other types of lubricant will
cause the transmission hydraulics to malfunction.


 Safety goggles
Removing

1:55:08 AM
1:55:11 Page 1

 Remove ATF drain plug - 1 -.

 Drain ATF.

 Loosen 23 bolts on oil pan in diagonal sequence and remove oil pan.
Installing
NOTE:  Replace seals and gaskets.

1:55:08 AM Page 2
 Clean all magnets in recesses on oil pan. Make sure that magnets make full contact with oil pan.
 Clean sealing surface thoroughly; remaining material from the previous gasket must be removed
completely.

 Tighten oil pan bolts in several stages and in diagonal sequence.

 Tighten new drain plug - 1 -.
Tightening torques
Component Nm
Drain plug to oil pan 12 * See note
Oil pan to transmission housing 12 * See note
*Replace plug.
*Tighten diagonally in stages.
ATF strainer, removing and installing
Removing
1:55:08 AM Page 3


 Carefully remove ATF strainer - A - from transmission.
NOTE:  The ATF strainer only has to be replaced if it has been damaged.
1:55:08 AM Page 4
If replacing ATF strainer:
 If installed, carefully remove oil seal for ATF strainer - A - from transmission using a screwdriver or
similar.
NOTE:  Take care not to damage sealing surface.

 For illustration purposes the oil seal is shown with mechatronics unit
removed.
 The new ATF strainer is supplied with oil seal installed.
Continuation for new and old ATF strainer:

 Press intake line of ATF strainer - A - carefully onto stop into mounting hole in transmission.
NOTE:  A new ATF strainer is pressed into transmission with oil seal installed.

Mechatronics unit, removing and installing
NOTE:  Always replace mechatronics unit if contaminated or faulty.

1:55:08 AM Page 5

Removing


 Remove ATF strainer --> ATF strainer, removing and installing.
 Disconnect 16-pin electrical connector - 2 - at transmission by folding out release tab and turning fastener
cap counter-clockwise.

1:55:08 AM Page 6

 Unfasten retaining clip - arrow - for wiring harness connector on outside of transmission housing.

 Remove securing bolts for mechatronics unit in sequence - 11 to 1 -.
NOTE:  Only remove securing bolts marked - 1 to 11 -.

 If other bolts are loosened, this may affect the operation of the
mechatronics unit or the mechatronics unit could come apart.
1:55:08 AM Page 7
 Remove mechatronics unit together with wiring harness from transmission, at the same time guide out
connector for wiring harness.
Installing
 Make sure that seal - B - is properly inserted and secured.

 Replace O-rings on connector for wiring harness and lightly lubricate with ATF.
1:55:08 AM Page 8
and installing.
 Install wiring harness connector in transmission housing.
 Installation position: flat part of rear shoulder faces downward, the lugs at shoulder are horizontal
Fig. 285: Inserting Transmission Selector Lever Stud Into Groove On Selector Slide
 While installing mechatronics unit without force, insert transmission selector lever stud - arrow - into
groove on selector slide - A - (move selector slide backward and forward if necessary).

1:55:08 AM Page 9
 Tighten securing bolts - 1 - and - 2 - for mechatronics unit to 2 Nm.

 Then tighten securing bolts in specified sequence - 1 to 11 - to 8 Nm.

 Push retainer clip - arrow - onto wiring harness connector.

 Install ATF strainer --> ATF strainer, removing and installing.

.
Removing
 Remove mechatronics unit --> Mechatronics unit, removing and installing


1:55:09 AM Page 10
 Carefully disconnect wiring harness - A - from mechatronics unit - B -. Make sure you detach tab - arrow
- on reverse side of wiring harness from mechatronics unit.
and installing.
 Carefully disconnect connector - C - from socket - D - of mechatronics unit.
Installing
 Carefully connect connector - C - to socket - D - on mechatronics unit.

 Install mechatronics unit --> Mechatronics unit, removing and installing.
1:55:09 AM Page 11
...

FRONT FINAL DRIVE GEAR OIL
Front final drive gear oil

Front final drive gear oil level, checking


 Safety goggles
Condition
Work sequence
 Drive vehicle onto a four-column lifting platform or over an inspection pit in order for it to be absolutely
horizontal.
1:55:47 AM
1:55:52 Page 1

 Oil level must be up to lower edge of filler hole.
 Drain off any excess oil or top off to proper level; specification --> Capacities .
Front final drive gear oil, topping up gear oil level after repairs

1:55:48 AM Page 2
 Safety goggles
Requirements:
Topping off



 Fill front final drive slowly and at a constant rate for a period of at least 5 minutes until gear oil (capacity
and specification --> Capacities ) comes out at lower edge of oil filler hole.
level can be balanced out between differential and baffle chamber.
NOTE:  The oil level does not need to be re-checked.
1:55:48 AM Page 3

Front final drive, assembly overview
Fig. 293: Front Final Drive, Assembly Overview

1 - Oil seal

 Replacing --> Final drive/transmission housing oil seal, replacing
1:55:48 AM Page 4
2 - Shim
4 - O-ring
 Replace
5 - Plug, 35 Nm
 Replace
6 - Flange shaft (right-side)
 Removing and installing --> Flanged shaft (right side), removing and installing
7 - Retaining ring
 Replace
8 - Flange shaft oil seal (right-side)
 Replacing --> Flanged shaft oil seal (right side), replacing
9 - Bolt, 23 Nm
 Follow correct tightening sequence --> Final drive cover O-ring, replacing
11 - Shim
13 - O-ring for final drive cover
 Replacing --> Final drive cover O-ring, replacing
14 - Differential
15 - Spring pin
1:55:48 AM Page 5
 Replacing --> Selector shaft oil seal, replacing
18 - Bolt, 23 Nm
19 - Flange shaft (left-side)
 Removing and installing --> Flange shaft (left-side), removing and installing
Flange shaft (left-side), removing and installing


1:55:48 AM Page 6
 Puller T10037
Removing

 Unbolt heat shield - arrow - from transmission above drive axle (left-side).
 Unbolt drive axle (left-side) from flange on transmission and tie up.
Fig. 297: Removing Bolts On Retaining Bracket For Left-Side Flange Shaft
 Remove bolts - arrows - on retaining bracket for left-side flange shaft.
1:55:48 AM Page 7
Fig. 298: Screwing Puller T10037 Onto Differential Cover

 Screw puller T10037 onto differential cover - arrow -.

 Pull out left flange shaft using puller T10037 only until bearing on shaft is removed from transmission
housing.
CAUTION: If the shaft is not kept centered, the splines of the shaft will fall against the
inner seal between the final drive and transmission housing. The seal will
be damaged and require replacement --> Final drive/transmission housing
oil seal, replacing.
 Pull left flange shaft - A - out of transmission making sure that the shaft remains centered in the opening
on differential - arrow -.
1:55:48 AM Page 8
Installing
 Insert flange shaft - A - into transmission and guide shaft into seal on differential - arrow - , keeping it
centered.
NOTE:  If the shaft is not kept centered, the splines of the shaft will damage the
seal between the final drive and transmission housing. The seal will
require replacement--> Final drive/transmission housing oil seal,
replacing.
 Bolt left drive axle to flange shaft --> 40 - FRONT SUSPENSION .

Tightening torques
Component Nm
Retaining bracket for left flange shaft to 23
transmission
Flanged shaft (right side), removing and installing
1:55:48 AM Page 9

Removing

 Unbolt heat shield - arrow - from transmission above drive axle (right-side).
 Unbolt drive axle (right-side) from flange on transmission and tie up.
1:55:48 AM Page 10
Fig. 303: Placing Chisel Or Suitable Spacer Under Flange Shaft And Pulling Flange Shaft Out By
Turning Bolt

 Remove flange shaft: Place a chisel or suitable spacer - A - under flange shaft and pull flange shaft out by
turning bolt - B -.
NOTE:  If the flange shaft does not come out easily, turn the shaft and screw the
bolt into the opposite hole to assist removal.
1:55:48 AM Page 11

 Replace circlip for flange shaft

 Clamp flange shaft in vise, using jaw protectors. Use new retaining ring - A - to press old retaining ring
out of groove in flange shaft.
Installing
 Clean flange shaft and seal.

 If seal is damaged, it must be replaced --> Flanged shaft oil seal (right side), replacing.
 Insert flange shaft by hand into splines of differential until splines lock properly into place.
 Press flange shaft in by hand or with mandrel VW 295 as far as stop.
NOTE:  The circlip on the flange shaft should click into place.
 Bolt right drive axle to flange shaft --> 40 - FRONT SUSPENSION .

Tightening torque
Component Nm
1:55:48 AM Page 12
Flanged shaft oil seal (right side), replacing
Fig. 305: Identifying Special Tools - Flanged Shaft Oil Seal (Right Side), Replacing

Procedure
1:55:48 AM Page 13



 Pull out flange shaft oil seal.
Fig. 307: Driving New Seal In Onto Stop


1:55:48 AM Page 14
Final drive cover O-ring, replacing

Procedure

1:55:48 AM Page 15

cover:
1:55:48 AM Page 16
as stop.

 Tighten bolts of final drive cover as follows.

II  Tighten bolts - 1 to 11 - to 23 Nm in sequence
indicated.
Final drive/transmission housing oil seal, replacing
1:55:48 AM Page 17
Fig. 312: Identifying Special Tools - Final Drive/Transmission Housing Oil Seal, Replacing

Requirements
 Transmission mounted on assembly stand --> Transmission, securing to assembly stand.
CAUTION: Do not place transmission down on the oil pan.
1:55:48 AM Page 18
Procedure
NOTE:  A faulty seal allows gear oil to enter the torque converter bell housing.

1:55:48 AM Page 19
 Remove differential.
 Remove tapered roller bearing outer race - 1 - for differential and shim - 2 - (behind outer race) from

 Remove flange shaft (left-side) --> Flange shaft (left-side), removing and installing.
 Remove seal.
NOTE:  The oil seal extractor lever VW 681 must be applied behind the two sealing
lips of the oil seal. Do not apply the lever to the outer circumference of the
seal, as this would damage the sealing surface in the transmission. Guide
the lever carefully when removing the seal.
 Examine oil seal seat in transmission housing for damage; reface surface if necessary.
1:55:48 AM Page 20
 Lightly lubricate outer circumference and sealing lip of oil seal with gear oil.
NOTE:  Push the seal onto the thrust piece with the protruding sealing lip of the
seal facing the tool.
Fig. 316: Driving In New Oil Seal As Far As Stop Using Thrust Piece T10139
 Drive in new oil seal as far as stop using thrust piece T10139.
 Insert shim - 2 - and tapered roller bearing outer race - 1 - for differential onto stop in transmission
housing by hand.
NOTE:  Make sure that shim and outer race are kept straight when inserting.
1:55:48 AM Page 21

 Install differential in transmission housing.
cover:
as the stop.

 Tighten bolts of cover for final drive as follows.
1:55:48 AM Page 22

sequence indicated.
 Install flange shaft (left-side) --> Flange shaft (left-side), removing and installing.

 Removal lever 80-200

1:55:48 AM Page 23
Procedure



1:55:48 AM Page 24
 Drive out roll pin - 1 - at selector shaft lever - 2 - - arrow - until it is possible to detach selector shaft
lever from selector shaft.

 Push a small screwdriver through seal and pull it out.

 Lubricate outer circumference and the space between sealing lips of seal with ATF.
 Install new seal onto selector shaft.
Fig. 325: Pressing On New Oil Seal Using Thrust Piece T10135 And Assembly Lever As Far As Stop
 Press on new oil seal using thrust piece T10135 and assembly lever - A - as far as stop; make sure that oil
seal remains straight.
NOTE:  To prevent slippage when pressing in oil seal, place something as a base
(e.g. piece of rubber) between assembly lever and subframe - arrow -.
1:55:48 AM Page 25
 Before installing, drive roll pin in selector shaft lever back through lever in opposite direction.
 Push selector shaft lever onto selector shaft and drive in roll pin.
NOTE:  Do not bend the selector shaft lever when pressing on the ball socket, as
otherwise it will no longer be possible to precisely adjust the gear selector
mechanism
TRANSFER GEAR OIL
Transfer gear oil

Transfer gear oil level, checking
1:55:48 AM Page 26


 Safety goggles
Condition
Work sequence

1:55:48 AM Page 27
 The oil level must be up to lower edge of filler hole.
 Top off with gear oil if necessary; specification --> Transfer gear.
Transfer gear oil, topping off after repairs


 Safety goggles
Conditions

 The cover was removed from transfer gear and all gear oil was thereby drained.
Work sequence
1:55:48 AM Page 28

NOTE:  The engine must not be started and vehicle must not be towed without
gear oil in transmission.
 Fill transfer gear slowly and evenly over a period of at least 5 minutes with gear oil (capacity and
specification --> Transfer gear).
level can be balanced out between Torsen differential and baffle chamber.
NOTE:  The level does not need to be re-checked.
TRANSFER GEAR, SERVICING
Transfer gear, servicing
CAUTION: Do not run the engine or tow the vehicle if the Torsen differential is
removed or if the gear oil has been drained from the transmission.
1:55:49 AM Page 29


 Safety goggles
Removing
CAUTION: The engine must not run and the vehicle must not be towed without gear
oil.


Vehicles with 2.0 ltr. TFSI engine
1:55:49 AM Page 30
NOTE:  The flexible line connection (de-coupling element) on the front exhaust
line must not be bent more than 10° - otherwise it can be damaged.


NOTE:  To prevent damage, the flexible couplings in the front exhaust lines must

exhaust system.
1:55:49 AM Page 31


1:55:49 AM Page 32
 Loosen securing bolts for cover for Torsen differential in sequence - 6 to 1 - and remove; allow gear oil to
drain out.
NOTE:  The cover is not equipped with a drain plug; drain gear oil by removing the
cover.
CAUTION: Pull the Torsen differential cover backward from the transmission housing
slowly and carefully. The Torsen differential may otherwise fall out of the
transmission.
 Secure Torsen differential - B - and baffle plate - A - to prevent them from dropping out, or pull them off
output shaft toward the rear.
1:55:49 AM Page 33
Fig. 338: Identifying If Torsen Differential And Baffle Plate Have Been Removed
Installing
NOTE:  Replace O-ring on cover for transfer gear.
Note the following if the Torsen differential - B - and the baffle plate - A - have been removed:
 Clean baffle plate, lubricate with gear oil and insert in transmission.
 Installation position: tongue on baffle plate should be positioned on the transmission so that the side lugs
are located above opening - B - - arrow -.
1:55:49 AM Page 34
 Install Torsen differential - B - onto splines of output shaft (turn slightly at the same time).
NOTE:  Check installation position of tongue on baffle plate - arrow - again.
 Check whether the attached Torsen differential can be turned manually.

 Check whether tongue - arrow - on baffle plate is still located properly.
 Place cover for Torsen differential with shaft installed onto Torsen differential, turn slightly if necessary.
 Tighten bolts of cover for Torsen differential as follows.

sequence indicated.

.
1:55:49 AM Page 35

ENGINE CODE(S): BKH
.
 Top off transfer gear oil--> Transfer gear oil, topping off after repairs
Tightening torques
Component Nm
Cross member to body 23
Flanged shaft oil seal (rear), replacing
1:55:49 AM Page 36
Fig. 341: Identifying Special Tools - Flanged Shaft Oil Seal (Rear), Replacing

 Punch VW 409
 Pressure application device T10136
Procedure
 Remove Torsen differential cover --> Torsen differential cover, removing and installing.
1:55:49 AM Page 37

 Remove circlip - arrow - on inner side of cover.
NOTE:  The circlip locates the flange shaft on the bearing in the cover.
Fig. 343: Using Punch VW 409 To Press Flange Shaft Out Of Torsen Differential Cover By Placing Cover
On Thrust Plate VW 401 And Thrust Plate VW 402
 Using punch VW 409, press flange shaft out of Torsen differential cover by placing cover on thrust plate
VW 401 and thrust plate VW 402.
NOTE:  Hold flange shaft - A - with one hand to prevent it from falling.
1:55:49 AM Page 38

 Pry out oil seal.
NOTE:  To prevent damage to the housing, place something underneath (e.g.

metal bar - A - ).
Fig. 345: Placing Torsen Differential Cover On Pressure Application Device T10136
 Place Torsen differential cover - A - on pressure application device T10136.
NOTE:  The peg in the middle of the tool is centered and faces upward in the
cover. It serves as a guide and stop for pressure application device
T10136/1.

 Push new seal onto pressure application device T10136/1.
 Installation position: open side of seal faces cover.
1:55:49 AM Page 39
Fig. 346: Inserting Pressure Application Device T10136/1 With Seal Into Cover From Above
 Insert pressure application device T10136/1 with seal into cover from above.
NOTE:  The peg of the pressure application device T10136 serves as a guide from
below and also as a stop for press tool T10136/1.
1:55:49 AM Page 40
Fig. 347: Pressing Flange Shaft Using Punch VW 409 And Thrust Pad VW 447 I Into Torsen Differential
Cover By Placing Cover On Thrust Plate VW 401 And Thrust Plate VW 402
 Press flange shaft using punch VW 409 and thrust pad VW 447 i into Torsen differential cover by placing
cover on thrust plate VW 401 and thrust plate VW 402.
NOTE:  Only insert flange shaft as far as necessary to install circlip.

 Install circlip - arrow - in groove of flange shaft on inner side of cover.

 Install Torsen differential cover --> Torsen differential cover, removing and installing.
 Top off transfer gear oil --> Transfer gear oil, topping off after repairs
1:55:49 AM Page 41
TRANSMISSION Continuously Variable Transmission (CVT) 01J
TRANSMISSION
Continuously Variable Transmission (CVT) 01J

The "Continuously Variable Transmission (CVT) 01J" is installed in conjunction with various engines in the
Audi A4 2002 -->. Allocation --> Code letters, assembly allocation, ratios, equipment.
Location of code letters on transmission
Fig. 1: Identifying Code Letters And Serial Number Of Transmission Stamped On Underside Of
Transmission Housing
Code letters and serial number of transmission are stamped on underside of transmission housing - arrow -.
Example: FRC 03 07 01
I I I I
Code letters Day Month Year (2001) of
manufacture
NOTE:  The code letters of the transmission are also listed on the vehicle data
stickers.
GENERAL INFORMATION FOR CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
General information for "Continuously Variable Transmission (CVT) 01J"
Extensive information about the construction and function of this transmission 951103 Continuously Variable
Transmission (CVT) 01J.
1:57:22 AM
1:58:05 Page 1
NOTE:  The continuously variable automatic transmission multitronic 01J is also

called "Continuously Variable Transmission" , short "CVT".
Guided Fault Finding
Always perform Guided Fault Finding using Diagnostic Operation System VAS 5051 A before starting
disassembly and assembly work.
CODE LETTERS, ASSEMBLY ALLOCATION, RATIOS, EQUIPMENT
Code letters, assembly allocation, ratios, equipment
Multitronic 01J.A 01J.B 01J.B

Transmission Code letters EVE EVJ FQG
Application Model Audi A4 2001 --> Audi A4 2001 --> Audi A4 Cabriolet
2003 -->
Engine 2.0L 5V -96 kW 3.0L 5V -162 kW 3.0L 5V -162 kW
Input gearing 57 : 41 1.390 51 : 46 1.109 51 : 46 1.109
ratio
Front final drive ratio 41 : 9 4.556 43 : 9 4.778 43 : 9 4.778
Ring gear Diameter mm 204 204 204
Flange shafts Center mm 108 88 88
diameter
Hole mm 94 104 104
circle
diameter
Multitronic 01J.E 01J.H 01J.H

Transmission Code letters FQH FQJ FSD
Application Model Audi A4 Cabriolet Audi A4 Cabriolet Audi A4 2001 --> ,
2003 --> USA 2003 --> Audi A4 Cabriolet
2003 -->
Engine 1.8 L 5VT - 125 kW 1.8 L 5VT -110 kW 1.8 L 5VT -110 kW
Input gearing 57 : 41 1.390 54 : 43 1.256 54 : 43 1.256
ratio
diameter
Hole mm 104 104 104
circle
diameter
1:57:22 AM Page 2
Multitronic 01J.E 01J.A 01J.B

Transmission Code letters FSE FSF FSG
Application Model Audi A4 2001 --> Audi A4 2001 --> Audi A4 2001 --> ,
USA, Mexico Audi A4 Cabriolet
2003 -->
Engine 1.8 L 5VT - 125 kW 2.0L 5V -96 kW 3.0L 5V -162 kW
Input gearing 57 : 41 1.390 57 : 41 1.390 51 : 46 1.109
ratio
diameter
Hole mm 104 94 104
circle
diameter
Multitronic 01J.C
Transmission Code letters FSH
Application Model Audi A4 2001 --> , Audi A4 Cabriolet
2003 --> USA, Mexico
Engine 3.0L 5V -162 kW
Input gearing ratio 53 : 45 1.178
Front final drive ratio 43 : 9 4.778
Ring gear Diameter mm 204
Flange shafts Center diameter mm 88
Hole circle diameter mm 104
Multitronic 01J.A 01J.B 01J.C

Transmission Code letters FYS FYU FYW
Application Model Audi A4 2001 --> Audi A4 2001 --> , Audi A4 2001 --> ,
Audi A4 Cabriolet Audi A4 Cabriolet
2003 --> also Mexico 2003 --> USA,
Mexico
Engine 2.0 L 4V FSI - 110 3.0 L 5V - 162 kW 3.0L 5V -162 kW
kW 3.0 L 5V - 160 kW
Input gearing 57 : 41 1.390 51 : 46 1.109 53 : 45 1.178
ratio
diameter
Hole mm 104 104 104
circle
1:57:22 AM Page 3
diameter
Multitronic 01J.A 01J.A

Transmission Code letters FYZ FZA
Application Model Audi A4 2001 --> Audi A4 2001 -->
Engine 2.0 L 4V FSI - 110 kW 2.0L 5V -96 kW
Input gearing 57 : 41 1.390 57 : 41 1.390
ratio
Front final drive ratio 41 : 9 4.556 41 : 9 4.556
Ring gear Diameter mm 204 204
Flange shafts Center mm 88 108
diameter
Hole circle mm 104 94
diameter
Multitronic 01J.H 01J.H 01J.E

Transmission Code letters FZB FZC FZD
Application Model Audi A4 2001 --> , Audi A4 Cabriolet Audi A4 2001 -->
Audi A4 Cabriolet 2003 --> USA, Mexico Audi
2003 --> A4 Cabriolet 2003 -->
USA
Engine 1.8 L 5VT -110 kW 1.8 L 5VT -110 kW 1.8 L 5VT - 125 kW
Input gearing 54 : 43 1.256 54 : 43 1.256 57 : 41 1.390
ratio
diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.H 01J.C 01J.E

Transmission Code letters GEB GGR GGS
Application Model Audi A4 2001 --> , Audi A4 2001 --> , Audi A4 2001 -->
2003 --> 2003 --> USA
1.8 L 5VT - 125 kW *
See note
Input gearing 54 : 43 1.256 53 : 45 1.178 57 : 41 1.390
ratio
1:57:22 AM Page 4

diameter
Hole mm 104 104 104
circle
diameter
*Only country version Mexico.
Multitronic 01J.E 01J.B 01J.C

Transmission Code letters GGT GHR GHS
Application Model Audi A4 Cabriolet Audi A4 2001 --> , Audi A4 2001 --> ,
2003 --> USA Audi A4 Cabriolet Audi A4 Cabriolet
2003 --> also Mexico 2003 --> USA
Input gearing 57 : 41 1.390 51 : 46 1.109 53 : 45 1.178
ratio
Ring gear Diameter mm 204 204 or 203 * See note 204 or 203 * See note
diameter
Hole mm 104 104 104
circle
diameter
* Version dependent .
Multitronic 01J.E 01J.E

Transmission Code letters GHU GHV
Engine 2.0 L 4V FSI - 110 kW 2.0L 5V -96 kW
Input gearing 57 : 41 1.390 57 : 41 1.390
ratio
Ring gear Diameter mm 204 or 203 * See note 204 or 203 * See note
diameter
diameter
*Only country version Belgium.
1:57:22 AM Page 5
Multitronic 01J.H 01J.E

Transmission Code letters GHW GHX
Application Model Audi A4 2001 --> , Audi A4 Audi A4 2001 --> , Audi A4
Cabriolet 2003 --> also Cabriolet 2003 --> USA
Mexico
Engine 1.8 L 5VT -120 kW 1.8 L 5VT - 125 kW
Input gearing 54 : 43 1.256 57 : 41 1.390
ratio
Ring gear Diameter mm 204 or 203 * See note 204 or 203 * See note
diameter
diameter
Multitronic 01J.E 01J.B

Transmission Code letters GNS GWN
Application Model Audi A4 2001 --> Audi A4 2001 --> , Audi A4
Cabriolet 2003 -->
Engine 1.8 L 5VT -140 kW 3.0L 5V -162 kW
Input gearing 57 : 41 1.390 51 : 46 1.109
ratio
Ring gear Diameter mm 204 or 203 * See note 204 or 203 depending on
version
diameter
diameter
Multitronic 01J.C 01J.E

Transmission Code letters GWP GWR
Application Model Audi A4 2001 --> , Audi A4 Audi A4 2001 -->
Cabriolet 2003 --> USA
Engine 3.0L 5V -162 kW 2.0 L 4V FSI - 110 kW
Input gearing 53 : 45 1.178 57 : 41 1.390
ratio
1:57:22 AM Page 6

diameter
diameter

Transmission Code letters GWS GWU
Application Model Audi A4 2001 --> Audi A4 2001 --> , Audi A4
Cabriolet 2003 --> USA
Engine 2.0L 5V -95 kW 1.8 L 5VT - 125 kW
Input gearing 57 : 41 1.390 57 : 41 1.390
ratio
diameter
diameter
Multitronic 01J.E 01J.H 01J.H

Transmission Code letters GZD GZE GZF
2003 --> USA 2003 -->
Engine 2.0L 5V -96 kW 1.8 L 5VT - 125 kW 1.8 L 5VT -120 kW
Input gearing 57 : 41 1.390 57 : 41 1.390 54 : 43 1.256
ratio
diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.H 01J.H 01J.E

Transmission Code letters GZL GZM HAY HAZ
Application Model Audi A4 2001 --> Audi A4 2001 --> Audi A4 2001 -->
Engine 1.8 L 5VT -140 kW 1.8 L 5VT -140 kW 2.0L 5V -96 kW
Input gearing 54 : 43 1.256 54 : 43 1.256 57 : 41 1.390
ratio
1:57:22 AM Page 7
Ring gear Diameter mm 203 203 204 or 203 * See note

diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.K 01J.H 01J.E

Transmission Code letters HBB HBC HBD HBE HBG
2003 --> 2003 -->
Engine 2.0L 5V -96 kW 1.8 L 5VT -120 kW 1.8 L 5VT -120 kW
Input gearing 57 : 41 1.390 54 : 43 1.256 57 : 41 1.390
ratio
Ring gear Diameter mm 203 204 or 203 * See note 204
diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.E 01J.G 01J.E

Transmission Code letters HBH HBV HCP
Application Model Audi A4 2001 --> , Audi A4 2001 --> , Audi A4 2001 --> ,
Audi A4 Cabriolet Audi A4 Cabriolet Audi A4 Cabriolet
2003 --> 2003 --> 2003 --> USA
Engine 1.8 L 5VT -120 kW 3.0L 5V -162 kW 1.8 L 5VT - 125 kW
Input gearing 57 : 41 1.390 51 : 46 1.109 57 : 41 1.390
ratio
Ring gear Diameter mm 204 or 203 * See note 203 203
diameter
Hole mm 104 104 104
circle
diameter
1:57:22 AM Page 8

Transmission Code letters HDX HDZ
Engine 2.0 L 4V - 105 kW FSI 2.0L 5V -96 kW
Input gearing 57 : 41 1.390 57 : 41 1.390
ratio
diameter
diameter
Multitronic 01J.K 01J.H 01J.E

Transmission Code letters HEB HED HEF
2003 --> 2003 -->
Engine 2.0L 5V -96 kW 1.8 L 5VT -120 kW 1.8 L 5VT -120 kW
Input gearing 57 : 41 1.390 54 : 43 1.256 57 : 41 1.390
ratio
diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.E
Transmission Code letters HEH
2003 --> USA
Engine 1.8 L 5VT - 125 kW
1:57:22 AM Page 9
Multitronic 01J.B 01J.B 01J.B

Transmission Code letters HHB HHD HHE
Application Model Audi A4 2001 --> Audi A4 2001 --> , Audi A4 2001 -->
Audi A4 Cabriolet USA
2003 -->
Engine 3.0L 5V -162 kW 2.0 L 4V TFSI - 147 2.0 L 4V TFSI - 147
kW kW
Input gearing 51 : 46 1.109 51 : 46 1.109 51 : 46 1.109
ratio
diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.M 01J.M

Transmission Code letters HJB HJC
Application Model Audi A4 2001 --> , Audi A4 Audi A4 2001 --> USA
Cabriolet 2003 -->
Engine 3.2 L FSI - 184 kW 3.2 L FSI - 184 kW
Input gearing 49 : 48 1.021 49 : 48 1.021
ratio
diameter
diameter
Multitronic 01J 01J.B

Transmission Code letters HSA HSB (USA) HWK
Application Model Audi A4 Cabriolet 2003 --> Audi A4 2001 --> , Audi A4
Cabriolet 2003 -->
Engine 3.0L 5V -162 kW 2.0 L 4V TFSI - 147 kW
Input gearing 51 : 46 1.109 51 : 46 1.109
ratio
diameter
1:57:22 AM Page 10
diameter
Multitronic 01J.B 01J.C 01J.M

Transmission Code letters HWT HYF JTS
Application Model Audi A4 Cabriolet Audi A4 Cabriolet Audi A4 2001 -->
2003 --> USA 2003 --> USA
Engine 3.0L 5V -162 kW 1.8 L 5VT - 125 kW 3.2 L FSI -188 kW
Input gearing 53 : 45 1.178 57 : 41 1.390 49 : 48 1.021
ratio
diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.G 01J.B 01J.M

Transmission Code letters JTT JYA JZK
Application Model Audi A4 2001 --> , Audi A4 2001 --> Audi A4 2001 -->
Audi A4 Cabriolet
2003 -->
Engine 3.0L 5V -162 kW 2.0 L 4V TFSI -125 3.2 L FSI -188 kW
kW
Input gearing 51 : 46 1.109 51 : 46 1.109 49 : 48 1,021
ratio
Front final drive ratio 43 : 9 4.778 43 : 9 4.778 43 : 9 4,778
diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.B 01J 01J.B

Transmission Code letters JZM JZN JZP JZQ
Application Model Audi A4 2001 --> , Audi A4 2001 --> Audi A4 2001 --> ,
2003 --> 2003 -->
Engine 2.0 L 4V TFSI - 147 2.0L 5V -96 kW 1.8 L 5VT -120 kW
kW
Input gearing 51 : 46 1.109 57 : 41 1.390 54 : 43 1.256
ratio
1:57:22 AM Page 11

diameter
Hole mm 104 104 104
circle
diameter
Multitronic 01J.E
Transmission Code letters JZR
2003 -->
Engine 1.8 L 5VT -120 kW
CAPACITIES
Capacities
Planetary transmission
Capacities Planetary transmission Multitronic

Initial filling Approx. 7.5 L 01J
Changing 4.5 to 5.0 L * See note
Lubricant ATF for CVT transmission
* ATF change interval for planetary gear -->
 01 - MAINTENANCE
 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
ATF for CVT transmission can be obtained as replacement part, container size:
 1.0 L - ATF (Automatic Transmission Fluid) G 052 180 A2
CAUTION: The Continuously Variable Automatic Transmission Multitronic 01J

requires a different ATF than shift automatics. Only ATF for CVT
1:57:23 AM Page 12
transmission which can be obtained as replacement part must be used in

the planetary gear.
Checking ATF level or replacing ATF --> ATF level, checking and topping off.
Front final drive
Capacities Front final drive Multitronic

Initial filling Approx. 1.3 L 01J
Changing Filled for life, No change
Lubricant Multitronic gear oil
Multitronic gear oil is available as a replacement part and comes in the following container size:
 1.0 L - Axle oil G 052 190 A2

requires a different axle oil than shift automatics. Only axle oil for
Multitronic which can be obtained as a replacement part must be used in
front final drive.
Oil level in front final drive, checking --> Gear oil level in front final drive, checking.
TOWING INSTRUCTIONS
Towing instructions
CAUTION: When towing, selector lever must be in position "N" and vehicle must not
to be towed for more than 50 km or at a speed in excess of 50 km/h as
otherwise transmission would be destroyed.
NOTE:  Tow-starting the engine, e.g. when the battery is too weak or the starter is
faulty, is not possible.
REPAIR INSTRUCTIONS
Repair instructions
When engine is running, an exhaust extraction system must always be

connected to exhaust system.
1:57:23 AM Page 13
transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.
Contact corrosion!
 Transmission housing of continuously variable automatic transmission Multitronic 01J consists of a

magnesium alloy.
 Bolts and other components which have direct contact with transmission have a surface coating which is
matched to magnesium transmission housing.
 On magnesium transmissions, bolts must always be replaced on following bolted connections:
transmission cover to transmission housing and final drive cover to transmission housing.
 Contact corrosion occurs when incorrect components (bolts, nuts, washers, etc.) are used. The
transmission housing will be damaged.
 Transmission housing, transmission cover and differential cover must all be of same material.
 If you are not sure whether used parts can be re-installed, always install new parts.
CAUTION:  Use only Genuine Audi Parts!

 Damage resulting from contact corrosion is not covered by the
warranty!
Transmission
 Observe rules of cleanliness for working on the transmission --> Rules for cleanliness when working on
transmission.
 Do not run engine with end cover removed or without ATF filling and do not tow vehicle.
before.
 After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary
gear --> ATF level, checking and topping off and axle oil in front final drive --> Gear oil level in front
final drive, checking. Capacities and specifications --> Capacities.
O-rings, seals, gaskets
 Always replace O-rings, gaskets and seals.

 Thoroughly clean housing joint surfaces before assembling.
 To install, thinly coat gaskets along outer circumference and on sealing lip with ATF.
1:57:23 AM Page 14
 Lightly lubricate O-rings with ATF when installing to prevent the rings from being pinched when
components are assembled.
 Only use ATF for automatic transmission components. Other types of lubrication cause faults to occur in
 Open sides of oil seals face fluid side.
 When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip
of the old seal (use insertion depth tolerances).
 After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary
gear --> ATF level, checking and topping off or axle oil in front final drive --> Gear oil level in front
final drive, checking. Capacities and specifications --> Capacities.
Bolts and nuts
 Loosen bolts in reverse of tightening sequence.

 Nuts and bolts which secure covers and housings should be tightened in stages according to specified
sequence and tightening method.

 Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with
locking fluid AMV 185 101 A1 .
 Threaded holes into which self-locking bolts or bolts coated with locking fluid are installed, must be
cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
Locking elements

Bearings
 Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the
drift.
 Insert bearing with axle oil or ATF, depending on installation location.
 Do not interchange outer or inner races of bearings of the same size.
 Always replace taper roller bearings on one shaft together and use new bearings from a single
manufacturer.
Adjustment shims
1:57:23 AM Page 15
 Use a micrometer to measure shims at several points. Varying tolerances make it possible to measure the
required shim thickness exactly.
 Inspect for burrs and signs of damage. Install only shims that are in perfect condition.
Guided Fault Finding
Always perform Guided Fault Finding using Diagnostic Operation System VAS 5051 A before starting
disassembly and assembly work.
Rules for cleanliness when working on transmission

 Place removed parts on a clean surface and cover them. Use sheeting or paper. Do not use fluffy cloths!
before.
Transmission bell housing, ATF leaking
Fig. 2: Identifying ATF Breather Pipe & Level Of Bolt

NOTE:  If ATF leak is determined from check hole behind ATF breather pipe - A - at
level of bolt - B - , transmission is malfunctioning and must be replaced.
1:57:23 AM Page 16

1 - Transmission Control Module (TCM) J217
 Installed location --> Transmission Control Module (TCM) J217

 Control module is checked with On Board Diagnostics (OBD)
 Removing and installing --> Transmission Control Module (TCM) J217 , removing and installing
2 - Hydraulic control module
 Installed location Hydraulic control module

 Valves are checked with On Board Diagnostics (OBD)
1:57:23 AM Page 17
 Removing and installing --> Hydraulic control module, removing and installing
3 - Shift mechanism cover
 --> Shift mechanism cover (through VIN 8E_6A156499), removing and installing
 --> Shift mechanism cover (from VIN 8E_6A156500), removing and installing
 Location: Integrated into circuit board in cover of shift mechanism

 Consists of 3 Hall sensors that are controlled by a magnet on the cover strip transverse slide.
 If malfunctions at Tiptronic Switch F189 occur, check first whether magnet at control slide masking panel
is properly secured and replace masking panel if necessary. Before replacing the printed circuit, check
wiring.
 --> Tiptronic Switch F189 (through VIN 8E_6A156499), removing and installing
 --> Tiptronic Switch F189 (from VIN 8E_6A156500), removing and installing
 Installed location --> Shift lock solenoid N110

 --> Shift Lock Solenoid N110 (through VIN 8E_6A156499), removing and installing
 --> Shift Lock Solenoid N110 (from VIN 8E_6A156500), removing and installing
 Installed location Data Link Connector (DLC)
7 - Cruise Control Switch E45
 Installed location --> Cruise Control Switch E45

 Removing and installing -->
 94 LIGHTS, SWITCHES - EXTERIOR
 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET
8 - Park/Neutral Position (PNP) Relay J226 (up to 10.04) or Starting Interlock Relay J207 (as of 11.04)
 Installed location --> Power supply relay terminal 87/Starter Interlock Alarm System Relay J60 and
Park/Neutral Position (PNP) Relay J226 (up to 10.04) or Starting Interlock Relay J207 (as of 11.04)
9 - Power supply relay terminal 87/ Starter Interlock Alarm System Relay J60
1:57:23 AM Page 18
10 - Transmission Range (TR) Display Y6
 Installed location --> Transmission Range (TR) Display Y6

 A fully illuminated gear selection indicator indicates a simple malfunction
 A blinking gear selection indicator indicates a critical malfunction
 No indication on display points to a fault in wiring or a faulty Transmission Range (TR) Display Y6
11 - Kick Down Switch F8
 Not a separate component, it adopts functions of Throttle Position (TP) Sensor G79 and Accelerator Pedal
Position Sensor 2 G185 in vehicles with gasoline engine, both are integrated in accelerator pedal module;
component location --> Kick Down Switch F8
 Installed as one unit with Throttle Position (TP) Sensor G79 in vehicles with Diesel engine, this is
integrated in the accelerator pedal module; component location --> Kick Down Switch F8
 Signal received in Engine Control Module (ECM), signal transferred from ECM to Transmission Control
Module (TCM) via CAN-Bus
 Removing and installing accelerator pedal module --> 20 - FUEL SUPPLY SYSTEM
12 - Brake Light Switch F
 Installed location --> Brake Light Switch F

 Removing and installing --> 46 - BRAKES - MECHANICAL COMPONENTS
Fig. 4: Identifying Sensors Of Soiling And Metal Shavings

 Location: Transmission Control Module (TCM) J217 is on the back end of transmission, secured directly
to hydraulic control module.
1:57:23 AM Page 19
The following components are integrated in the control module:
A - Transmission Output Speed (RPM) Sensor G195 and Transmission Output Speed (RPM) Sensor 2 G196
B - Transmission Fluid Temperature Sensor G93
C - Multi-Function Transmission Range (TR) Switch F125
D - Transmission Input Speed (RPM) Sensor G182
E - Automatic Transmission Hydraulic Pressure Sensor 1 G193
F - Automatic Transmission Hydraulic Pressure Sensor 2 G194
Removing and installing Transmission Control Module (TCM) J217 --> Transmission Control Module
(TCM) J217 , removing and installing.
Hydraulic control module
Fig. 5: Identifying Hydraulic Control Module Components

 Location: Hydraulic control module is bolted to back end of transmission. Transmission Control Module
(TCM) J217 is fastened directly to hydraulic control module.
A - Harness connector for Automatic Transmission Pressure Regulating Valve 1 N215
B - Harness connector for Automatic Transmission Pressure Regulating Valve 2 N216
C - Harness connector for Solenoid Valve 1 N88
Following valves are integrated into hydraulic control module (not depicted here).
 Automatic Transmission Pressure Regulating Valve 1 N215 (clutch solenoid valve)

 Automatic Transmission Pressure Regulating Valve 2 N216 (solenoid valve gear)
1:57:23 AM Page 20
 Solenoid Valve 1 N88 (clutch cooling/safety shut-off)

 Clutch cooling valve
 Minimum pressure valve

 Pressure relief valve
 Clutch control valve
 Pressure control valve
NOTE:  Valves are monitored via On Board Diagnostic (OBD).

 Description and functions of individual valves 951103Continuously
Variable Automatic Transmission Multitronic 01J.
Removing and installing hydraulic control module --> Hydraulic control module, removing and installing.

 Location: Shift Lock Solenoid N110 is located in shift mechanism - arrow -.
1:57:23 AM Page 21
Connector (DLC)
 Location: Diagnostic connection is located beneath knee bolster on left of steering wheel.
Cruise Control Switch E45
Fig. 8: Cruise Control Switch E45

 Location: Cruise control switch is located on steering column switch.
1:57:23 AM Page 22
Fig. 9: Transmission Range (TR) Display Y6

 Location: Integrated in instrument cluster.
NOTE:  Transmission Range (TR) Display Y6 can only be replaced as a set with the
instrument cluster.
Power supply relay terminal 87/Starter Interlock Alarm System Relay J60 and Park/Neutral Position (PNP) Relay J226
(up to 10.04) or Starting Interlock Relay J207 (as of 11.04)
Fig. 10: Power Supply Relay Terminal 87/Starter Interlock Alarm System Relay J60 And Park/Neutral
Position (PNP) Relay J226 (Up To 10.04) Or Starting Interlock Relay J207 (As Of 11.04)
 Location: On relay carrier in E-box, plenum chamber.
Voltage is supplied differently via terminal 87:
1 - Starter Interlock Alarm System Relay J60 - only in vehicles with 2.4 L gasoline engine
3 - Motronic Engine Control Module (ECM) Power Supply Relay J271 - in all other vehicles with gasoline
engine
1:57:23 AM Page 23
3 - Power Supply Relay (terminal 30, B+) J317 - in vehicles with Diesel engine
NOTE:  In vehicles as of 11.04, activation of reverse driving lights occurs via CAN-
Bus.
Brake Light Switch F

 Location: Brake light switch - arrow - is located in brake pedal assembly.
NOTE:  Switch is only to be installed once so as to ensure a firm fit.
Kick Down Switch F8
1:57:23 AM Page 24

 Location: In accelerator pedal module - arrow -.
NOTE:  In vehicles with gasoline engine, Kick Down Switch F8 adopts the
functions of Throttle Position (TP) Sensor G79 and Accelerator Pedal
Position Sensor 2 G185.
SHIFT MECHANISM (THROUGH VIN 8E_6A156499), SERVICING
Shift mechanism (through VIN 8E_6A156499), servicing
Shift mechanism (through VIN 8E_6A156499), checking
Overview:
 1. Selector mechanism function test --> Selector mechanism function test

 2. Checking ignition key removal lock --> Check ignition key withdrawal lock
 3. Locking button on selector lever handle, checking --> Check locking button on selector lever handle
 If shift mechanism does not function as described, perform "Guided Fault Finding" with Vehicle
Diagnosis, Testing and Information System VAS 5051B.
1:57:23 AM Page 25
Selector mechanism function test
 In selector lever positions "S" , "D" , "R" and "Tiptronic gate" the starter motor will not operate.
 If selector lever position "N" is selected at speeds greater than 5 km/h, the selector lever lock solenoid
must not engage and block selector lever. Selector lever can be shifted into driving gear.
 For speeds below 2 km/h (almost standstill) and shifting into selector lever position "N" , the shift lock
solenoid must only engage after approx. 1 second. Selector lever can only be shifted out of position "N"
with brake pedal operated.
 Do not operate brake pedal.
 Selector lever is locked and also cannot be shifted out of position "P" while locking button on selector
lever handle is pressed. Shift Lock Solenoid N110 blocks selector lever.
 Press brake pedal and hold.
 Shift Lock Solenoid N110 releases selector lever. It must be possible to select a driving mode without
"hitching" while locking button on selector lever handle is pressed.
 Slowly shift selector lever from "P" through "R, N, D, S" , checking whether Transmission Range (TR)
Display Y6 in instrument cluster matches selector lever position.
 Up to approx. 08.01: Selector lever is locked and cannot be shifted out of position "N" without pressing
button on selector lever handle. Shift Lock Solenoid N110 blocks selector lever.
 As of approx. 08.01: Selector lever is not locked immediately when rapidly shifting through position
"N" (e.g. from "R" to "D"). This enables e.g. "forward and reverse maneuvers" when vehicle is stuck.
Shift lock engages when selector lever is located in "N" for longer than approx. 1 s with brake not being
pressed.
 Operate brake pedal.
Selector lever in position "D" , ignition switched on:
 Brightening of "D" symbol must go out in selector mechanism cover and "+" and "-" symbols must light
up.
 The Transmission Range (TR) Display Y6 in instrument cluster must change from "PRND" to "654321"
1:57:23 AM Page 26
or (from VIN 8E_5400001) from "PRNDS" to "7654321" when selector lever is shifted into "Tiptronic
Gate".
If specified values are not obtained:
 Adjust selector lever cable --> Selector lever cable (through VIN 8E_6A156499), adjusting.
 Check ignition key removal lock.
Check ignition key withdrawal lock
 Switch ignition key to driving position ("ignition on").

 It must be possible to shift selector lever out of position "P" without "hitching" while locking button on
selector lever handle is pressed.
 Switch ignition off.
 It should not be possible to remove ignition key when selector lever is in any other position than "P".
 Place selector lever in position "P".
 It must be possible to remove ignition key only in position "P".

 Selector lever cannot be shifted out of position "P" with locking button pressed and foot brake operated.
Check locking button on selector lever handle
Check locking button for ease of movement:
 It must be possible to press locking button without great force.

 After releasing, the locking button must come all the way back out by itself
 Check whether selector lever handle is installed correctly.

 Check whether selector rod or selector lever is bent.
Function test:
 Ignition switched on
Locking button on selector lever handle must be pressed for the following shifts. If it is not pressed, the selector
1:57:23 AM Page 27
lever cannot be shifted into specified position.
 "P" to "R" and also press brake pedal

 "D" to "S"
 "N" to "R" ; in standstill, also press brake pedal after long wait
 "R" to "P"

Shift mechanism, through VIN 8E_6A156499, removing and installing
Removing
 Remove selector lever handle --> Selector lever handle (through VIN 8E_6A156499), removing and
installing.
Fig. 13: Removing Trim Panel

 Open ashtray in center console and remove trim panel - arrows -.

 Remove air conditioning operating unit --> 87 AIR CONDITIONING .
 Remove ashtray in center console -->
1:57:23 AM Page 28
Fig. 14: Releasing Clips And Pull Cover With Guide Upwards To Remove
 Release all 4 clips - arrows - and pull cover - 1 - with guide upwards to remove.
 Disconnect connector from side of guide plate.

 Disengage locking cable - arrows -.
1:57:23 AM Page 29

 Loosen quick-release screws - 2 - and - 3 - and remove rear noise insulation.
Vehicles with 4-cyl. engine:
Fig. 17: Removing Vehicle Floor Plates At Inside Left/Right

 Remove vehicle floor plates at inside left - 2 - and inside right - 1 -.
Fig. 18: Removing Bolts And Rear Cross Member For Vehicle Floor
 Remove rear cross member for vehicle floor, to do so remove bolts - 1 through 4 -.
1:57:23 AM Page 30
All:
Fig. 19: Removing Bolts To Remove Front Cross Member For Vehicle Floor
 Remove bolts - 1 to 6 - to remove front cross member for vehicle floor.
NOTE:  Depicted in illustration for a vehicle with 4-cyl. engine.
NOTE:  Flex joint in front exhaust pipe must not be bent more than 10°, otherwise
it may be damaged.
Fig. 20: Disconnecting Exhaust System At Double Clamp

 Disconnect exhaust system at double clamp - arrows -.
 Remove heat shield below shift mechanism.
1:57:23 AM Page 31

 Remove lower cover from shift mechanism - arrows -.

 Detach selector lever cable sleeve from shift mechanism bottom cover and slide back.
 Pull plastic securing spring - 2 - slightly to front and push pin - 3 - upward only as far as necessary -
arrow -.
1:57:23 AM Page 32
Fig. 23: Pressing Holder Clips & Removing Nuts

NOTE:  A second technician is required when detaching shift mechanism below

vehicle.
Installing
 Install selector lever cable --> Selector lever cable, (through VIN 8E_6A156499), removing and
installing.
 Install locking cable --> Locking lever (through VIN 8E_6A156499), removing and installing.
 Adjust locking cable --> Locking lever (through VIN 8E_6A156499), adjusting.
 Install exhaust system and align it free of tension -->
 26 - EXHAUST SYSTEM, EMISSION CONTROLS 3.2 V6 4V ENGINE MECHANICAL,
ENGINE CODE(S): BKH
.
1:57:23 AM Page 33
 Check shift mechanism --> Shift mechanism (through VIN 8E_6A156499), checking.
Component Nm
Front cross member to vehicle floor 55
Rear cross member to vehicle floor 60
Selector lever handle, shift mechanism cover (through VIN 8E_6A156499), assembly overview
052 142 A2 .
1:57:23 AM Page 34
1 - Selector lever
2 - Selector lever shaft piece
 Removing and installing --> Selector lever handle (through VIN 8E_6A156499), removing and
installing
installing
4 - Cover
 With selector scale and Tiptronic gate

 Removing and installing --> Tiptronic Switch F189 (through VIN 8E_6A156499), removing and
installing and also unclipping symbol inserts
5 - Symbol panel
 Clipped into cover
 With integrated Tiptronic Switch F189

installing
 Switch consists of 3 Hall sensors, which are activated by a magnet on transverse slide of cover strip.
 Before replacing circuit board when DTC "18161" is entered in DTC memory, first check adjustment of
selector lever cable --> Selector lever cable (through VIN 8E_6A156499), adjusting
7 - Cover strip
 With solenoid for Tiptronic Switch F189 on transverse slide

installing
8 - Masking panel guide
Selector lever handle (through VIN 8E_6A156499), removing and installing
Removing
1:57:23 AM Page 35
 Place selector lever in position "D".

 Rotate sleeve - 1 - to left and push downward as far as stop.

 Carefully pull switch - 2 - just enough out of selector lever handle - 3 - until a cable tie can be inserted
between button and selector lever handle.
NOTE:  Do not pull out the button any further, otherwise the selector lever handle
will be damaged.
 Pull selector lever handle upward and off.
Installing
1:57:23 AM Page 36
NOTE:  To install new selector lever handle - 3 - , button - 2 - must be pulled out as
far as stop and secured with a cable tie - arrow - or using assembly aid
included with new handle.
 If the button was not secured, it must not be pulled out from the handle
using mechanical aids. Apply compressed air gun to bottom of handle and
press button out with compressed air.
 Place selector lever handle - 3 - completely onto selector lever - button - 2 - faces toward driver. When
doing this, handle must engage into ring groove of selector lever.
 Remove cable tie - arrow - or assembly aid, thereby button mechanism engages in vertical groove of
selector lever. If necessary press button into selector lever handle.
 Pull sleeve - 1 - upward and engage by rotating clockwise.
Shift mechanism cover (through VIN 8E_6A156499), removing and installing
Removing
installing.


 Remove 2 retaining bolts for ashtray and lift ashtray at rear.
1:57:24 AM Page 37
Installing
 Install selector lever handle --> Selector lever handle (through VIN 8E_6A156499), removing and
installing.
Tiptronic Switch F189 (through VIN 8E_6A156499), removing and installing
is properly secured and replace masking panel if necessary. Before replacing the printed circuit, check the
wiring.
Removing
 Remove cover for shift mechanism --> Shift mechanism cover (through VIN 8E_6A156499),
1:57:24 AM Page 38
Fig. 29: Pressing Down Retaining Hooks And Pull Off Cover From Guide
 Press down retaining hooks - arrows - and pull off cover - 2 - from guide - 1 -.
 Remove circuit board with integrated Tiptronic Switch F189.
Fig. 30: Checking Magnets On Cover Strip For Secure Seating

 Check magnets - arrows - on cover strip for secure seating.
 Cover strip must be replaced if a magnet is missing.
Installing
 Install cover for shift mechanism --> Shift mechanism cover (through VIN 8E_6A156499), removing
and installing.
Shift mechanism (through VIN 8E_6A156499,), assembly overview
052 142 A2 .
1:57:24 AM Page 39
Fig. 31: Shift Mechanism (Through VIN 8E_6A156499,), Assembly Overview

2 - Bracket
3 - Bushing
5 - Pivot pin
6 - Selector lever
1:57:24 AM Page 40
8 - Operating lever for locking cable
11 - Locking lever
12 - Shift lever guide
NOTE:  If selector lever guide or shift unit is faulty, entire shift mechanism must
be replaced. It is not possible to adjust both components using shop
equipment.
13 - Nut
 10 Nm
14 - Shift unit
15 - Bushing
16 - Retaining bracket for selector lever
17 - Retaining clip
19 - Pivot pin
20 - Nut
 10 Nm
Shift mechanism (through VIN 8E_6A156499), disassembling and assembling
Disassembling
NOTE:  Securing spring for locking cable, removing and installing Retaining
spring for locking cable, removing and installing
1:57:24 AM Page 41
Fig. 32: Shift Mechanism (Through VIN 8E_6A156499), Disassembling And Assembling
6 - Selector lever

 Remove shift lock solenoid - 7 - --> Shift Lock Solenoid N110 (through VIN 8E_6A156499),
 Unclip selector lever guide - 12 -.
 Release pivot pins - 5 - and - 19 - and pull them out from side.
 Unclip retaining brackets - 2 - and - 16 -.

 Swing locking lever - 11 - fully upwards.
 Pull selector lever - 6 - with bushings - 3 - and - 15 - as well as Tiptronic locking levers - 4 - and - 18 -
1:57:24 AM Page 42
downward out of shift unit - 14 -.
Assembling
6 - Selector lever
 Check whether selector lever is in position "D".

 Insert selector lever - 6 - from below into shift unit - 14 -.
 Connect locking levers for Tiptronic - 4 - and - 18 - as well as bushings - 3 - and - 15 - on selector lever.
 Press selector lever - 6 - with bushes into shift unit and position it with retaining clip - 17 -.
1:57:24 AM Page 43
 Engage retaining brackets - 2 - and - 16 - on shift unit.

 Push pivot pins - 5 - and - 19 - into selector lever - 6 - until they engage.
 Check whether mounting pins in Tiptronic locking lever engage.
 Install shift lock solenoid - 7 - --> Shift Lock Solenoid N110 (through VIN 8E_6A156499), removing
and installing.
 Clip in selector lever guide - 12 -.
Retaining spring for locking cable, removing and installing
Fig. 34: Retaining Spring For Locking Cable, Removing And Installing
Removing:
 To remove locking cable, slightly lift spring at top - arrow B -.

 Unhook spring at retaining tab - arrow C - and remove toward top.
Installing:
 Insert spring - arrow B - from top and hook in at retaining clip - arrow C -.
 Align spring so that it is seated evenly in groove - arrow A -.
Shift Lock Solenoid N110 (through VIN 8E_6A156499), removing and installing
Removing
1:57:24 AM Page 44
Fig. 35: Releasing Lugs And Removing Shift Lock Solenoid Forward
 Release lugs and remove shift lock solenoid forward - arrows -.
Installing
 Press shift lock solenoid into guide until it engages; operating lever - 2 - of solenoid must engage in
locking lever - 1 - on shift mechanism.
and installing.
Selector lever cable and locking cable (through VIN 8E_6A156499), assembly overview

 Lightly grease eyelet and ball socket with polycarbamide grease G 052 142
A2 before installing.
1:57:24 AM Page 45
Fig. 37: Selector Lever Cable And Locking Cable (Through VIN 8E_6A156499), Assembly Overview
1 - Nut
 23 Nm
 Do not bend or kink, lightly grease cable eye and ball socket before installing.
 Removing and installing --> Selector lever cable, (through VIN 8E_6A156499), removing and
installing
 Adjusting --> Selector lever cable (through VIN 8E_6A156499), adjusting
 In case of damaged rubber boots, selector lever cable must be replaced
 When installing, make sure that rubber sleeve on transmission side is not twisted
1:57:24 AM Page 46
3 - Lock nuts
 13 Nm
4 - Boot for selector lever cable
 To be buttoned into selector mechanism bottom cover
5 - Retaining clip
6 - Ignition/starter switch
 with ignition key removal lock
7 - Locking cable

 Not to be kinked
 Removing and installing --> Locking lever (through VIN 8E_6A156499), removing and installing
 Adjusting --> Locking lever (through VIN 8E_6A156499), adjusting
8 - Bolt
 9 Nm
9 - Clamping screw
 13 Nm
10 - Pin

 To remove selector lever cable, move plastic retaining spring at selector mechanism forward slightly and
put screws upward, only as far as necessary.
12 - Bracket for selector lever cable
13 - Bolt
 23 Nm
1:57:24 AM Page 47
Selector lever cable, (through VIN 8E_6A156499), removing and installing

Removing

1:57:24 AM Page 48

 Remove rear cross member for vehicle floor, remove bolts - 1 through 4 - to do so.
All:
1:57:24 AM Page 49
 Remove bolts - 1 through 6 - and remove front cross member for vehicle floor.

it may be damaged.
1:57:24 AM Page 50
Fig. 44: Removing Bracket For Selector Lever Cable By First Removing Bolts
 Remove bracket - 3 - for selector lever cable by first removing bolts - 2 -.
Fig. 45: Using Pry Lever 80-200 To Press Selector Lever Cable From Lever For Selector Shaft
 Using pry lever 80-200 , press selector lever cable - A - from lever for selector shaft - arrow -.
1:57:24 AM Page 51


arrow -.
1:57:24 AM Page 52
 Loosen lock nuts - 6 - and remove selector lever cable - 5 - from support bracket - 4 -.
Installing

 Lightly grease eyelet and ball socket of selector lever cable with
polycarbamide grease G 052 142 A2 before installing.
1:57:24 AM Page 53
 Slide selector lever cable into shift mechanism and secure it with retaining clip - 1 -.
 Installation position: Angled end of retaining clip points toward rear.

 Press pin - 3 - downward - arrow -.
 Check whether plastic securing spring - 2 - has locked the pin.
 Button selector lever cable boot into lower cover.

 Bolt lower cover securely to shift mechanism - arrows -.
1:57:24 AM Page 54
Fig. 51: Bolting Selector Lever Cable To Support Bracket & Tightening Lock Nuts
 Tightly bolt selector lever cable - 5 - to support bracket - 4 - , tighten lock nuts - 6 - to 12 Nm.
Fig. 52: Pressing Selector Shaft Lever On Transmission Completely Toward Rear
 Press selector shaft lever - A - on transmission completely toward rear - arrow - until parking lock
engages.
 Check whether selector lever is in position "P" , then press ball socket of selector lever cable - 5 -
carefully onto lever for selector shaft - 7 -.
1:57:25 AM Page 55
NOTE:  Take care not to bend selector shaft lever when pressing it on; support it if
necessary, as otherwise selector mechanism can no longer be adjusted
properly.
ENGINE CODE(S): BKH
.
Component Nm
Bracket to transmission 23
Support bracket to mounting base 23
Selector lever cable (through VIN 8E_6A156499), adjusting
1:57:25 AM Page 56

NOTE:  There is a distinction between vehicles with "PRND" shift mechanisms (up
to model year 2004) and vehicles with "PRNDS" shift mechanisms (as of
model year 2005).
 In vehicles with "PRND" shift mechanisms (through model year 2004),
selector lever cable adjustment is performed in selector lever position "D".
 In vehicles with "PRNDS" shift mechanisms (from model year 2005),
selector lever cable adjustment is performed in selector lever position "S".
Vehicles with "PRND" shift mechanisms
1:57:25 AM Page 57
 Loosen rear clamping screw on selector lever cable through hole in shift mechanism approx. one turn
using socket and key T40031.
NOTE:  Loosen clamping screw only approx. 1 turn. Do not remove.

 Clamping screw is only accessible in selector lever position "D".
 Selector lever must remain in position "D" while clamping screw is loose.
 Carefully move selector lever lightly toward front and rear without shifting into another selector lever
position, this releases the tension on selector lever cable.
 Check exact position of selector lever in position "D" by pushing selector lever lightly towards drivers
seat - arrow A -.
NOTE:  Do not touch selector lever during the adjustment.
 Without touching selector lever, tighten clamping screw in this position using socket and key T40031.
Vehicles with "PRNDS" shift mechanisms
 Place selector lever in position "S".
1:57:25 AM Page 58
Fig. 57: Inserting Socket And Key T40031 Through Access Hole In Selector Mechanism To
Loosen/Tightening Clamping Bolt At Rear Of Selector Lever Cable
 Loosen rear clamping screw on selector lever cable through the hole in shift mechanism approx. one turn
NOTE:  Loosen clamping screw only 1 turn. Do not remove.

 The selector lever must remain in position "S" with clamping bolt
loosened, otherwise the setting is not correct.
 Carefully move selector lever forwards and backwards slightly without shifting to a different selector
lever position.
 Pull selector lever completely toward rear once more until it stops in position "S" and release selector
lever.
Vehicles with "PRND" and "PRNDS" shift mechanisms
and installing.
1:57:25 AM Page 59

NOTE:  Using Vehicle Diagnosis, Testing and Information System VAS 5051 A , the
position of Multi-Function Transmission Range (TR) Switch F125 can be
compared to position on selector lever via On Board Diagnostic (OBD), 02
- Transmission electronics, 08 - Read measured value block, display group
2 in display field - 1 -.
If shift mechanism does not function properly after adjusting selector lever cable:
 Bring selector lever cable into basic setting --> Selector lever cable (VIN through 8E_6A156499),
bringing into basic setting.
Component Nm
Selector lever cable (VIN through 8E_6A156499), bringing into basic setting
1:57:25 AM Page 60

Work procedure
model year 2005).
NOTE:  Before performing basic setting, make sure that the clamping screw is
tightened. It is accessible through the hole in shift mechanism in position
"D" using socket and key T40031.
 Tighten clamping screw in this position using socket and key T40031 (13 Nm).
1:57:25 AM Page 61
"S" using socket and key T40031.

1:57:25 AM Page 62
Fig. 63: Removing Support Bracket For Selector Lever Cable

 Remove support bracket for selector lever cable - 1 -.
NOTE:  Make sure selector lever is in position "P".
 Push lever for selector shaft - 2 - at transmission completely toward rear until parking lock engages.
NOTE:  When parking lock is engaged, it must not be possible to turn both front
wheels in one direction at the same time.
 Make sure that selector lever cable has been routed free of kinks and tension.
1:57:25 AM Page 63
 Make sure that selector lever cable - 5 - is secured with nuts - 6 - to support bracket - 4 - (13 Nm).

 Install support bracket for selector lever cable tightly to bracket - 1 -.

Component Nm
Support bracket to bracket, bolt M8 - 1 - 23
Locking lever (through VIN 8E_6A156499), removing and installing
1:57:25 AM Page 64

1 - Locking cable
Removing
NOTE:  Do not kink locking cable.
CAUTION: Observe procedures for disconnecting battery -->

1:57:25 AM Page 65
 Disconnect Ground (GND) wire at battery.

.
 Remove steering column trim -->
.
 Remove A/C system operating unit --> 87 AIR CONDITIONING .

.
 Turn ignition key into driving position ("ignition on").
1:57:25 AM Page 66

1 - Locking cable
Installing
 Route locking cable kink-free behind instrument panel strut - arrow -.

 Check interlock lever - 2 -.
 Bring ignition/starter switch into locking position ("ignition off").
1:57:25 AM Page 67
 Check whether selector lever is in position "P".

 Engage locking cable eye into pin - 3 -.
 Lift securing spring - 4 - slightly.
 Slide locking cable support bracket - 5 - from right into shift mechanism until securing spring - 4 -
engages.
 Observe procedures for connecting battery -->

.
Locking lever (through VIN 8E_6A156499), adjusting

 Safety glasses
Work preparations
NOTE:  The procedure described below will save you the effort of removing the
center console.
1:57:25 AM Page 68

 Cut through adjustment pin for shift lock 3 3352 A at rear end of flat area - arrow - using a cutting
grinder.
 Order a new adjustment pin for shift lock as a replacement for other use.
Work procedure
 Position steering wheel column adjustment all the way and back toward drivers seat.
1:57:25 AM Page 69
 Insert adjustment pin for shift lock 3 3352 A between pin on locking cable lever and locking cable eye.
 Pull locking cable in direction of - arrow - and tighten bolt to 9 Nm.
 Remove adjustment pin.
 Check ignition key removal lock after every adjustment of locking cable --> Shift mechanism (through
VIN 8E_6A156499), checking.
Component Nm
Locking cable to mounting bracket 9
SHIFT MECHANISM (FROM VIN 8E_6A156500), SERVICING
Shift mechanism (from VIN 8E_6A156500), servicing
Shift mechanism (from VIN 8E_6A156500), checking
Overview:
 1. Selector mechanism function test Selector mechanism function test

 2. Checking ignition key removal lock Check ignition key withdrawal lock
 3. Locking button on selector lever handle, checking Check locking button on selector lever handle
 In selector lever positions "S" , "D" , "R" and "Tiptronic gate" starter motor will not operate.
 If selector lever position "N" is selected at speeds greater than 5 km/h, selector lever lock solenoid must
not engage and block selector lever. Selector lever can be shifted into driving gear.
1:57:26 AM Page 70
 Selector lever is not locked immediately when rapidly shifting through position "N" (e.g. from "R" to
"D"). This enables e.g. "forward and reverse maneuvers" when vehicle is stuck. Shift lock engages when
selector lever is located in "N" for longer than approx. 1 s with brake not being pressed.
up.
 The Transmission Range (TR) Display Y6 in instrument cluster should switch from "PRNDS" to
"7654321" when selector lever is shifted into "Tiptronic gate".
 Adjust selector lever cable --> Selector lever cable (from VIN 8E_6A156500), adjusting.

1:57:26 AM Page 71

 Selector lever cannot be shifted out of position "P" with locking button pressed and parking brake
operated.

 After releasing, locking button must come all the way back out by itself

Function test:
Locking button on selector lever handle must be pressed for the following shifts. If it is not pressed, selector

 "D" to "S"
 "R" to "P"

1:57:26 AM Page 72
Selector lever handle, shift mechanism cover (from VIN 8E_6A156500), assembly overview
052 142 A2 .
1 - Selector lever
 Removing and installing --> Selector lever handle (from VIN 8E_6A156500), removing and installing
1:57:26 AM Page 73
4 - Cover

 Removing and installing --> Tiptronic Switch F189 (from VIN 8E_6A156500), removing and
5 - Symbol panel

installing
selector lever cable --> Selector lever cable (from VIN 8E_6A156500), adjusting
7 - Cover strip

installing
Selector lever handle (from VIN 8E_6A156500), removing and installing
Removing
1:57:26 AM Page 74


will be damaged.
Installing

1:57:26 AM Page 75
 Remove cable tie - arrow - or assembly aid, thereby the button mechanism engages in the vertical groove
of the selector lever. If necessary press button into selector lever handle.
Shift mechanism cover (from VIN 8E_6A156500), removing and installing
Removing
 Remove selector lever handle --> Selector lever handle (from VIN 8E_6A156500), removing and
installing.


1:57:26 AM Page 76
 Disconnect connector from the side of the guide plate.
Installing
 Install selector lever handle --> Selector lever handle (from VIN 8E_6A156500), removing and
installing.
Tiptronic Switch F189 (from VIN 8E_6A156500), removing and installing
 If malfunctions at Tiptronic Switch F189 occur, first check whether magnet at control slide masking panel
wiring.
To replace Tiptronic switch, circuit board must be replaced.
Removing
 Remove cover for shift mechanism --> Shift mechanism cover (from VIN 8E_6A156500), removing
and installing.
1:57:26 AM Page 77

Installing
1:57:26 AM Page 78
 Install cover for shift mechanism --> Shift mechanism cover (from VIN 8E_6A156500), removing and
installing.
Shift mechanism (from VIN 8E_6A156500), assembly overview
052 142 A2 .
Fig. 78: Shift Mechanism (From VIN 8E_6A156500), Assembly Overview

1 - Rubber seal
2 - Press tube
3 - Bolt, 2 Nm
1:57:26 AM Page 79
 Qty. 4
4 - Selector mechanism function unit
6 - Noise insulation
 Not installed on all vehicles
7 - Lock washers
 Qty. 4, always replace

 For securing sound insulation on selector mechanism function unit
8 - Retaining clip
 Secures selector lever cable on selector mechanism function unit
 --> Selector lever cable (from VIN 8E_6A156500), removing and installing
 Adjusting --> Selector lever cable (from VIN 8E_6A156500), adjusting
10 - O-Ring
 Always replace
Shift mechanism (from VIN 8E_6A156500), removing and installing
1:57:26 AM Page 80

Removing
installing.
1:57:26 AM Page 81
Fig. 81: Raising Retaining Tab And Removing Locking Lever

 Raise retaining tab - A - and remove locking lever in direction of - arrow -.



1:57:26 AM Page 82
Fig. 84: Removing Tunnel Braces

 Remove tunnel braces -->

 66 EXTERIOR EQUIPMENT
 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET

it may be damaged.
 Disconnect exhaust system at double clamps - arrows -.

 Remove heat shield under shift mechanism -->
For vehicles with noise insulation - A - under shift mechanism:
1:57:27 AM Page 83
Fig. 86: Removing Lock Washers

 Remove lock washers - arrows -.
NOTE:  Always replace lock washers
 Remove sound insulation - A - and slide forward.
All:
Fig. 87: Removing Selector Lever Cable Retaining Clip Sideways & Selector Lever Cable From Shift
Mechanism
 Remove selector lever cable retaining clip - 1 - sideways.

1:57:27 AM Page 84


vehicle.
Installing
 Install selector lever cable --> Selector lever cable (from VIN 8E_6A156500), removing and
installing.
 Install locking cable --> Locking lever (from VIN 8E_6A156500), removing and installing.
 Adjust locking cable --> Locking cable (from VIN 8E_6A156500), adjusting.
ENGINE CODE(S): BKH
.
1:57:27 AM Page 85
 Check shift mechanism --> Shift mechanism (from VIN 8E_6A156500), checking.
Component Nm
Shift Lock Solenoid N110 (from VIN 8E_6A156500), removing and installing
Fig. 89: Pressing Retaining Hooks Into Shift Mechanism And Hold It Down
Removing
and installing.
 Press retaining hooks - A - into shift mechanism - arrow - and hold it down.
NOTE:  If retaining hook - A - is broken off, selector mechanism function unit must
be replaced.
1:57:27 AM Page 86
Fig. 90: Disengaging Ball Head From Operating Lever On Shift Mechanism
 Tip Shift Lock Solenoid N110 down and out in direction of - arrow - so that ball head - 1 - disengages
from operating lever on shift mechanism.
 Remove Shift Lock Solenoid N110.
Installing
 Rotate ball head - 1 - to correct installation position.

 Guide Shift Lock Solenoid N110 diagonally from above into shift mechanism.
 Tip Shift Lock Solenoid N110 down in opposite direction of - arrow -.
 Ball head - 1 - must be completely engaged in operating lever on shift mechanism.

 Secure Shift Lock Solenoid N110 on retaining hook - A -.
installing.
Selector lever cable and locking cable (from VIN 8E_6A156500), assembly overview

1:57:27 AM Page 87
Fig. 92: Selector Lever Cable And Locking Cable (From VIN 8E_6A156500), Assembly Overview
 Removing and installing --> Selector lever cable (from VIN 8E_6A156500), removing and installing
2 - Lock nuts
 13 Nm
1:57:27 AM Page 88
3 - Retaining clip
5 - Locking cable

 Removing and installing --> Locking lever (from VIN 8E_6A156500), removing and installing
 Adjusting --> Locking cable (from VIN 8E_6A156500), adjusting
6 - Bolt
 9 Nm
7 - Clamping screw
 13 Nm
8 - O-Ring
 Always replace
10 - Bolt
 20 Nm
 For securing bracket to selector lever cable bracket
 Different equipment depending on version
12 - Bolt
 20 Nm
 Qty. 3
 For securing selector lever cable bracket to transmission
1:57:27 AM Page 89
Selector lever cable (from VIN 8E_6A156500), removing and installing


Removing
installing.
and installing.
1:57:27 AM Page 90

Removing

1:57:27 AM Page 91


it may be damaged.


1:57:27 AM Page 92

All:
Mechanism

Installing
1:57:27 AM Page 93
Torque specifications --> Selector lever cable and locking cable (from VIN 8E_6A156500), assembly
overview


 Slide noise insulation - A - over opening on selector lever cable.
All:
Fig. 102: Replacing O-ring on selector lever cable & Slide selector lever cable into shift mechanism
 Replace O-ring - 1 - on selector lever cable.
1:57:27 AM Page 94
 Slide selector lever cable into shift mechanism - arrow -.
Mechanism
 Secure selector lever cable - 2 - to shift mechanism with retaining clip - 1 -.
 Installation position: Angled end of retaining clip faces toward shift mechanism.

 Secure sound insulation to shift mechanism with four new lock washers - arrows -.
All:
1:57:28 AM Page 95
 Tightly bolt selector lever cable - 5 - to support bracket - 4 - , tighten lock nuts - 6 -.
engages.
 Then press selector shaft forward 3 detents, so transmission is in "D" position.

 Ensure selector lever in vehicle is also in "D" position.
1:57:28 AM Page 96
 Carefully press selector lever cable ball socket - 5 - onto selector shaft lever - 7 - in this position.
properly.
seat - arrow A -.
1:57:28 AM Page 97
 Tighten clamping screw with Socket T40031 through hole in shift mechanism while in this position,
without touching selector lever.
ENGINE CODE(S): BKH
.
Selector lever cable (from VIN 8E_6A156500), adjusting

1:57:28 AM Page 98
and installing.

seat - arrow A -.
1:57:28 AM Page 99
installing.

 Bring selector lever cable into basic setting --> Selector lever cable, from VIN 8E_6A156500),
Component Nm
Selector lever cable, from VIN 8E_6A156500), bringing into basic setting
1:57:28 AM Page 100


Work procedure
and installing.
tightened. It is accessible through hole in shift mechanism in position "D"
1:57:28 AM Page 101



1:57:28 AM Page 102



Component Nm
Selector lever cable to bracket (lock nut, qty. 2) 13
1:57:28 AM Page 103

Locking lever (from VIN 8E_6A156500), removing and installing
Overview
Fig. 119: Locking Lever (From VIN 8E_6A156500), Removing And Installing Overview
1 - Locking cable
2 - Retaining clip
3 - Locking cable eye pins
4 - Locking cable bracket
1:57:28 AM Page 104

5 - Bolt, 10 Nm
 For adjusting locking cable
Removing


.
.

.
and installing.
 Turn ignition key into driving position "ignition on".
1:57:29 AM Page 105

Fig. 120: Lifting Retaining Clip From Interlock Lever And Pulling Locking Cable Out Of
Ignition/Starter Switch

 Raise retaining tab - A - and remove locking lever in direction of - arrow - from locking cable eye pins.
Installing
1:57:29 AM Page 106

Fig. 122: Routing Locking Cable Without Kinks Under Wiring Harness And Behind Instrument Panel
Brace
 Route locking cable without kinks under wiring harness - arrow A - and behind instrument panel brace -
arrow B -.

 Bring ignition/starter switch into locking position "ignition off".
1:57:29 AM Page 107


 Slide locking cable in opposite in direction of - arrow - onto locking cable eye pins.
 The retaining tab - A - must engage over locking cable

.
Locking cable (from VIN 8E_6A156500), adjusting
1:57:29 AM Page 108

 Safety glasses
Work preparations
center console.

grinder.
Work procedure
and installing.
.
1:57:29 AM Page 109


 Check ignition key removal lock after every adjustment of locking cable --> Shift mechanism (from
Component Nm
Overview:
 --> Transmission (vehicles with 1.8 L turbo engine, also Audi Cabriolet), removing
 --> Transmission (vehicles with 2.0 L normally-aspirated engine, also Audi Cabriolet), removing
 --> Transmission (vehicles with 2.0 L TFSI engine, also Audi Cabriolet), removing
 --> Transmission (vehicles with 6-cyl. 3.0 L gasoline engine, also Audi Cabriolet), removing
 --> Transmission (vehicles with 6-cyl. 3.2 L FSI gasoline engine, also Audi Cabriolet), removing
 --> Installing transmission
Transmission (vehicles with 1.8 L turbo engine, also Audi Cabriolet), removing
1:57:29 AM Page 110

Fig. 128: Identifying Special Tools - Transmission (Vehicles With 1.8 L Turbo Engine, Also Audi
Cabriolet), Removing

 Engine/Gearbox Jack V.A.G 1383 A
1:57:29 AM Page 111


 Fender insert pads T40045
Work procedure

Fig. 130: Sliding Cover Over Battery To Right And Pull It Off Upwards
 Slide cover over battery to right - arrow 1 - and pull it off upwards - arrow 2 -.
1:57:29 AM Page 112

Fig. 131: Locating Battery Ground Strap

 With ignition switched off, disconnect Battery Ground (GND) wire - arrow -.

1:57:29 AM Page 113

Fig. 133: Placing Insert Pad For Front Fender T40045 On Both Sides Between Fender Attachment Edge
And Web Plate Lying Beneath
 Pull off sealing rubber at bolted flanges of fender.

 To prevent damage to bolted flanges of fender when using engine support bridge 10-222 A , insert fender
insert pads T40045 on both sides between bolted flange of fender and web plate lying beneath.
Fig. 134: Positioning Engine Support Bridge 10-222 A Onto Bolted Flange Of Fenders
 Position engine support bridge 10-222 A onto bolted flange of fenders; spindle stands at rear.
 Expose rear lifting eye on engine.
 Connect hook on spindle with lifting eye on back of engine.
 Take up some of the engine weight by tightening spindle of support bar, but do not lift.
1:57:29 AM Page 114


 On vehicles equipped with auxiliary heater, remove bolts - arrows - for exhaust pipe of
auxiliary/additional heater to noise insulation.

 Remove bolts or quick-release screws - 1 to 3 - and remove noise insulation at front and rear.
1:57:30 AM Page 115

Fig. 137: Removing Bracket For Noise Insulation

 Remove noise insulation bracket - arrows -.

1:57:30 AM Page 116

 Remove bolts - 1 through 4 - and remove rear cross member for vehicle floor:
 Remove bolts - 1 to 6 - and remove front cross member for vehicle floor.

1:57:30 AM Page 117

it may be damaged.

 Remove heat shield for exhaust system.
Fig. 142: Placing Plunger Of Engine/Transmission Jack V.A.G 1383 A With Block Of Wood Inserted In
Between On Transmission At Bottom
 Place plunger of Engine/Transmission Jack V.A.G 1383 A with a block of wood inserted in between - 1 -
on transmission at bottom.
 Support tunnel cross member using Engine/Transmission Jack V.A.G 1383 A.
CAUTION: The lock carrier must be installed - danger of injury.
Fig. 143: Removing Bolts & Slowly Release Rear Crossmember Using VAG1383A Engine/Transmission
Jack
 First remove bolts - 1 - and - 2 - , then bolts - 3 - and - 4 -.
1:57:30 AM Page 118

 Slowly lower tunnel cross member using Engine/Transmission Jack V.A.G 1383 A.
Fig. 144: Removing Nuts And Tunnel Cross Member

 Remove nuts - arrows - and remove tunnel cross member.

 Remove heat shield - 1 - for right drive axle.

 Remove drive axle from transmission flange on left and right sides --> 40 - FRONT SUSPENSION .
 Remove front exhaust pipe bracket - 1 -.
1:57:30 AM Page 119

Fig. 146: Removing Front Exhaust Pipe Bracket & Bolts Front Exhaust Pipe/Catalytic Converter
 Remove bolts - arrows - for front exhaust pipe/catalytic converter.
it may be damaged.
NOTE:  Observe the rules of cleanliness for working on automatic transmissions --

> Rules for cleanliness when working on transmission.
 Place an oil receptacle underneath transmission.
Fig. 147: Removing Union Nuts And Disconnecting ATF Lines

 Remove union nuts - 1 - and - 2 - and disconnect ATF lines.

 Remove bracket for ATF-lines - arrows -.
1:57:30 AM Page 120

Fig. 148: Removing ATF Filter On Transmission

 Remove ATF filter on transmission - arrows -.

Fig. 150: Removing Bolt And ATF Lines From Transmission
1:57:30 AM Page 121

 Remove bolt - arrow - and remove ATF lines from transmission.

 Disconnect ATF lines.
For transmission with right-angled connector:
Fig. 151: Disengaging Harness Connector From Transmission

 Disengage harness connector - A - in direction of - arrow - and disconnect it from transmission.

 Free up wiring harness.
For transmission with round connector:
Fig. 152: Disengaging Electrical Harness Connector And Disconnecting From Transmission
1:57:30 AM Page 122

 Disengage electrical harness connector - 1 - and disconnect from transmission.

 Move wiring harness clear - arrows -.
All:
1:57:30 AM Page 123

Fig. 155: Removing Bolts And Transmission Support From Transmission

 Remove bolts - 2 - and remove transmission support - 1 - from transmission.
Fig. 156: Identifying Engine/Transmission Mountings (Automatic/Manual Transmission)

 Remove bolts - 1 to 5 - and - 11 - on engine/transmission flange.

 Loosen bolt - 6 - only and then tighten by hand.
NOTE:  Starter must not be removed.
 Mount transmission support 3282 on Engine/Transmission Jack V.A.G 1383 A.
1:57:30 AM Page 124

Fig. 157: Identifying Template 3282/30

 Set Template 3282/30 on to transmission support 3282 (template only installs in one position).
 Align arms of transmission support to correspond with holes in adjustment plate.
 Attach support elements on adjustment plate, as illustrated.
Fig. 158: Moving Engine/Transmission Jack V.A.G 1383 A With Transmission Mount 3282 Under
Transmission And Support Transmission
 Move engine/transmission jack V.A.G 1383 A with transmission mount 3282 under transmission and
support transmission.
NOTE:  The arrow symbol on the adjusting plate points in direction of travel.
1:57:31 AM Page 125

 Align template parallel to transmission and secure to transmission using a bolt M10 x 20 - arrow -.
Audi Cabriolet:
NOTE:  So that the 4 engine/transmission connecting bolts at bottom can be

removed on the Audi Cabriolet, the following work steps must also be
performed:
 Raise transmission slightly using Engine/Transmission Jack V.A.G 1383 A.
Fig. 159: Removing Torque Support

 Remove torque support - arrows -.
Fig. 160: Swivel Stabilizer Bar Nuts, Engine Mountings Nut And End Of Stud
 Remove left and right nuts - 1 - and swing stabilizer bar - 2 - downward.
 Remove nuts - 3 - at engine mount on left and right far enough until lower edge of nut is flush with
threaded pin - arrow -.
 Raise engine using engine support bridge 10-222 A far enough until both nuts - 3 - (on left and right
1:57:31 AM Page 126

sides) make contact on plate from below.
All:

 Remove bolts - 7 to 10 - at engine/transmission flange.
Audi Cabriolet:
 Lower engine again.

 Lower transmission again slowly.
All:
 Tie up drive axles.

 Remove last engine/transmission mounting bolt.
 Press off transmission from bushings and let it down carefully.
Transmission (vehicles with 2.0 L normally-aspirated engine, also Audi Cabriolet), removing
1:57:31 AM Page 127

Fig. 162: Identifying Special Tools - Transmission (Vehicles With 2.0 L Normally-Aspirated Engine, Also
Audi Cabriolet), Removing

 Engine/Transmission Jack V.A.G 1383 A
1:57:31 AM Page 128


Work procedure

1:57:31 AM Page 129



Fig. 167: Disconnecting Air Guide Hose Between Mass Air Flow (MAF) Sensor And Intake Manifold
1:57:31 AM Page 130

 Disconnect air guide hose between Mass Air Flow (MAF) sensor and intake manifold - arrows -.

1:57:31 AM Page 131




1:57:31 AM Page 132



1:57:32 AM Page 133

 Remove bolts - 1 through 4 - and remove rear cross member for vehicle floor.

1:57:32 AM Page 134

it may be damaged.

Jack
1:57:32 AM Page 135




1:57:32 AM Page 136


 Remove bolts front exhaust pipe/catalytic converter - arrows -.
it may be damaged.
Fig. 182: Removing Bracket For ATF-Lines

 Remove bracket for ATF-lines - arrow -.
1:57:32 AM Page 137




 Move ATF lines clear to one side and secure in place.

1:57:32 AM Page 138


All:
1:57:32 AM Page 139



1:57:32 AM Page 140



 Set Template 3282/30 on to transmission support 3282 (template only fits in one position).
1:57:33 AM Page 141

NOTE:  The arrow symbol on the adjusting plate points in the direction of travel.


 Remove last bolt securing transmission to engine.
Transmission (vehicles with 2.0 L TFSI engine, also Audi Cabriolet), removing
1:57:33 AM Page 142

Fig. 193: Identifying Special Tools - Transmission (Vehicles With 2.0 L TFSI Engine, Also Audi

1:57:33 AM Page 143


Work procedure

1:57:33 AM Page 144




1:57:33 AM Page 145

 Position engine support bridge 10-222 A with adapters 10-222/3 on to bolted flanges of fender.
 Position engine support bridge 10-222 A with adapters 10-222 A/3 on to bolted flanges of fender.
 Engage spindles onto engine lifting eyes as shown.
 Pre-tension engine slightly using spindles on engine support bridge.
1:57:33 AM Page 146




 Loosen quick-release screws - 1 to 3 - and remove front and rear noise insulation.
1:57:33 AM Page 147



1:57:33 AM Page 148


it may be damaged.
 Loosen bolts of front double clamp - arrows -.

 To disconnect exhaust system, slide clamping sleeve toward rear.
1:57:34 AM Page 149

Jack

1:57:34 AM Page 150




it may be damaged.
1:57:34 AM Page 151




 Remove bolts - arrows - for front exhaust pipe/catalytic converter connection.

 Remove nut - 1 - on front exhaust pipe bar and remove front exhaust pipe.
1:57:34 AM Page 152






1:57:34 AM Page 153



 Disengage electrical harness connector - 1 - and disconnect it from transmission.

 Move wiring harness - arrows - to clear engine.
NOTE:  For the sake of illustration, shown with transmission removed.
1:57:34 AM Page 154

1:57:34 AM Page 155




1:57:34 AM Page 156



1:57:35 AM Page 157

Audi Cabriolet:

performed:
Fig. 224: Removing Bolts And Torque Supports From Oil Pan
 Remove bolts - arrows - and remove torque support.
1:57:35 AM Page 158


All:

Audi Cabriolet:

All:

Transmission (vehicles with 6-cyl. 3.0 L gasoline engine, also Audi Cabriolet), removing
1:57:35 AM Page 159

Fig. 227: Identifying Special Tools - Transmission (Vehicles With 6-Cyl. 3.0 L Gasoline Engine, Also Audi

1:57:35 AM Page 160


Work procedure
NOTE:  Reinstall cable ties that were loosened or cut off during removal at same
locations during installation.

1:57:35 AM Page 161



1:57:35 AM Page 162



 Remove left cover - 1 - in engine compartment.
Fig. 234: Removing Coolant Hoses

 Remove coolant reservoir - arrow -.

 Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant
expansion tank.
 Tie coolant expansion tank with connected coolant hoses - 1 to 3 - to side.
 If present, remove connector heat shield at left of bulkhead.
1:57:35 AM Page 163

Fig. 235: Removing Harness Connectors From Bracket At Left Of Bulkhead

 Remove electrical connectors - 1 through 4 - from bracket at left of bulkhead.

 Guide out wiring for lambda probes from below.
Fig. 236: Left Front Exhaust Pipe To Exhaust Manifold Nuts

 Remove nut - 2 - which is accessible from top for left exhaust pipe/exhaust manifold.
NOTE:  For the sake of illustration, shown with engine removed.
1:57:36 AM Page 164


 Remove right cover - 1 - in engine compartment.

 Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - at air duct.
 Remove air duct - 2 -.
1:57:36 AM Page 165

Fig. 239: Removing Air Filter Housing

 Remove air filter housing - arrows -.
Fig. 240: Identifying Holding Plate, Intake Air Hose, Hose & Air Duct
 Remove bolts for holding plate - 3 - for solenoid valves - arrows -.

 Disconnect electrical harness connector at Mass Air Flow (MAF) Sensor G70.
 Disconnect crankcase ventilation hose - 4 - from air guide - 2 -.
Fig. 241: Removing Bolt And Disconnect Air Duct At Throttle Valve Control Module
 Remove bolt - arrow - and disconnect air guide - 2 - from throttle valve control module.
 Disconnect hose - 1 - from air guide.
NOTE:  For sake of illustration, air guide is shown from rear with engine removed.
1:57:36 AM Page 166

Fig. 242: Removing Harness Connectors From Bracket At Right Of Bulkhead

 Remove electrical connectors - 1 through 4 - from bracket at right of bulkhead.

Fig. 243: Removing Nut Which Is Accessible From Top For Right Exhaust Pipe/Exhaust Manifold
 Remove nut - 2 - which is accessible from top for right exhaust pipe/exhaust manifold.
1:57:36 AM Page 167


1:57:36 AM Page 168

 Position engine support bridge 10-222 A onto bolted flange of fenders; spindle stands at front.


1:57:36 AM Page 169


Fig. 249: Removing Bolts For Front Vehicle Floor Crossmember

Fig. 250: Exhaust System And Clamps

1:57:36 AM Page 170

it may be damaged.
 Disconnect exhaust system at both double clamps - arrows -.
Jack

1:57:37 AM Page 171


Fig. 254: Removing Bolt For Noise Insulation Cover Over Left/Right Drive Axle, Disengaging Hook And
Removing Noise Insulation Cover
 Remove bolt - 1 - for noise insulation cover over left and right drive axle.
 Disengage hook - 2 - and remove noise insulation cover.
1:57:37 AM Page 172


 Remove left and right heat shields for drive axles - 1 -.

Fig. 256: Removing Bracket For Left Front Exhaust Pipe

 Remove bracket for left front exhaust pipe - arrow -.

 Free up oxygen sensor wiring.

 Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/left exhaust manifold.
 Remove front exhaust pipe complete with primary and main catalytic converter.
1:57:37 AM Page 173

Fig. 258: Removing Bracket For Right Front Exhaust Pipe

 Remove bracket for right front exhaust pipe - arrow -.

 Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/right exhaust
manifold.
1:57:37 AM Page 174

Fig. 260: Location Of Engine Speed (RPM) Sensor G28 On Coupling Housing
 Remove Engine Speed (RPM) Sensor G28 on left of transmission - arrow - and lay to side.


1:57:37 AM Page 175





1:57:37 AM Page 176


All:
1:57:38 AM Page 177


Fig. 268: Identifying Engine/Transmission Tightening/Loosening Sequence

1:57:38 AM Page 178


 Mount transmission support 3282 on the Engine/Transmission Jack V.A.G 1383 A.

1:57:38 AM Page 179

Audi Cabriolet:

performed:

1:57:38 AM Page 180

sides) make contact on from below.
All:

 Remove bolts - 1 - and - 9 through 11 - on engine/transmission flange.
Audi Cabriolet:

All:
 Move drive shafts towards rear.

Transmission (vehicles with 6-cyl. 3.2 L FSI gasoline engine, also Audi Cabriolet), removing
1:57:38 AM Page 181

Fig. 274: Identifying Special Tools - Transmission (Vehicles With 6-Cyl. 3.2 L FSI Gasoline Engine, Also

1:57:38 AM Page 182



 Drip tray for VAS 6100 VAS 6208
Work procedure

1:57:38 AM Page 183



1:57:39 AM Page 184



1:57:39 AM Page 185

Flanges
 Position engine support bridge 10-222 A with two adapters 10 - 222 A/3 on to bolted flanges of fender.

1:57:39 AM Page 186




1:57:39 AM Page 187


it may be damaged.
1:57:39 AM Page 188

Jack


1:57:39 AM Page 189

 If installed, remove bolt - 1 - for noise insulation cover over left and right drive axle.


 Remove left and right front exhaust pipe with catalytic converter -->
ENGINE CODE(S): BKH
.
1:57:40 AM Page 190



 Place drip tray for workshop crane VAS 6208 under transmission.

1:57:40 AM Page 191



 Seal openings with clean cover caps.

 Loosen bolts - arrows - at torque support stop approx. two rotations each.
1:57:40 AM Page 192


 Remove left and right stabilizer mounts - 1 - and - 2 -.

 Swing stabilizer downward.
 Raise engine using spindles of engine support bridge 10-222 A far enough until both nuts - 3 - (on left
and right sides) make contact on from below.
Between Transmission At Bottom
 Place plunger of Engine/Transmission Jack V.A.G 1383 A with a block of wood - 1 - inserted in between
transmission at bottom.
NOTE:
1:57:40 AM Page 193

 Lower connecting bolts on engine/transmission flange are accessible by

doing this.

 Remove bolts - 8, 9 and 10 - on engine/transmission flange.

 Lower engine again using spindles of engine support bridge 10-222 A.

1:57:40 AM Page 194




 Loosen bolts - 1 - and - 7 - only and then tighten by hand.
1:57:40 AM Page 195



1:57:41 AM Page 196


 Remove last mounting bolts - 1 - and - 7 - on engine/transmission flange.

 Press transmission off bushings - A - and carefully lower it far enough until selector lever cable is
accessible.

 Mark installation position of support bracket for selector lever cable.

 Remove bolt - 1 - support bracket for selector lever cable.
 Press selector lever cable ball joint - 2 - off from selector shaft lever.
1:57:41 AM Page 197

 Slowly lower transmission.

 Pay attention to clearance of drive axles when lowering transmission.
Installing transmission
NOTE:  Before installing a replacement transmission, clean ATF lines and ATF
cooler --> ATF lines and ATF cooler, cleaning.
 When performing repairs, replace self-locking nuts and bolts.
 Always replace bolts that are secured with tightening torque as well as
seals, gaskets and O-rings.
 Clean input shaft splines of transmission and damper unit splines on
flywheel, remove corrosion and apply only a very thin coating of lubricant
G 000 100 on splines. Excess grease must be removed.
 Secure all hose connections with hose clamps of the same type as those
equipped by the factory .
 When installing, bring all cable ties back to same positions.
 Check if alignment sleeves for centering engine/transmission are in cylinder block, and install if
necessary.
 Before installing transmission, tie electrical wiring to one side so that it cannot be trapped between engine
and transmission.
 Raise engine far enough until selector lever cable can be installed.
engages.
1:57:41 AM Page 198


 Carefully press ball socket of selector lever cable - 2 - onto lever for selector rod.
properly.
If bracket for selector lever cable - 3 - was removed from transmission:
 Tighten bolts - 2 - on bracket - 3 - for selector lever cable to 23 Nm on transmission.
1:57:41 AM Page 199


 Lightly grease ball socket of selector lever cable with polycarbamide
grease G 052 142 A2 before installing.

 Install support bracket for selector lever cable - 1 - according to marking on bracket.
 Place intermediate panel or intermediate plate onto bushings.
 Carefully raise transmission and bring into installation position using transmission support 3282.
1:57:41 AM Page 200

greased, oiled, covered with a thin coat of phosphate or blackened,
tightening torques Securing engine/transmission (transmission flange
pattern).
 Additional lubricant such as engine or transmission oil may be used, but
do not use graphite lubricant.
 Do not use degreased parts.
 Tolerance for torque specification ± 15%.
 Tighten connecting bolts on engine/transmission flange to tightening torque (tables Securing

engine/transmission (transmission flange pattern)).
 Tighten nuts for left and right engine mounts - 3 - -->

 10 - ENGINE - ASSEMBLY for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL,
ENGINE CODE(S): AMB
 10 ENGINE - ASSEMBLY for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE
CODE(S): AVK, BGN
 10 - ENGINE - ASSEMBLY for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE

(S): BNS
(S): BHF
.
 Tighten stabilizer bolts - 2 - --> 40 - FRONT SUSPENSION .
 Tighten bolts of torque support or torque support stop to engine -->
1:57:41 AM Page 201

ENGINE CODE(S): AMB

CODE(S): AVK, BGN
(S): BNS
(S): BHF
.

 Bolt transmission mount - 1 - onto transmission with bolts - 2 - --> Transmission mount, transmission
support and tunnel cross member, removing and installing
 Install ATF lines with new sealing rings --> ATF lines, ATF cooler and auxiliary ATF filter, servicing.
 Install exhaust system -->
ENGINE CODE(S): BKH
1:57:42 AM Page 202

.
 Install heat shield for left and right drive axle.

 Install tunnel cross member --> Transmission mount, transmission support and tunnel cross member,
 Align exhaust system so it is free of tension -->
ENGINE CODE(S): BKH
.
 Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component
Locations.


.
 Check adjustment of selector lever cable --> Selector lever cable (through VIN 8E_6A156499),
adjusting.
 Check oil level in front final drive --> Gear oil level in front final drive, checking.
 Check ATF level and top off --> ATF level, checking and topping off.
Securing engine/transmission (transmission flange pattern)
1:57:42 AM Page 203


Vehicles with 1.8 L turbo engine:
Item Bolt Nm
2, 3, 4, 6, 11 M12x67 65 * See note
5 M12x100 65 * See note
8 10 M10x45 45 * See note
A Alignment sleeves for centering
*Replace bolts.

Vehicles with 2.0 L normally aspirated engine:
Item Bolt Nm
1:57:42 AM Page 204


3, 4 M12x75 65 * See note
5 M12x110 65 * See note
8 10 M10x45 45 * See note
11 M12x90 65 * See note
*Replace bolts.

Vehicles with 2.0 L TFSI engine:
Item Bolt Nm
2, 3, 4, 6 M12x75 65 * See note
5 M12x100 65 * See note
8 10 M10x45 45 * See note
11 M12x67 65 * See note
*Replace bolts.
1:57:42 AM Page 205


Vehicles with 3.0 L 6-cyl. gasoline engine:
Item Bolt Nm
1, 10, 11 M10x60 45 * See note
2 M10x90 65 * See notes
3 M12x110 65 * See note
5, 6 M12x90 65 * See note
7 M10x100 45 * See note
*Replace bolts.
*Bolt strength rating 10.9
1:57:42 AM Page 206


Vehicles with 3.2 L FSI 6-cyl. gasoline engine:
Item Bolt Nm
1, 7 M10x115 65 * See note
2 M12x130 65
3, 4, 5, 6 M12x110 65
8, 9, 10 M10x80 45
*Bolt strength rating 10.9.
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Mounting base for selector lever cable to gearbox 23
Automatic transmission, transporting
1:57:43 AM Page 207

Fig. 319: Lifting Tackle T40013

 Lifting tackle T40013
Fig. 320: Identifying Transmission Lift Hook T40013 Used To Transporting The Transmission
Work procedure
The transmission lift hook T40013 can be used when transporting the transmission and for aligning
 Mount and secure transmission lift hook T40013 on upper rib of transmission housing as shown in the
illustration.
1:57:43 AM Page 208



 Holding fixture VW 313
 Transmission support VW 353
 Engine and Transmission Holder VW 540

Suspending transmission vertically
1:57:43 AM Page 209

Fig. 322: Securing Transmission To Assembly Stand With Bolts & Installing Transmission Support VW
353 Onto Holding Plate VW 309
 Secure transmission to assembly stand with bolts - 1 - and - 2 -.

 Install transmission support VW 353 onto holding plate VW 309.
Fig. 323: Using Workshop Crane VAS 6100 To Insert Transmission Into Holding Fixture VW 313
 Using workshop crane VAS 6100 , insert transmission into holding fixture VW 313.
CAUTION: Center of gravity of transmission is outside center of rotation at holding

fixture. To turn the transmission, a second technician must hold the
transmission housing to prevent back-swing.
Securing transmission in horizontal position
1:57:43 AM Page 210

Fig. 324: Securing Transmission In Horizontal Position

 Bolt transmission onto engine/transmission holder VW 540 - arrows -.


Transmission mount, transmission support and tunnel cross member, removing and installing


 Wooden block
Removing
1:57:43 AM Page 211



it may be damaged.
1:57:43 AM Page 212

Jack
1:57:44 AM Page 213


 Remove nuts - arrows - and slide tunnel cross member slightly toward rear.

 Remove bolts - 2 - and remove transmission mount - 1 - from transmission.
Installing
Installation is in reverse order of removal.
1:57:44 AM Page 214


Transmission mount - 1 - to transmission
 Bolts M8 - 2 - , tightening torque: 23 Nm

Transmission mount to tunnel cross member
 Nuts M8 - arrows - , tightening torque: 23 Nm
1:57:44 AM Page 215

Jack
Tunnel cross member to chassis
 Always replace bolts M12 - 3 - and - 4 - , tightening torque: 110 Nm plus an additional 90° (corresponds
to one-quarter turn)
 Bolts M10 - 1 - and - 2 - , tightening torque: 65 Nm

ENGINE CODE(S): BKH
.
ATF IN PLANETARY GEARING
ATF in planetary gearing
NOTE:  Rules of cleanliness for working on automatic transmissions --> Rules for
cleanliness when working on transmission.
 General repair notes --> Repair instructions.
1:57:44 AM Page 216

ATF level, checking and topping off
 Vehicle Diagnosis, Testing and Information System VAS 5051 A with Diagnostic cable VAS 5051/5A
Fig. 336: ATF Filler System F/CVT Transmission VAS 5162

 ATF filler system F/CVT transmission VAS 5162

 Safety glasses
 Oil receptacle

the planetary gear. ATF specifications --> Capacities.
1:57:44 AM Page 217

Fig. 337: Identifying Illustration On Reservoir For ATF Filler System F/CVT Transmission VAS5162
NOTE:  The illustration on the reservoir for Atf Filler System F/CVT Transmission
VAS5162 in upper left graphic refers to the use of special ATF for CVT
transmissions.
 The illustration also shows pictures of the steps required to fill the
transmission. These steps will be explained in the following.
CAUTION:  Engine must not be started if only a small amount or no ATF is in the
transmission after repair work or after significant ATF loss.
 In this case, a preliminary filling with 4.5 to 5 liters ATF must be
performed.
Test conditions
 Transmission not in emergency operating mode.

 Move vehicle onto a lifting platform or over a work pit so that it stands absolutely horizontal.
 Engine idling.
 Air conditioner and heating must be switched off.
1:57:45 AM Page 218


 Vehicle Diagnostic, Testing and Information System VAS 5051 A connected, Vehicle Self-Diagnosis and
vehicle system "02 - Transmission electronics" selected.
 ATF temperature must not be higher than 30°C at start of test, allow transmission to cool down if
necessary.
NOTE:  The ATF level will vary according to the temperature of the ATF.
 Checking ATF level at too low ATF temperature leads to overfilling.
 If the ATF level is checked when the ATF temperature is too high, this will
result in under filling.
 Over and under filling lead to impaired functioning of transmission.
 ATF temperature is read off on the Vehicle Diagnosis, Testing and
Information System VAS 5051 A.
1:57:45 AM Page 219


Display on VAS 5051 A :
 In selection - 1 - , click on diagnostic function "08 - Read measuring value block".

 In button field - 2 - , enter "10" for "Display group 10" and confirm input by pressing Q button.
1:57:45 AM Page 220


 Read off ATF temperature indicated in display field - 3 -.
Checking ATF level and topping off
NOTE:  Engine keeps running at idle speed.

 The ATF level is checked at the ATF inspection plug.
between 35°and 45°C (50°C for hot countries) ATF temperature (dependent
on the fluid level when warming up).
 Fill ATF filler system F/CVT transmission VAS 5162 with ATF for CVT transmissions.
 ATF specification --> Capacities.
CAUTION: The ATF filler tool must be clean and the ATF must not be mixed with any
other ATF oils!
1:57:45 AM Page 221

Fig. 342: Securing Filled Reservoir Of ATF Filler System F/CVT Transmission VAS 5162 As High As
Possible On Vehicle
 Secure filled reservoir of ATF filler system F/CVT transmission VAS 5162 as high as possible on
vehicle.
NOTE:  The shut-off valve on ATF filler system F/CVT transmission VAS 5162 must
be closed.
 While brake pedal is depressed, shift through all selector lever positions ("P" , "R" , "N" , "D" , "S") let
each position remain shifted at idle for approx. 2 seconds.

1:57:45 AM Page 222

Fig. 344: Identifying ATF Check Plug

 If an ATF temperature of 35°C is reached, remove ATF check plug - B -.
NOTE:  Approx. 5 cl of ATF will always drain initially from the internal oil level pipe
when the plug is removed.
If ATF continues to flow out of the ATF filler plug hole over the overflow tube before the ATF reaches
40°C, the ATF level is OK.
 Replace and tighten ATF check plug.
NOTE:  At the latest at 45°C (50°C for hot countries) the ATF check plug must be
installed again.
 At an ATF temperature above 45°C, too much ATF flows out due to heat up
and the transmission is not filled sufficiently!
The ATF check is now completed.
 Select "06 - End output".
 Switch off ignition and disconnect Data Link Connector (DLC).
Add ATF if no ATF has escaped from the ATF check plug hole by 40°C Filling ATF.
1:57:45 AM Page 223

Filling ATF

 Thread connection on shut-off valve of ATF filler system F/CVT transmission VAS 5162 into opening of
ATF check plug - B -.
Fig. 346: Rotating Shut-Off Valve In Direction Of Filler Hose & Filling ATF Into Transmission
 Rotate shut-off valve in direction of filler hose - lower arrow -. ATF flows into transmission.
 Hold a suitable container beneath outlet of ATF filler system F/CVT transmission VAS 5162.
1:57:46 AM Page 224

Fig. 347: Checking Atf Level By Rotating Shut-Off Valve In Direction Of Outlet
 Check ATF level by rotating shut-off valve in direction of outlet - lower arrow -.
ATF level is correct when ATF drips out only lightly from outlet before 45°C is reached.
NOTE:  Approx. 5 cl of ATF will initially drain from the internal oil level pipe. This
is normal.
 If no additional ATF flows out, rotate shut-off valve back in direction of filler hose and fill with more
ATF; repeat check of ATF level.
 After reaching correct ATF level, remove shut-off valve again.
NOTE:  After removing shut-off valve, ATF drips out lightly.
1:57:46 AM Page 225


NOTE:  At the latest at 45°C (50°C for hot countries) the ATF check plug - B - must
be installed again.
ATF, changing or filling after repairs
Fig. 349: Identifying Triple Square Socket Driver 3357

 Triple square socket driver 3357
1:57:46 AM Page 226



 Safety glasses
Work procedure
CAUTION: Do not allow engine to run without filling ATF and do not tow the vehicle.
 Observe disposal regulations!
 Always blow compressed air through ATF cooler and ATF lines (max. 10
mbar) and replace auxiliary ATF filter before installing a replacement
transmission --> Additional ATF filter.
other ATF oils!
1:57:46 AM Page 227

Possible On Vehicle
 Secure filled reservoir of ATF filler system F/CVT transmission VAS 5162 as high as possible on the
vehicle.
NOTE:  The shut-off valve on the ATF filler system F/CVT transmission VAS 5162
must be closed.


1:57:46 AM Page 228


 Remove ATF drain plug - A - using triple square socket driver 3357 and drain ATF.
 Tighten ATF drain plug again.
 Remove ATF check plug - B -.

1:57:47 AM Page 229

 Fill at least 4.5 to liters ATF into transmission.
 Selector lever in "P" , start engine and let it run at idle.
For vehicles as of model year 2005:
 Selector lever in position "P"
 Let engine run at high speed at a minimum of 2500 RPM by depressing accelerator pedal.
CAUTION: It is necessary to run engine at high speed so that ATF pump is ventilated
after performing repairs on the transmission.
All model years:
NOTE:  Observe all notes and test requirements for "Checking ATF level and
topping off".
ATF LINES, ATF COOLER AND AUXILIARY ATF FILTER, SERVICING
ATF lines, ATF cooler and auxiliary ATF filter, servicing
transmission --> ATF lines and ATF cooler, cleaning. If extremely dirty ATF
flows out when blowing with compressed air, ATF cooler and ATF lines
must also be flushed with clean ATF.
 To install, first insert ATF lines into transmission or cooler by hand as far
as they will go, then bolt on.
 Check ATF level --> ATF level, checking and topping off after replacing
ATF lines.
ATF lines, ATF cooler and auxiliary ATF filter (vehicles with 1.8 L turbo engine)
Part 1
1:57:47 AM Page 230

Fig. 355: ATF Lines, ATF Cooler And Auxiliary ATF Filter Overview (Vehicles With 1.8 L Turbo
Engine) Part 1
1 - Combi bolt, 5 Nm
2 - O-Ring
 Replace
 Insert with ATF
3 - O-Ring
 Replace
 Insert with ATF
1:57:47 AM Page 231

Part 2
Engine) Part 2
1 - Bracket
1:57:47 AM Page 232

3 - Additional ATF filter
 Must be replaced when transmission is malfunctioning

 Removing and installing --> Additional ATF filter
7 - Clamp
11 - Clamp
13 - Bracket
14 - Clamp
16 - Double bolt, 10 Nm
17 - Clamp
18 - Combi nut, 10 Nm
19 - O-Ring
 Replace
 Insert with ATF
20 - ATF line
21 - ATF line
1:57:47 AM Page 233

ATF lines, ATF cooler and auxiliary ATF filter (vehicles with 2.0 L normally aspirated engine)
Fig. 357: ATF Lines, ATF Cooler And Auxiliary ATF Filter Overview (Vehicles With 2.0 L Normally
Aspirated Engine)
1 - Bolt, 20 Nm
2 - ATF lines
3 - O-Ring
 Replace
 Insert with ATF
4 - ATF line
1:57:48 AM Page 234

5 - O-Ring
 Replace
 Insert with ATF

10 - O-Ring
 Replace
 Insert with ATF
11 - ATF line
15 - Bracket
17 - Clamp
ATF lines, ATF cooler and auxiliary ATF filter (vehicles with 2.0 L TFSI engine)
1:57:48 AM Page 235

Fig. 358: ATF Lines, ATF Cooler And Auxiliary ATF Filter Overview (Vehicles With 2.0 L TFSI Engine)
1 - Socket head cap screw, 21 Nm
2 - ATF lines
 To auxiliary ATF filter and to ATF cooler
3 - O-Ring
 Replace
 Insert with ATF
1:57:48 AM Page 236

5 - Bracket

11 - Clamp
15 - Clamp
17 - O-Ring
 Replace
 Insert with ATF
18 - ATF line
19 - ATF lines
20 - O-Ring
 Replace
 Insert with ATF
23 - Clamp
1:57:48 AM Page 237

25 - ATF lines
ATF lines, ATF cooler and auxiliary ATF filter (vehicles with 6-cyl. gasoline engine)
Fig. 359: ATF Lines, ATF Cooler And Auxiliary ATF Filter Overview (Vehicles With 6-Cyl. Gasoline
Engine)
2 - ATF lines
1:57:48 AM Page 238

3 - O-Ring
 Replace
 Insert with ATF
4 - ATF line
5 - O-Ring
 Replace
 Insert with ATF

10 - O-Ring
 Replace
 Insert with ATF
11 - ATF line
 Not installed on 3.2 L FSI engine
15 - Bracket
16 - 10 Nm
 Combination nut for 3.0 L engines

 Bolt for 3.2 L FSI engines
1:57:49 AM Page 239

18 - Clamp

 Hose diameter approx. 18 mm
 Compressed air gun, commercially available
 Safety glasses
Work procedure
 Before installing a replacement transmission, always blow into ATF cooler and ATF lines with
compressed air (max. 10 bar).
 Before installing a replacement transmission, always replace auxiliary ATF filter.
NOTE:  If extremely dirty ATF flows out when blowing with compressed air, ATF
cooler and ATF lines must also be flushed with clean ATF.
 ATF lines, removing and installing --> ATF lines, ATF cooler and auxiliary
ATF filter, servicing.
Additional ATF filter
transmission. If extremely dirty ATF flows out when blowing with
compressed air, ATF cooler and ATF lines must also be flushed with clean
ATF.
Auxiliary ATF filter, removing and installing (vehicles with 1.8 turbo and 2.0 L TFSI)
1:57:49 AM Page 240

 Oil receptacle
Removing


1:57:49 AM Page 241





 Remove clamp for ATF-lines - arrow -.
1:57:49 AM Page 242


 Remove auxiliary ATF filter on transmission - arrows -.
Installing
Component Nm
ATF auxiliary filter to bracket 20
ATF auxiliary filter bracket to transmission 40
ATF lines to transmission 21
Line clamp to engine 5
ATF line union nut 29
Auxiliary ATF filter, removing and installing (vehicles with 2.0 L normally aspirated- and 6-cyl. gasoline engine)
 Oil receptacle
Removing
NOTE:  Removal and installation is here described for vehicles with 6-cyl. gasoline
engine in the following. On vehicles installed with 2.0l engines
components inside the vehicle possibly look different from the ones
shown in the illustrations.
1:57:49 AM Page 243



 Loosen bolts or quick-release screws - 1 - and - 2 - and remove front noise insulation.

1:57:50 AM Page 244

Fig. 367: Removing Union Nut And Disconnecting Atf-Line To Auxiliary Atf Filter
 Remove union nut - arrow - and disconnect ATF-line to auxiliary ATF filter.
Fig. 368: Disconnecting Air Hoses At Secondary Air Injection (AIR) Pump
 Disconnect air hoses - 1 - and - 2 - at Secondary Air Injection (AIR) pump.
NOTE:  Electrical harness connector - 3 - remains connected.
1:57:50 AM Page 245

Fig. 369: Removing Bolts At Auxiliary Atf Filter Bracket

 Remove bolts - 1 - at auxiliary ATF filter bracket - 2 -.


1:57:50 AM Page 246


Fig. 373: Disconnecting ATF-Lines At Top And Bottom Of Radiator

 Disconnect upper ATF line - arrow - from cooler.

 Remove auxiliary ATF filter.
Installing
Component Nm
1:57:50 AM Page 247

ATF line to cooler 5

ATF BREATHER PIPE
ATF breather pipe
 If ATF flows out at underside of transmission bell housing, input shaft seal and/or ATF breather pipe may
be leaking. Before replacing any parts, be sure to find actual cause of malfunction.
 Input shaft seal must be replaced if leaking --> Input shaft seal, replacing.
 ATF breather pipe must be replaced if leaking.
ATF breather pipe, removing and installing
Removing
 Transmission removed.

1:57:51 AM Page 248

 Pull ATF breather pipe - A - out of mount.
NOTE:  If ATF leak is determined from check hole behind ATF breather pipe - A - ,
slightly below bolt - B - , transmission is malfunctioning and must be
replaced.
Installing
 Insert new ATF breather pipe - A - until it reaches stop.

 Tighten ATF breather pipe with strap and bolt - B - on transmission housing.
Component Nm
ATF breather pipe to transmission housing 25

End cover, removing and installing
1:57:51 AM Page 249

Fig. 375: Identifying Special Tools - End Cover, Removing And Installing

 Oil receptacle
Removing
1:57:51 AM Page 250


CAUTION: Do not run engine with the end cover removed or without ATF filling and
do not tow vehicle.
Jack
 Remove tunnel cross member --> Transmission mount, transmission support and tunnel cross
member, removing and installing.
Vehicles with oval connector:
1:57:51 AM Page 251


Vehicles with round connector:
All:
1:57:51 AM Page 252

1:57:52 AM Page 253


Fig. 382: Removing Bolts And End Cover

 Remove bolts - arrows - and remove end cover.
Installing
NOTE:  Replace sealing rings, seals and bolts for end cover.
1:57:52 AM Page 254

Fig. 383: Sliding New Twin Lip Oil Seal With Twin Lips Facing Outward Onto Connector At
 Slide new twin lip oil seal - A - with twin lips facing outward onto connector at Transmission Control
Module (TCM) J217.
1:57:52 AM Page 255

Module (TCM) J217.
All:
 Clean sealing surfaces on transmission housing and on end cover.

 If bushings were installed in transmission housing or in cover, they must be remounted in same location.
Module (TCM) J217.
NOTE:  There are metal and paper seals. The new seal must be made of the same
material as the old one .
 Make sure bushings are seated properly.
 Put on end cover and make sure seal does not slip.
1:57:52 AM Page 256

Fig. 386: Tightening New Bolts First Hand-Tight And In Diagonal Sequence
 Tighten new bolts - arrows - first hand-tight and in diagonal sequence, and then to tightening torque
(table Torque specifications).
 Check installation position of twin lip oil seal - A - :
 Twin lip oil seal must fit flush (sealing lips must not be twisted).
 Check installation position of twin lip oil seal - A - : It must fit flush (sealing lips must not be twisted).
1:57:52 AM Page 257

 Tighten bolts - 2 - of bracket for selector lever cable - 3 - on transmission.

engages.

carefully onto lever for selector shaft.
1:57:53 AM Page 258


properly.

 Bolt transmission mount - 1 - onto transmission - 2 - --> Transmission mount, transmission support
and tunnel cross member, removing and installing.
ENGINE CODE(S): BKH
.
 Fill with ATF --> ATF, changing or filling after repairs.
Component Nm
End cover to transmission, replace bolts 15 + 90°* See note
1:57:53 AM Page 259

Mounting base for selector lever cable to 23

transmission
* 90° is a quarter turn.
Transmission Control Module (TCM) J217 , removing and installing
 Remove end cover --> End cover, removing and installing.
The corresponding description for Transmission Control Module (TCM) J217 , removing and installing
can be found in --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS .
Selector shaft, cleaning
 Transmission Control Module (TCM) J217 removed
Work procedure
Fig. 391: Identifying Catch Of Selector Shaft, Spring & Roller

 Clean catch - arrow - of selector shaft. Do not use fluffy materials for cleaning. Clean contact surfaces of
magnet especially thoroughly of metal shavings and the like.
1:57:53 AM Page 260

NOTE:  Make sure that spring - A - and roller - B - are secured properly.

 If necessary, clean sensors - A - , - C - and - D - of soiling and metal shavings.

 Install Transmission Control Module (TCM) J217 --> Transmission Control Module (TCM) J217 ,
Hydraulic control module, removing and installing
 Always replace hydraulic control assembly if it has collected dirt or if it is
defective.
The corresponding description for removal and installation of the hydraulic control unit can be found in --> 38 -
AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS .
CAUTION: The hydraulic control assembly must not under any circumstances be
supported on the long pump shaft on the back side or raised up.
Otherwise, the blades inside the vane pump will be crushed and the pump
damaged.
Input shaft, removing and installing
1:57:53 AM Page 261

 Transmission removed and secured vertically to assembly stand

Suspending transmission vertically.
The corresponding description for removal and installation of the input shaft can be found in --> 38 -
Input shaft, servicing
The corresponding description, along with disassembling and assembling input shaft, can be found in --> 38 -

GEAR OIL IN FRONT FINAL DRIVE
Gear oil in front final drive
NOTE:  General repair notes --> Repair instructions.

 Rules of cleanliness for working on automatic transmissions --> Rules for
Gear oil level in front final drive, checking
NOTE:  The specified oil level must be maintained exactly; the transmission reacts
very sensitively to over-filling.
Test sequence
 Take vehicle for a short test drive to heat gear oil to approx. 60°C.
 Move vehicle onto a lifting platform or over a work pit so that it is absolutely level.
 Switch off engine and allow 5 minutes for gear oil to settle back into transmission case.
1:57:54 AM Page 262

 If installed, remove bolt - 1 - for noise insulation cover over left drive axle.
Fig. 395: Removing Inspection Plug

 Remove inspection plug - arrow -.

 Check oil level using a tool created in the workshop, e.g. an angled section of wire.
 Specified value: Oil level 8.5 mm below bottom of filler hole.
 If necessary, top off gear oil level.
 Axle oil specification --> Capacities.
1:57:54 AM Page 263

NOTE:  When servicing at the workshop the oil can also be filled up to the lower
edge of the oil filler hole. In this case it is necessary to draw off 0.2 ltr. to
attain the correct oil level.
 Tighten new screw plug.
Component Nm
Screw plug to transmission 20 * See note
*Replace screw plug.

Left flange shaft, removing and installing
Fig. 396: Drift VW 295

 Drift VW 295
1:57:54 AM Page 264


 Puller T10037
 Oil receptacle
Removing
 Transmission installed.
 Remove left front wheel.

1:57:54 AM Page 265


 Where installed, remove heat shield for left drive axle.
 Remove left drive axle.
1:57:54 AM Page 266

Fig. 401: Removing Drive Flange (Left Side)

 Tightly thread lower support of puller T10037 on cover for differential - arrow -.
NOTE:  To avoid damage to the needle bearings (polygon bearings) or differential

during removal, the flange shaft must be removed evenly, parallel and
without one sided pressure
 Pull left flange shaft using puller T10037 only far enough out until bearing on shaft is pulled out of
Installing
 Replace securing ring for flange shaft, to do this, clamp flange shaft in a vise with protective pads.
1:57:55 AM Page 267


 Press old securing ring out of groove of flange shaft with new securing ring - A -.
 A damaged sealing ring must be replaced --> Left flange shaft oil seal, replacing.
 Drive in flange shaft using needle bearing drift VW 295.
 Install left drive axle --> 40 - FRONT SUSPENSION .

 Check gear oil level in front final drive --> Gear oil level in front final drive, checking.
Component Nm
Right flange shaft, removing and installing
 Oil receptacle
Removing
 Remove right front wheel.
1:57:55 AM Page 268



1:57:55 AM Page 269


 Where installed, remove bolt - 1 - for noise insulation cover over right drive axle.
 Remove right drive axle --> 40 - FRONT SUSPENSION .
Fig. 406: Removing Mounting Bracket For Flange Shaft

 Remove mounting bracket for flange shaft - arrows -.

 Pull out right flange shaft together with mounting bracket.
Installing

 A damaged sealing ring must be replaced --> Sealing ring for right flange shaft and grooved ball
bearing, replacing.
Fig. 407: Replacing O-Ring, Sliding Spring With Cap Outward Into Hole On End Of Flange Shaft &
1:57:55 AM Page 270

Inserting Flange Shaft Into Transmission Housing

 Replace O-ring - arrow A - in mounting bracket for flange shaft.

 Slide spring - C - with cap outward into hole on end of flange shaft - arrow -.
 Insert flange shaft - B - into transmission housing.
NOTE:  While sliding in the flange shaft, make sure that spring - C - remains in the
flange shaft and does not fall into transmission.

 Tightly bolt mounting bracket for flange shaft - arrows -.

 Install right drive axle --> 40 - FRONT SUSPENSION .
Component Nm
Bearing bracket for right-hand flange shaft to 25
transmission
Left flange shaft oil seal, replacing
1:57:56 AM Page 271


Fig. 410: Fitting Drift 2062

 Driver 2062
Work procedure
 Remove left flange shaft --> Left flange shaft, removing and installing.
1:57:56 AM Page 272


 Pull out sealing ring for flange shaft using extractor lever VW 681.
NOTE:  Do not damage seating surfaces for oil seal.
Fig. 412: Flange Shaft Design

Setup of flange shaft with polygon bearing
1. Flange shaft
2. Needle bearing (polygon bearing)
3. Spacer ring
4. Circlip
5. Not installed
NOTE:  If the polygon bearings do not run smoothly with the flange shaft removed,
this does indicate that the bearings are faulty. A test for noisy bearings
can only be performed with the bearings installed.
1:57:56 AM Page 273

 Watch for damage to the polygon bearings (e.g. cracks in bearing outer
ring)
 If polygon bearings are damaged, flange shaft must be replaced.
 Coat outer edge and sealing lip of oil seal with axle oil.
Fig. 413: Driving In New Sealing Ring For Left Flange Shaft Uniformly Using Driver Below Surface Of
Cover
 Drive in new sealing ring for left flange shaft uniformly using driver 2062 5.5 mm below surface of
cover, do not cant when doing so.
NOTE:  If reinstalling an old flange shaft, the seal must be driven in approx. 6.5
mm so that the new seal does not sit on the running surface of the old
seal.
 Install left flange shaft --> Left flange shaft, removing and installing.
Sealing ring for right flange shaft and grooved ball bearing, replacing
1:57:56 AM Page 274

Fig. 414: Identifying Special Tools - Sealing Ring For Right Flange Shaft And Grooved Ball Bearing,
Replacing
 Pressure plate VW 401

 Punch VW 407
 Punch VW 412

1:57:57 AM Page 275

Fig. 415: Tube 2040

 Tube 2040

 Driver 2062
Work procedure
 Remove right flange shaft --> Right flange shaft, removing and installing.
Seal, removing
1:57:57 AM Page 276


 Remove securing ring - arrow A - for grooved ball bearing.
 Press flange shaft out of mounting bracket for flange shaft as shown in the illustration.
 Pull sealing ring for flange shaft out of mounting bracket using extractor lever VW 681.
1:57:57 AM Page 277


Sealing ring, installing
1:57:57 AM Page 278

Fig. 421: Pressing New Grooved Ball Bearing Into Mounting Bracket

 Drive in new sealing ring for right flange shaft uniformly using driver 2062 5.5 mm below surface of
mounting bracket, do not cant when doing so.
seal.
1:57:57 AM Page 279

 Press mounting bracket with grooved ball bearing onto flange shaft.

 Insert securing ring - arrow A -.

 Install right flange shaft --> Right flange shaft, removing and installing.
Input shaft seal, replacing
 Input shaft seal must be replaced if leaking.
 ATF breather pipe must be replaced if leaking --> ATF breather pipe.
1:57:58 AM Page 280

Fig. 424: Seal Remover T40014

 Seal remover T40014

Work procedure
1:57:58 AM Page 281

Fig. 426: Rotating Seal Ring Extractor T40014 By Hand Into Shaft Seal Until Tool Has Good Hold In
Shaft Sea
 Rotate seal ring extractor T40014 by hand into shaft seal until tool has a good hold in the shaft seal. Then
tighten puller with an open-end wrench.
 You can pull out oil seal a short distance by screwing in rear bolt of puller.
 Re-tighten extractor using open-end wrench so that extractor again grasps the shaft seal tightly and pull
out sealing ring further by tightening the screw.
 Repeat procedure until shaft seal has been pulled out completely.
NOTE:  Input shaft must be installed to install the shaft seal.
 Coat new shaft seal with ATF.
Fig. 427: Sliding Shaft Seal Onto Input Shaft With Open Side Facing Transmission
 Slide shaft seal - A - onto input shaft with open side facing transmission.
NOTE:  Slide sealing ring as far as possible into cover so that it cannot bend when
driving in.
1:57:58 AM Page 282

Fig. 428: Driving In Sealing Ring Until It Stops Using Thrust Piece T40015
 Drive in sealing ring until it stops using thrust piece T40015.
Fig. 429: Sleeve VW 418 A

 Tube VW 418 A
Work procedure
1:57:58 AM Page 283

 Remove bolt - B - completely and remove lever for selector shaft - A - upward.
 Carefully pry out sealing ring for selector shaft lying underneath using a screwdriver.
NOTE:  Sealing surface and selector shaft must not be damaged.
 Coat outer circumference of new sealing ring with ATF.

 Slide on new sealing ring over selector shaft and press in.
 Drive in sealing ring until it stops using tube 31.5 mm dia. VW 418 A.
 Connect lever for selector shaft - A - to selector shaft and tighten bolt - B -.
Component Nm
Lever for selector shaft to selector shaft 10
1:57:59 AM Page 284

TRANSMISSION Continuously Variable Transmission (CVT) 01J - Internal Components, Servicing
TRANSMISSION
Continuously Variable Transmission (CVT) 01J - Internal Components, Servicing

REPAIR INSTRUCTIONS
To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of
good and proper tools is essential. The usual basic safety precautions also, naturally apply when carrying out
vehicle repairs.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned
Transmission
 Observe rules of cleanliness for working on the transmission --> Rules for cleanliness when working on
transmission.
 After transmission repairs, clean ATF lines and ATF cooler --> 37 - AUTOMATIC TRANSMISSION -
CONTROLS, HOUSING .
 Reusable components must be cleaned, checked and reconditioned if necessary before installation -->
Transmission components, evaluating wear
 The old transmission should be installed and put into operation as quickly as possible to prevent corrosion
on the newly installed components.
After installing, following fluid levels must be checked and topped off if necessary:
 Top off ATF level after repair --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .
 Gear oil in front final drive --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Capacities and specifications --> 00 - GENERAL, TECHNICAL DATA .
O-rings, gaskets, seals
 O-rings, gaskets and seals must be replaced.

 To install, thinly coat gaskets along outer circumference and on sealing lip with ATF.
 Coat O-rings with transmission fluid or Vaseline before inserting to prevent crushing rings during
installation.
2:04:22 AM
2:04:34 Page 1
 When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip
of the old seal (use insertion depth tolerances).
 Replace paper seals, always clean sealing surfaces and remove old seals completely.
Bolts and nuts
 Loosen bolts in reverse order of tightening.

Fig. 1: Identifying Spring Pins Installation Position

Locking elements

 Replace spring pins. Installation position: Slot is longitudinal to line of force.
Bearings
 Slightly grease mount with ATF before inserting.

 Attach mount and adjustment shims only with Vaseline. Other lubricants cause malfunctions of the
hydraulic transmission controls.
Contact corrosion!
General:
2:04:23 AM Page 2
Contact corrosion can occur if non-approved fasteners are used on vehicle (bolts, nuts, washers, etc.).
For this reason, all fasteners used in production are specially treated. These parts can be identified by their
greenish color.
Rubber, plastic and adhesives also consist of non-conductive materials.
If you are not sure whether used parts can be re-installed, always install new parts.
The following points should be observed especially for transmission:
 Multitronic transmission 01J or 0AN housing is made of magnesium alloy.

 Bolts and other components which have direct contact with transmission have a surface coating which is
matched to magnesium transmission housing.
 On magnesium transmissions, bolts must always be replaced on following bolted connections:
Transmission housing cover and final drive cover on transmission housing as well as engine bolts on
transmission.
 Contact corrosion occurs when incorrect components (bolts, nuts, washers, etc.) are used. The
transmission housing will be damaged.
 Transmission housing, transmission cover and differential cover must all be of same material.
 If you are not sure whether used parts can be re-installed, always install new parts.
CAUTION:  Accessories must be approved by AUDI AG!

 Damage resulting from contact corrosion is not covered by the
warranty!
Rules for cleanliness when working on transmission

 Place removed parts on a clean surface and cover them. Use sheeting or paper. Use lint-free cloths only!
before.

ATF FLUSHING PROCESS
ATF flushing process
2:04:23 AM Page 3
 Vehicle Diagnosis, Testing and Information System VAS 5051 with Diagnostic cable VAS 5051/5A

 ATF filler system F/CVT gearbox VAS 5162

2:04:23 AM Page 4

 Drip tray
 Safety glasses
Work procedure
With normal ATF change, only about 55 to 60% of total ATF in transmission is replaced.
"ATF flush" procedure is necessary when old ATF in transmission must be removed completely.
ATF must always be flushed with following procedures:
 Changing input shaft

 Servicing input shaft
In addition, test run must be performed 2 times and afterwards ATF must be changed, as described below.
Only by doing this will ATF in transmission be changed completely.
CAUTION: If all these steps are not followed completely, transmission components
will be damaged.
 After installing transmission: --> ATF, filling for ATF flushing process.
CAUTION:  After installing the transmission with a new disc pack or input shaft,
the Vehicle Diagnosis, Testing and Information System VAS 5051 A
must check before the first drive whether or not update programming
in the Transmission Control Module (TCM) J217 must be carried out.
 If update programming is needed but not carried out, transmission
components will be damaged.
 If update programming is not needed but carried out, transmission
components will be damaged.
Check whether update programming in the Transmission Control Module (TCM) J217 must be carried
out.
 Vehicle Diagnosis, Testing, and Information System VAS 5051 connected.
 Vehicle-specific access to Vehicle Diagnosis, Testing, and Information System VAS 5051 in "Guided
Fault Finding".
 Using Goto button, select "Complaint registration " function in test plan and find following selection:
2:04:23 AM Page 5
Text lines to select

"Repair solution"
"Drive"
"Function"
" Jerking when
accelerating from stop"
 Press " Transfer" text line and select test program " Jerking when accelerating from stop".
NOTE:  Through this process in Vehicle Diagnosis, Testing, and Information

System VAS 5051 update programming is only carried out for the
Transmission Control Module (TCM) J217 if this is necessary.
 If necessary, carrying out update programming in Transmission Control Module (TCM) J217.
ATF flush
CAUTION: If all steps are not carried out in correct order or followed exactly,
transmission components will be damaged.
 --> Input shaft adjustment (air gap), checking

 First test run pass through: --> Carry out ATF flush test run.
 Second test run pass through: --> Carry out ATF flush test run.
 Check and correct ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .
topping off".
After ATF level is checked and restored, flushing process is complete.
Input shaft adjustment (air gap), checking
 ATF filled
 Drive vehicle off hoist.
NOTE:  On vehicles with air suspension, vehicle lifting mode must be deactivated -
-> 43 - SELF-LEVELING SUSPENSION .
 ATF filled
2:04:23 AM Page 6
 Place vehicle on level surface.
NOTE:  With parking brake released, vehicle may roll forward or backward by itself
when in selector lever position "N".
 Start engine.
 Place selector lever in position "N".
 Do not engage parking brake.

 Do not operate brake pedal.
 Press accelerator.
 Vehicle should not be allowed to roll.
If vehicle rolls in selector lever position "N":
 Adjust selector lever cable --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
If selector lever cable adjustment is OK but vehicle still rolls in selector lever position "N":
 Input shaft, servicing --> Input shaft, servicing with 6 lining discs or --> Input shaft, servicing with 7
lining discs
NOTE:  In this case, input shaft adjustment (air gap) was not performed correctly.
If vehicle does not roll in selector lever position "N" :
The input shaft adjustment with evaluation of air play is OK.
 Carry out ATF flush First test run pass through: under ATF flush
Carry out ATF flush test run
 ATF filled --> ATF, filling for ATF flushing process.

 The input shaft (air gap) adjustment is OK --> Input shaft adjustment (air gap), checking
 Drive vehicle off hoist.
NOTE:  On vehicles with air suspension, vehicle lifting mode must be deactivated -
-> 43 - SELF-LEVELING SUSPENSION .
2:04:23 AM Page 7
 Follow specifications exactly and carry out all safety instructions.
CAUTION: In following test drive, all traffic laws must be followed. If necessary,
vehicle must be driven on a test site.
 Start engine.
 Move wheels by lightly pressing accelerator.
 Note driving mode display in instrument cluster

 Move from 1st to highest gear by moving selector level towards "+".
 Then move back to 1st gear by moving selector lever back towards "-".
NOTE:  Press brake pedal if necessary
 Press brake pedal and brake wheels down to 0 km/h.

 Place selector lever in position "R".
 Accelerate wheels up to 20 km/h by lightly pressing accelerator.
 Press brake pedal and brake wheels down to 0 km/h.
 Place selector lever in position "D" again and repeat same procedure 5 times.
NOTE:  Process must be repeated five times so that all old ATF is mixed with new
ATF.
 Place selector lever in position "P" afterwards and switch engine off.
 Drain ATF --> ATF, draining for ATF flushing process.
 Fill with ATF --> ATF, filling for ATF flushing process.
 Carry out ATF flush ATF flush
ATF, draining for ATF flushing process
 Vehicle on a flat surface
NOTE:  Observe disposal regulations!

 Activate vehicle lifting mode --> 43 - SELF-LEVELING SUSPENSION before
driving vehicle with air suspension onto hoist, that is, with all four wheels
hanging.
2:04:23 AM Page 8
Fig. 5: Front And Rear Sound Insulation And Fasteners

 Loosen fasteners - 2 - and - 3 - and remove rear noise insulation - B -.


ATF, filling for ATF flushing process
CAUTION:  The Multitronic 01J or 0AN transmission requires a different ATF than
shift automatics. Only ATF for CVT transmission which can be
obtained as replacement part must be used .
2:04:23 AM Page 9
 Do not allow engine to run without filling ATF and do not tow the
vehicle.
 Vehicle on a flat surface
NOTE:  The illustration on the reservoir for ATF filler system F/CVT gearbox VAS
5162 in upper left graphic refers to the use of special ATF for CVT
transmissions.
2:04:23 AM Page 10
Fig. 8: Securing Filled Reservoir Of ATF Filler System F/CVT Gearbox VAS 5162 As High As Possible
On Vehicle
 Secure filled reservoir of ATF filler system F/CVT gearbox VAS 5162 as high as possible on the vehicle.
 The shut-off valve on the ATF filler system F/CVT gearbox VAS 5162 must be closed.
performed.

2:04:23 AM Page 11
 Thread connection on shut-off valve of ATF filler system F/CVT gearbox VAS 5162 into opening of
Fig. 10: Securing Filled Reservoir Of ATF Filler System F/CVT Gearbox VAS 5162 As High As Possible
On Vehicle
 Fill transmission with 5 Liter ATF.
CAUTION: Let engine run at high speed at "2500 - -3000 RPM" for approx. 4 to 5
seconds immediately after starting.
Running the engine at high speeds is necessary so that the ATF pump is
bled after a transmission repair.
If running at high speeds is not performed, the transmission can be

damaged.
 Start engine
 By pressing the gas pedal, run engine at high speed at "2500 - -3000 RPM" for approx. 5 seconds.
 Shift through all selector lever positions "P, R, N, D, S" and let each position remain shifted at idle for
approx. 2 seconds.
 Selector lever in "P" and let engine continue to run at idle.
2:04:23 AM Page 12

 Thread connection on shut-off valve of ATF filler system F/CVT gearbox VAS 5162 from ATF check
plug opening - B -.
 Allow excess ATF to drain off.
 Install ATF check plug - B -.
TRANSMISSION, ATTACHING TO ASSEMBLY STAND
2:04:23 AM Page 13



2:04:23 AM Page 14
 Secure transmission to assembly block with 2 bolts.

 Using Shop Crane VAS 6100 , insert transmission into Holding Fixture VW 313.



 Using Shop Crane VAS 6100 , insert transmission into Holding Fixture VW 313.

2:04:23 AM Page 15
SELECTOR SHAFT SEAL, REPLACING
Selector shaft seal, replacing

 Tube VW 418 A
Work procedure
Fig. 16: Removing Bolt Completely And Lever For Selector Shaft Upward
 Carefully pry selector shaft seal lying below out with screwdriver.
2:04:23 AM Page 16
 Coat outer circumference of new shaft seal with ATF.

 Slide on new shaft seal over selector shaft and press in.
 Drive in shaft seal until it stops using tube VW 418 A.
Component Nm
ATF BREATHER PIPE, REMOVING AND INSTALLING
If ATF flows out at underside of transmission bell housing, input shaft seal and/or ATF breather pipe may be
leaking. Before replacing any parts, be sure to find actual cause of malfunction.
Removing
NOTE:  Observe general repair notes --> Repair instructions .

 Transmission removed
2:04:23 AM Page 17

Installing
Installation in reverse order of removal, note the following:

Component Nm

End cover, transmission removed, removing and installing
2:04:23 AM Page 18
Fig. 18: Identifying Old Oil Collecting And Extracting Device V.A.G 1782
 General repair notes --> Repair instructions .
 To remove the end cover, the transmission must "not" be removed.
 End cover, removing with transmission installed --> 38 - AUTOMATIC
TRANSMISSION - GEARS, HYDRAULIC CONTROLS
Removing
 Transmission fastened vertically to assembly stand --> Transmission, attaching to assembly stand
 Place used oil collection and extraction device V.A.G 1782 under transmission.

2:04:23 AM Page 19
Fig. 20: Removing/Installing Bolts And End Cover

Installing
NOTE:  Replace seals and bolts for end cover.
2:04:23 AM Page 20
 Slide new gasket - A - with double lip outward onto connector on Transmission Control Module (TCM)
J217.
 If bushings were installed in transmission housing or in cover, they must be re-mounted in the same
location.
2:04:23 AM Page 21
Fig. 22: Placing New Seal For End Cover Onto Transmission Housing
 Place new seal for end cover - A - onto transmission housing.
 Put on end cover and make sure the seal does not slip.
Fig. 23: Removing/Installing Bolts And End Cover

 Tighten new bolts - arrows - first hand-tight and in diagonal sequence, and then to tightening torque.
 Check installation position of gasket - A - :
 Gasket must fit flush (sealing lips must not be twisted).
NOTE:  All instructions and steps for "Changing ATF or filling after a repair" must
be followed exactly --> 37 - AUTOMATIC TRANSMISSION - CONTROLS,
HOUSING
 Fill with ATF --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .
2:04:23 AM Page 22
Component Nm
End cover to transmission Replace bolts tighten 15 + 90°
diagonally

Removing
The Transmission Control Module (TCM) J217 can be removed with transmission installed.
 Remove end cover --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC

CONTROLS .
Fig. 24: Removing/Installing Bolts & Twin Lip Oil Seal

 Remove bolts - arrows - and pull out Transmission Control Module (TCM) J217 without tilting it.
 Remove twin lip oil seal - A - from Transmission Control Module (TCM) J217.
NOTE:  When positioning Transmission Control Module (TCM) J217 , ensure

sensor on control module is not damaged.
Installing
2:04:23 AM Page 23
NOTE:  Replace gaskets and O-rings.


 Clean selector shaft --> Selector shaft, cleaning.
Fig. 26: Coating New O-Rings On Hydraulic Control Module With ATF
 Before installing Transmission Control Module (TCM) J217 , coat new O-rings - A - on hydraulic control
module with ATF.
2:04:23 AM Page 24

 Install Transmission Control Module (TCM) J217 without canting it.
 Harness connectors - A - , - B - and - C - on rear side of control module must engage on hydraulic control
module.
Fig. 28: Removing/Installing Bolts & Twin Lip Oil Seal


 Install end cover --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS .
After connecting Transmission Control Module (TCM) J217 , the following steps must be performed:
 Complete coding for new Transmission Control Module (TCM) J217.
2:04:23 AM Page 25
 Perform adaptation for Transmission Control Module (TCM) J217.
Use Vehicle Diagnosis, Testing and Information System VAS 5051 for this.
Component Nm
Transmission Control Module (TCM) J217 to 10
hydraulic control module

Work procedure

CONTROLS .
 Remove Transmission Control Module (TCM) J217 --> Transmission Control Module (TCM) J217 ,

NOTE:  Make sure that spring - A - and roller - B - are properly secured.
2:04:23 AM Page 26



 Always replace a dirty or faulty hydraulic control module.
Removing

CONTROLS .
 Remove Transmission Control Module (TCM) J217 --> Transmission Control Module (TCM) J217 ,
2:04:23 AM Page 27

 Pull slider for selector lever position - C - downward out of bearing hole of hydraulic control module.
 Disengage spring - A - from selector shaft - D -.
 Remove bolts - arrows - and remove hydraulic control module.
damaged.
Installing
NOTE:  Replace gaskets and O-rings.
2:04:23 AM Page 28
Fig. 33: Identifying Axial Sealing Elements, Cover, Selector Shaft & Shifting Cam
 Replace axial sealing elements - A - (qty. 4) and - B -.

 Coat axial sealing elements with ATF before installing.
 Axial sealing elements - A - must be inserted into mounts with smaller diameter facing transmission.
 Install cover - C - , while doing so note locating tab.
 Locating tab on rear side of cover must be inserted into small hole on transmission surface.
 Push lever for selector shaft - 2 - completely toward front until it stops so that shifting cam - 1 - stands
almost vertically (with slight tilt toward right).
2:04:23 AM Page 29
Fig. 34: Pressing Control Piston On Rear Side Of Hydraulic Control Module Completely Inward Until It
Engages Into Assembly Spring
 Press control piston - B - on rear side of hydraulic control module completely inward (left) until it
engages into assembly spring - A -.
 Insert hydraulic control assembly into transmission. Align unit properly to fit without jamming.
NOTE:  When installing control module, make sure that shifting cam (item 1 in Fig.
33 ) engages into free groove - arrow - on control piston - B -.
2:04:24 AM Page 30
 Hand-tighten bolts - arrows -. Bolt - arrow 1 - is shorter than the other two bolts.
 Check that cover is properly mounted.
 Locating tab - B - must be inserted into hole intended for it on the transmission.
Check function of control piston
Fig. 36: Moving Selector Shaft At Detent Plate

 Move selector shaft at detent plate - C - or at lever for selector shaft several times toward left and right.
 When doing this, control piston - B - must travel outward and inward accordingly - arrow -.
2:04:24 AM Page 31
Fig. 37: Pressing Control Piston On Rear Side Of Hydraulic Control Module Completely Inward Until It
Engages Into Assembly Spring
If control piston does not move, shifting cam has not engaged into groove - arrow - at control piston on rear
side of hydraulic control module. In this case:
 Remove hydraulic control module once again and insert again.
2:04:24 AM Page 32
Installing slider for selector lever position

 Connect roller - B - with collar downward onto slider for selector lever position - C -.
 Engage spring - A - into selector shaft - D - and slider for selector lever position.
 Slide slider for selector lever position into bearing hole in housing of hydraulic control module.
NOTE:  For the sake of illustration, transmission is shown without hydraulic

control module.
Fig. 40: Identifying Axial Sealing Elements, Cover, Selector Shaft & Shifting Cam
2:04:24 AM Page 33
 Shift lever for selector shaft - 2 - toward front and rear until stop:

 Detent plate - arrow - moves toward front or toward rear.

 When doing this, it must allow the roller - B - to be engaged in the individual notches.
 Slider for selector lever position - C - moves in steps toward front or rear.
 Roller must be installed with collar facing downward so that it cannot be pulled off upward.
 Clean selector shaft --> Selector shaft, cleaning.

 Insert Transmission Control Module (TCM) J217 with new O-rings --> Transmission Control Module
 After installing transmission, check ATF level and correct --> 37 - AUTOMATIC TRANSMISSION -
CONTROLS, HOUSING .
Component Nm
Hydraulic control module to transmission housing 10
 ATF breather pipe must be replaced if leaking --> ATF breather pipe, removing and installing.
2:04:24 AM Page 34


Work procedure

2:04:24 AM Page 35
Shaft Sea
 Rotate seal ring extractor T40014 by hand into shaft seal until the tool has a good hold in the shaft seal.
Then tighten puller with an opened wrench.
 You can pull out shaft seal a short distance by screwing in rear bolt of puller.
 Re-tighten puller T40014 so that it re-engages securely in the shaft seal and continue tightening shaft seal
by installing bolt.
 Input shaft and flange cover must be installed to install seal.
 Coat new shaft seal - A - with ATF.

 Slide shaft seal onto input shaft with open side facing transmission.
NOTE:  Slide shaft seal as far as possible into cover so that it cannot bend when
driving in.
2:04:24 AM Page 36
 Drive in shaft seal until it stops using thrust piece T40015.

 After installing transmission, check ATF level and correct --> 37 - AUTOMATIC TRANSMISSION -
CONTROLS, HOUSING .

 Puller T40050
Removing

2:04:24 AM Page 37

 Drain ATF --> ATF, draining for ATF flushing process , pivot transmission in installation position
(level),
NOTE:  Transmission must not be turned so that flange points downward.
Fig. 48: Removing Bolts


 Using a plastic mallet, carefully knock input shaft flange cover so that input shaft flange cover loosens
itself from seal.
Fig. 49: Securing Puller T40050 On Transmission Input Shaft

 Secure Puller T40050 on transmission input shaft.

 Check Puller T40050 for secure seating on input shaft.
 Circlip must be pushed all the way down.
2:04:24 AM Page 38
 Pull input shaft with flange cover and forward clutch on Puller T40050 out of transmission housing -
arrow -.
CAUTION:  Input shaft must not be set down on the projecting oil pipe - arrow -
otherwise it will be damaged.
 If the oil pipe is damaged, starting problems or a transmission
malfunction will result.
Fig. 50: Identifying Oil Pipe

CAUTION: The reverse gear clutch plates must not be removed from the transmission
housing.
Installing
 Check wear on transmission components --> Transmission components, evaluating wear

 Clean sealing surfaces on transmission housing and flange cover.
2:04:24 AM Page 39
Fig. 51: Checking Whether Bushings For Centering Flange Cover On Transmission Housing Are
Installed And Seated Securely
 Check whether bushings - arrows - for centering flange cover on transmission housing are installed and
seated securely.
Fig. 52: Checking Condition Of Sealing Ring

 Check condition of sealing ring - arrow - , replace if necessary.
 Installation position of oil seal: Sealing lip towards flange cover.
 Place paper gasket in position.
2:04:24 AM Page 40
Fig. 53: Aligning Clutch Discs Of Reverse Gear Clutch E.G. Using Straight-Edge
 Align clutch discs of reverse gear clutch e.g. using a straight-edge.
 Splines must stand exactly in a row.

 Check installation dimension of oil pipe - arrow - :
 If oil pipe is inserted completely, the dimension from its end to the input shaft is approx. 11.5 mm.
If the dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.
If the dimension is larger, it is not pushed in far enough.
2:04:24 AM Page 41
 Insert entire input shaft into transmission housing.
Fig. 55: Using Back And Forth Rotating Motions On Input Shaft Until Clutch Discs Of Reverse Gear
Clutch Have Engaged
 Use back and forth rotating motions - arrow - on input shaft until clutch discs of reverse gear clutch have
engaged. Raise input shaft slightly when doing this.
 Just before the input shaft is fully in position, rotate it counter-clockwise over the last few millimeters so
that it engages in the teeth of the helical intermediate gearing.

 Tighten bolts - arrows - in diagonal sequence and in stages.

2:04:24 AM Page 42
obtained as replacement part must be used in planetary gearing .
 Flush ATF after installing transmission --> ATF flushing process.
Component Nm
Flange cover on transmission housing 23

Fig. 58: Pressure Stand T40099

2:04:24 AM Page 43
 Pressure stand T40099

 Ice spray
 Protective gloves
Removing:
 Input shaft removed --> Input shaft, removing and installing.

 Pull oil pipe - arrow - upward and out to avoid damage.
Fig. 60: Checking All 8 Screws On Pressure Stand T40099

 Check all 8 screws - arrows - on Pressure Stand T40099.
2:04:24 AM Page 44
 Screws must be installed flush to 25 Nm Assembly instructions for pressure stand T40099.
Fig. 61: Pulling Out Input Shaft

 Insert input shaft in pressure stand T40099.

tighten puller with an opened wrench.
 You can pull out shaft seal a short distance by installing rear bolt - arrow -.
 Re-tighten Seal ring extractor T40014 so that puller engages securely in shaft seal again and continue
turning bolt to pull out shaft seal.
Fig. 62: Removing Input Shaft Cover Circlip

2:04:24 AM Page 45
 Remove input shaft cover circlip - A -.

 Measure and note thickness of removed circlip.
NOTE:  When installing, circlip must be replaced with a new circlip of same
thickness.
Fig. 63: Cleaning Cover Sealing Surface

 Clean cover sealing surface - arrow -.
The ice spray can reach temperatures under 0° Celsius which can freeze
the skin without protective gloves.
2:04:24 AM Page 46
Fig. 64: Cooling Hollow Shaft On Inside Of Ball Bearing Seat Over Opening Of Removed Oil Pipe With
Ice Spray
 Cool hollow shaft - 1 - on inside of ball bearing - 2 - seat - arrow 2 - over opening - arrow 1 - of
removed oil pipe with ice spray, for example.
NOTE:  Shaft represented in section here.

 Shaft must be cooled so that ball bearing - 2 - can be pressed off more
easily and not be damaged.
Fig. 65: Inserting Input Shaft In Pressure Stand T40099

 Clean surface of pressure stand T40099.

 Insert input shaft in pressure stand T40099.
 Input shaft sealing surface must be flush.

 There must be no objects such as cable ties or dirt between input shaft sealing surfaces and surface of
pressure stand T40099.
CAUTION: Shavings or dirt damage cover sealing surfaces when pressed, cover must
then be replaced.
 Also cool shaft from outside - arrow - with ice spray, for example.
NOTE:
2:04:24 AM Page 47
 Shaft must be cooled so that ball bearing can be pressed off more easily
and not be damaged.
 Place input shaft together with pressure stand T40099 on hydraulic press thrust plate.
NOTE:  Pressure stand T40099 should lie on as much surface of hydraulic press
as possible.
Fig. 66: Holding Shaft From Below And Pressing Shaft Out Of Cover With Hydraulic Press
 Hold shaft from below and at the same time, press shaft out of cover with hydraulic press.
Fig. 67: Placing Input Shaft On Assembly Tool T10219/1

2:04:24 AM Page 48
 Place input shaft on assembly tool T10219/1.
NOTE:  Ignore screwdriver and arrows.
Installing:
 Replace ball bearing in input shaft cover --> Ball bearing in input shaft cover, replacing
Fig. 68: Placing Input Shaft Cover On Input Shaft And Pressing On By Hand As Far As Possible
 Place input shaft cover on input shaft and press on by hand as far as possible.
Fig. 69: Placing Input Shaft On Thrust Plate VW 401 & Pressing Input Shaft Cover With Tube VW 416
B Onto Input Shaft Up To Stop
2:04:24 AM Page 49
 Place input shaft - B - on Thrust plate VW 401.
CAUTION: Place input shaft straight and centered under hydraulic press thrust disc;
otherwise input shaft can tip to the side when cover is pressed on.
 With hydraulic press, press input shaft cover - A - with Tube VW 416 B onto input shaft up to stop.
Input shaft cover circlip, installing
Fig. 70: Input Shaft Cover Circlip, Installing

 When installing, circlip - A - must be replaced with a new circlip of same thickness.
NOTE:  Check for correct circlip seating.
Oil pipe, installing
 Check wear on transmission components --> Transmission components, evaluating wear
2:04:25 AM Page 50
Fig. 71: Identifying O-Ring, Oil Pipe & Rotor Blades

 Replace O-ring on oil pipe - 2 -.
 The oil pipe is pressed into the input shaft with the O-ring - 2 -.
 Oil pipe must engage noticeably, rotor blades - arrow A - on oil pipe must lie completely in input shaft.

 Press oil pipe - arrow - down into input shaft to stop.
 If oil pipe is inserted completely, the dimension from its end to the input shaft is approx. 11.5 mm.
If dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.
If dimension is larger, it is not pushed in far enough.
2:04:25 AM Page 51
Ball bearing in input shaft cover, replacing
 Input shaft cover removed --> Torsen differential cover, removing and installing.
Fig. 73: Identifying Circlip, Ball Bearing & Input Shaft Cover
Assembly overview
1. Circlip, measure and always replace

2. Ball bearing, always replace
3. Input shaft cover
Removing
2:04:25 AM Page 52
Fig. 74: Identifying Circlip

 Remove circlip - A -.
 Measure and note thickness of removed circlip.
NOTE:  When installing, circlip must be replaced with a new circlip of same
thickness.
Fig. 75: Laying Input Shaft Cover On Pressure Stand T40099, Placing Under Hydraulic Press & Pressing
Ball Bearing With Tube VW 416 B Out Of Input Shaft Cover
 Lay input shaft cover - 1 - on pressure stand T40099 and place under hydraulic press.
 Press ball bearing with Tube VW 416 B out of input shaft cover.
2:04:25 AM Page 53
NOTE:  In some cases, ball bearing can also be pressed out by hand without
hydraulic press.
 Ball bearing must be replaced.
Installing
Fig. 76: Cleaning Cover Sealing Surface

 Check cover sealing surface - arrow - and cover for damage:
 Surface of sealing surfaces must not show any damage.

 Input shaft cover must not be broken cracked.
NOTE:  The illustration is shown with input shaft.
If sealing surface or cover is damaged:
 Replace input shaft cover.
NOTE:  A new ball bearing is installed with a new input shaft cover.
If sealing surface and cover are not damaged:
 Replace ball bearing.
2:04:25 AM Page 54
Fig. 77: Identifying Circlip, Ball Bearing & Input Shaft Cover
 Clean ball bearing seat in cover - arrow B -.
CAUTION: Note ball bearing position:
 The ball bearing cause must face downward in cover.

 The open side of the ball bearing must face upward, the balls - arrow
A - in the bearing must be visible when inserting.
If the ball bearing is installed incorrectly, it can be damaged during

operation and the transmission could possibly be damaged.
 Install ball bearing - 2 - flush and press in by hand as far as possible.
2:04:25 AM Page 55
Fig. 78: Laying Input Shaft Cover On Thrust Plate VW 401 & Using Tube 2010 To Press Ball Bearing In
As Far As Stop
 Lay input shaft cover on Thrust plate VW 401.

 Using a Tube 2010 , press ball bearing in as far as stop.
Fig. 79: Identifying Circlip

 When installing, circlip - A - must be replaced with a new circlip of same thickness.
 Check for correct circlip seating, push ball bearing in or use next thinnest circlip, if necessary.
INPUT SHAFT, SERVICING WITH 7 LINING DISCS
Input shaft, servicing with 7 lining discs
2:04:25 AM Page 56
CAUTION:  Servicing with the incorrect number of lining discs leads to input
shaft damage after bringing vehicle into operation again.
 In this case, the software in the Transmission Control Module (TCM)
J217 does not match the number of lining discs.
There are two types of transmissions. They are differentiated according to transmission code :
1. Transmission with 7 lining discs serviced
These transmissions are installed in vehicles with 4-cyl. 1.9L TDI engine, 4-cyl. 2.0L TDI engine, 6-cyl. 2.5L
TDI engine, 6-cyl. 3.0L MPI gasoline engine and 6-cyl. 3.2L FSI gasoline engine.
 --> Input shaft with 7 lining discs, assembly overview

 --> Input shaft with 7 lining discs, disassembling and assembling
These transmissions are installed in vehicles with all other engines.

Input shaft with 7 lining discs, assembly overview
CAUTION:  Note the difference between input shafts with 6 and 7 lining discs -->
Fig. 80: Input Shaft With 7 Lining Discs, Assembly Overview
2:04:25 AM Page 57
1 - Input shaft seal
 Replace --> Input shaft seal, replacing
2 - Input shaft cover circlip
 Replace with same thickness
3 - Input shaft cover
 After removing cover, input shaft cover ball bearing must be replaced --> Ball bearing in input shaft
cover, replacing
4 - Piston
 Check for wear --> Transmission components, evaluating wear
5 - Pressure plate
6 - Corrugated spring washer
7 - Upper adjustment disc
 Determine thickness --> Input shaft with 7 lining discs, adjusting with air gap determination
 Replace
8 - Coated plate
 Qty. 7
 Replace
9 - Outer plate
 Qty. 6
 Replace
10 - Lower adjustment disc
 Replace
11 - Input shaft cylinder
2:04:25 AM Page 58
12 - O-Ring
 Replace
13 - Oil pipe
Input shaft with 7 lining discs, disassembling and assembling
Fig. 81: Identifying Special Tools - Input Shaft With 7 Lining Discs, Disassembling And Assembling (1 Of
2:04:25 AM Page 59
2)

 Assembly tool T10219/1
 Tube 2010
 Tube VW 416 B
Fig. 82: Identifying Special Tools - Input Shaft With 7 Lining Discs, Disassembling And Assembling (2 Of
2)
2:04:25 AM Page 60

 2 piece ruler T40100
 4 piece calipers T40101
 2 piece feeler gauge T40102 for input shafts with 7 lining discs

 Ice spray
Input shaft, disassembling

 Remove input shaft --> Input shaft, removing and installing.

 Remove input shaft cover from shaft --> Torsen differential cover, removing and installing


 Carefully raise thrust plate with pistons with two screwdrivers - arrows -.
2:04:25 AM Page 61
Fig. 84: Inner Running And Sealing Surfaces Of Thrust Plate And Pistons
Precautionary measures:
CAUTION:  The inner running and sealing surfaces - arrow A - of the thrust plate
and pistons - arrow C - must not touch shaft during removal and
installation.
 The running and contact surfaces must not show the smallest signs
of damage such as scratches or grooves as a result of removing or
installing.
 If damaged, the thrust plate or pistons must be replaced.
2:04:25 AM Page 62
Fig. 85: Guiding Thrust Plate With Pistons Up Over Shaft

 Carefully guide thrust plate - 1 - with pistons - 2 - up over shaft - 3 -.
 Inner running surfaces of thrust plate - 1 - and pistons - 2 - must not touch shaft.
Disc pack, removing
Fig. 86: Identifying Disc Pack

2:04:25 AM Page 63
 Remove corrugated spring washer - 5 - , they must be used again.

 Remove upper adjustment disc - 4 - from input shaft cylinder - A -.
 Measure adjustment disc thickness - 4 - and note measurement.
 Remove all lining discs - 2 - and outer discs - 3 - from input shaft cylinder - A -.
NOTE:  With old version of input shaft, only 6 lining discs and 5 outer discs are
installed. They must also be replaced with new disc pack with 7 lining
discs and 6 outer discs .
 Remove lower adjustment disc - 1 - from input shaft cylinder - A -.

CAUTION:  All old, used adjustment discs, outer discs and lining discs must be
replaced. They must not be reinstalled as that would not ensure the
input shaft function (surface is used up).
 The corrugated spring washer must be used again.
Input shaft, assembling
CAUTION: Before assembly, check for wear on transmission components.
 Replace ball bearing in input shaft cover --> Ball bearing in input shaft cover, replacing.
 Adjust input shaft and determine air gap --> Input shaft with 7 lining discs, adjusting with air gap
determination

2:04:25 AM Page 64

 Insert determined lower adjustment disc - 1 - in input shaft cylinder - A -.

 Insert alternately and with same alignment each lining disc - 2 - (7 pieces) and outer disc - 3 - (6 pieces,
1.9 mm thickness).
Fig. 89: Lining Disc Alignment

Lining disc alignment:
2:04:25 AM Page 65
CAUTION:  The lining discs must be installed with the same alignment, that is
the places without outside teeth - arrows - must always lie one on top
of the other. Only in this way is the adjustment correct; you must
mark the cylinder for correct installation, if necessary.
installed. They must also be replaced with new disc pack with 7 lining
discs and 6 outer discs .

 Insert determined upper adjustment disc - 4 - in input shaft cylinder - A -.

 Lastly, insert corrugated spring washer - 5 -.
2:04:26 AM Page 66
 Press piston - 1 - into stop on thrust plate - 2 -.
installation.
installing.
2:04:26 AM Page 67

 Carefully guide pressure plate - 1 - with pistons - 2 - down over shaft - 3 -.
 Press thrust plate with pistons uniformly into input shaft up to stop.
Fig. 93: Checking Air Play With Feeler Gauge T40102

2:04:26 AM Page 68
Checking air play with feeler gauge T40102
 Insert both feeler gauges T40102 under thrust plate - A -.

 A second technician must push thrust plate - A - down to stop - arrow 1 - with Tube VW 416 B.
 Guide both feeler gauges T40102 circularly in direction of - arrow - back and forth under thrust plate.
 Both feeler gauges T40102 must be guided oppositely.

 Feeler gauges T40102 must not be angled.
 Entire circular area must be checked.
 Both feeler gauges T40102 must always move freely without slightest resistance.
If feeler gauges T40102 cannot be guided in direction of - arrow - without blocking:
 Repeat input shaft adjustment --> Input shaft with 7 lining discs, adjusting with air gap
determination.
CAUTION: Air play must pass check with feeler gauges T40102 , otherwise
transmission will exhibit problems after reassembly.
If feeler gauges T40102 can be guided in direction of - arrow - without blocking:
 Install input shaft cover --> Torsen differential cover, removing and installing.

 Install input shaft --> Input shaft, removing and installing.
2:04:26 AM Page 69
 Install input shaft seal - A - --> Input shaft seal, replacing.

Input shaft with 7 lining discs, adjusting with air gap determination

 All components must be cleaned thoroughly before inserting.
Clutch measurement
Fig. 96: Identifying Distance Of Clutch From Upper Contact Ring Shim On Shaft & Corrugated Spring
2:04:26 AM Page 70
Washer Is Installed Under Disc Pack

NOTE:  Distance - K - of the clutch from the upper contact ring shim on the shaft
(Thrust plate contact surface) is determined.
 The corrugated spring washer - 1 - is installed under the disc pack to
perform measurements.

Fig. 98: Identifying Adjustment Discs, Lining Discs, Outer Discs And Corrugated Spring Washer
2:04:26 AM Page 71
 Insert new lower adjustment disc - 1 - of same thickness as old in input shaft cylinder - A -.
 Insert corrugated spring washer - 2 -.
NOTE:  The corrugated spring washer is installed at the bottom only for
measurement, it is installed again at the time during assembly.
1.9 mm thickness).

installed. They must be replaced with new disc pack with 7 lining discs
and 6 outer discs .
2:04:26 AM Page 72
 Last, insert new upper shim - 5 - of same thickness as old in input shaft.
NOTE:  For the following measurements, all tool and component surfaces must be
completely clean in order to obtain exact values.
Fig. 101: Placing 4 Calipers T40101 On Upper Shim

2:04:26 AM Page 73
 Place 4 calipers T40101 on upper shim.
Fig. 102: Laying Ruler T40100 Centered Over Every 2 Calipers T40101
 Lay a ruler T40100 centered over every 2 calipers T40101.
Fig. 103: Measuring Shim With Digital Depth Gauge VAS 6087 And Note Measurement
 Measure shim with digital depth gauge VAS 6087 and note measurement - A -.
 Digital depth gauge VAS 6087 must lie flush on both rulers T40100 when measuring.
2:04:26 AM Page 74
Fig. 104: Measuring With Digital Depth Gauge VAS 6087 On Shaft Contact Ring (Thrust Plate Contact
Surface) And Note Measurement
 Measure with digital depth gauge VAS 6087 on shaft contact ring (Thrust plate contact surface) and note
measurement - B -.
 Subtract both measurements "B A" , to obtain clutch distance - K -.
Clutch distance calculation - K - : "B A = K"
NOTE:  The corrugated spring washer - 1 - is installed under the disc pack to
 Repeat measurement on opposite side of input shaft and also determine clutch distance - K -.
 Insert 4 calipers T40101 and 2 rulers T40100 at 90° on input shaft and repeat measurements.
 Using 4 values determined for clutch distance - K - , calculate average M K .
2:04:26 AM Page 75
Average: " (Value 1 + Value 2 + Value 3 + Value 4) : 4 = M K "
Thrust plate measurement
 First check for damage and replace, if necessary.

 Rotate thrust play and lay on level and clean surface.
Fig. 106: Placing 2 Calipers T40101 On Cleaned Thrust Plate Running Surface
 Place 2 calipers T40101 on cleaned thrust plate running surface.
 Calipers T40101 must lie completely on clean running surfaces and must not lie on edge
Fig. 107: Measuring Shim With Digital Depth Gauge VAS 6087 On Upper Running Surface And Note
Measurement
 Lay rulers T40100 centered on calipers T40101.

 Measure shim with digital depth gauge VAS 6087 on upper running surface and note measurement - A -.
2:04:26 AM Page 76
Fig. 108: Measuring With Digital Depth Gauge VAS 6087 On Lower Running Surface And Note
Measurement
 Measure with digital depth gauge VAS 6087 on lower running surface and note measurement - B -.
 Subtract value of both measurements "B A" to determine distance "D" of both running surfaces to thrust
plate.
Thrust plate distance calculation "D" : "B A = D"
 Repeat measurement on 2 additional places on thrust plate off-set at 120°.

 Using these three measurements, calculate thrust plate average M D .
Average: " (Value 1 + Value 2 + Value 3) : 3 = M D "
Determining air play
Average of thrust plate measurements " M D

" (Value 1 + Value 2 + Value 3) : 3
Average of clutch measurements " M K " (Value 1 +
Value 2 + Value 3 + Value 4) : 4
= Air gap
Air gap = " M D " " M K "
Air gap specified value: 1.8 ± 0.2 mm.
A - Measured value too small:
2:04:26 AM Page 77
 Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.
 Check air gap again after installing new adjustment disc --> Input shaft with 7 lining discs, adjusting
with air gap determination.
B - Measured value too large:
 Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.
Following adjustment discs are available:
Available adjustment discs [thickness in mm]

1.90 2.15 2.65
2.90 3.15
NOTE:  Air gap can be adjusted using upper and lower adjustment discs.
 Remove all adjustment discs, lining discs, outer discs and the corrugated spring washer - 5 - , - 4 - , - 3 - ,
- 2 - and - 1 - from input shaft cylinder - A -.
CAUTION: This step is necessary because the corrugated spring washer - 2 - is only
2:04:26 AM Page 78
installed over the lower adjustment disc - 1 - in order to adjust the input
shaft. When assembling the input shaft, the corrugated spring washer is
installed in the upper position.
 Assemble input shaft Input shaft, assembling.
INPUT SHAFT, SERVICING WITH 6 LINING DISCS
CAUTION:  Servicing with the incorrect number of lining discs leads to input
shaft damage after bringing vehicle into operation again.
 In this case, the software in the Transmission Control Module (TCM)
J217 does not match the number of lining discs.
There are two types of transmissions. They are differentiated according to transmission code :
These transmissions are installed in vehicles with 4-cyl. 1.9L TDI engine, 4-cyl. 2.0L TDI engine, 6-cyl. 2.5L
TDI engine, 6-cyl. 3.0L MPI gasoline engine and 6-cyl. 3.2L FSI gasoline engine.

These transmissions are installed in vehicles with all other engines.

Input shaft with 6 lining discs, assembly overview
2:04:26 AM Page 79
Fig. 110: Input Shaft With 6 Lining Discs, Assembly Overview

1 - Input shaft seal
 Replace --> Input shaft seal, replacing
2 - Input shaft cover circlip
 Replace with same thickness
3 - Input shaft cover
 After removing cover, input shaft cover ball bearing must be replaced --> Ball bearing in input shaft
cover, replacing
2:04:27 AM Page 80
4 - Piston
5 - Pressure plate
6 - Corrugated spring washer
7 - Upper adjustment disc
 Replace
8 - Coated plate
 Qty. 6
 Replace
9 - Outer plate
 Qty. 5
 Replace
10 - Lower adjustment disc
 Replace
12 - O-Ring
 Replace
13 - Oil pipe
Input shaft with 6 lining discs, disassembling and assembling
2:04:27 AM Page 81
Fig. 111: Identifying Special Tools - Input Shaft With 6 Lining Discs, Disassembling And Assembling (1
Of 2)

 Assembly tool T10219/1
 Tube 2010
 Tube VW 416 B
2:04:27 AM Page 82
Fig. 112: Identifying Special Tools - Input Shaft With 6 Lining Discs, Disassembling And Assembling (2
Of 2)

 2 piece ruler T40100
 4 piece calipers T40101
 2 piece feeler gauge T40117 for input shafts with 6 lining discs

 Ice spray
2:04:27 AM Page 83
Work procedure

 Remove input shaft --> Input shaft, removing and installing.

 Remove input shaft cover from shaft --> Torsen differential cover, removing and installing


 Carefully raise thrust plate with pistons with two screwdrivers - arrows -.
2:04:27 AM Page 84
Precautionary measures:
installation.
installing.
2:04:27 AM Page 85

 Carefully guide thrust plate - 1 - with pistons - 2 - up over shaft - 3 -.
Disc pack, removing

2:04:27 AM Page 86
 Remove corrugated spring washer - 5 - , they must be used again.

 Remove upper adjustment disc - 4 - from input shaft cylinder - A -.
 Remove all lining discs - 2 - and outer discs - 3 - from input shaft cylinder - A -.
 Remove lower adjustment disc - 1 - from input shaft cylinder - A -.

CAUTION:  All old, used adjustment discs, outer discs and lining discs must be
replaced. They must not be reinstalled as that would not ensure the
input shaft function (surface is used up).
 The corrugated spring washer must be used again.
CAUTION: Before assembly, check for wear on transmission components -->

Transmission components, evaluating wear.
 Replace ball bearing in input shaft cover --> Ball bearing in input shaft cover, replacing.
 Adjust input shaft and determine air gap --> Input shaft with 6 lining discs, adjusting with air gap
determination.

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 Insert determined lower adjustment disc - 1 - in input shaft cylinder - A -.

1.9 mm thickness).

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 Insert determined upper adjustment disc - 4 - in input shaft cylinder - A -.

 Lastly, insert corrugated spring washer - 5 -.
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 Press pistons - 1 - into stop on thrust plate - 2 -.
installation.
installing.
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 Carefully guide pressure plate - 1 - with pistons - 2 - down over shaft - 3 -.
 Press thrust plate with pistons uniformly into input shaft up to stop.
Fig. 123: Checking Air Play With Feeler Gauge T40117

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Checking air play with feeler gauge T40117
 Insert both feeler gauges T40117 under thrust plate - A -.

 A second technician must push thrust plate - A - down to stop - arrow 1 - with Tube VW 416 B.
 Guide both feeler gauges T40117 circularly in direction of - arrow - back and forth under thrust plate.
 Both feeler gauges T40117 must be guided oppositely.

 Feeler gauges T40117 must not be angled.
 Entire circular area must be checked.
 Both feeler gauges T40117 must always move freely without slightest resistance.
If feeler gauges T40117 cannot be guided in direction of - arrow - without blocking:
 Repeat input shaft adjustment --> Input shaft with 6 lining discs, adjusting with air gap
determination.
CAUTION: Air play must pass check with feeler gauges T40117 , otherwise
transmission will exhibit problems after reassembly.
If feeler gauges T40117 can be guided in direction of - arrow - without blocking:
 Install input shaft cover --> Torsen differential cover, removing and installing.

 Install input shaft --> Input shaft, removing and installing.
2:04:28 AM Page 92
 Install input shaft seal - A - --> Input shaft seal, replacing.

Input shaft with 6 lining discs, adjusting with air gap determination

 All components must be cleaned thoroughly before inserting.
Clutch measurement
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NOTE:  The distance - K - of the clutch from the upper contact ring shim on the
shaft (Thrust plate contact surface) is determined.
 The corrugated spring washer - 1 - is installed under the disc pack to

2:04:28 AM Page 94
 Insert new lower adjustment disc - 1 - of same thickness as old in input shaft cylinder - A -.
 Insert corrugated spring washer - 2 -.
NOTE:  The corrugated spring washer is installed at the bottom only for
measurement, it is installed again at the time during assembly.
1.9 mm thickness).

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 Last, insert new upper shim - 5 - of same thickness as old in input shaft.
NOTE:  For the following measurements, all tool and component surfaces must be
completely clean in order to obtain exact values.
Fig. 131: Placing 4 Calipers T40101 On Upper Shim

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 Place 4 calipers T40101 on upper shim.
Fig. 132: Laying Ruler T40100 Centered Over Every 2 Calipers T40101
 Lay a ruler T40100 centered over every 2 calipers T40101.
Fig. 133: Measuring Shim With Digital Depth Gauge VAS 6087 And Note Measurement
 Measure shim with digital depth gauge VAS 6087 and note measurement - A -.
 Digital depth gauge VAS 6087 must lie flush on both rulers T40100 when measuring.
2:04:28 AM Page 97
Fig. 134: Measuring With Digital Depth Gauge VAS 6087 On Shaft Contact Ring (Thrust Plate Contact
Surface) And Note Measurement
 Measure with digital depth gauge VAS 6087 on shaft contact ring (Thrust plate contact surface) and note
measurement - B -.
 Subtract both measurements "B A" , to obtain clutch distance - K -.
Clutch distance calculation - K - : "B A = K"
NOTE:  The corrugated spring washer - 1 - is installed under the disc pack to
 Repeat measurement on opposite side of input shaft and also determine clutch distance - K -.
 Insert 4 calipers T40101 and 2 rulers T40100 at 90° on input shaft and repeat measurements.
 Using 4 values determined for clutch distance - K - , calculate average M K .
2:04:28 AM Page 98
Average: " (Value 1 + Value 2 + Value 3 + Value 4) : 4 = M K "
Thrust plate measurement
 First check for damage and replace, if necessary Checking pistons and thrust plate for wear.
 Rotate thrust play and lay on level and clean surface.
Fig. 136: Placing 2 Calipers T40101 On Cleaned Thrust Plate Running Surface
 Place 2 calipers T40101 on cleaned thrust plate running surface.
 Calipers T40101 must lie completely on clean running surfaces and must not lie on edge
Fig. 137: Measuring Shim With Digital Depth Gauge VAS 6087 On Upper Running Surface And Note
Measurement
 Lay rulers T40100 centered on calipers T40101.

 Measure shim with digital depth gauge VAS 6087 on upper running surface and note measurement - A -.
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Fig. 138: Measuring With Digital Depth Gauge VAS 6087 On Lower Running Surface And Note
Measurement
 Measure with digital depth gauge VAS 6087 on lower running surface and note measurement - B -.
 Subtract value of both measurements "B A" to determine distance "D" of both running surfaces to thrust
plate.
Thrust plate distance calculation "D" : "B A = D"
 Repeat measurement on 2 additional places on thrust plate off-set at 120°.

 Using these three measurements, calculate thrust plate average M D .
Average: " (Value 1 + Value 2 + Value 3) : 3 = M D "
Determining air play
Average of thrust plate measurements " M D

" (Value 1 + Value 2 + Value 3) : 3
Average of clutch measurements " M K " (Value 1 +
Value 2 + Value 3 + Value 4) : 4
= Air gap
Air gap = " M D " " M K "
Air gap specified value: 1.4 ± 0.2 mm.
A - Measured value too small:
2:04:28 AM Page 100

 Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.
B - Measured value too large:
 Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.
Following adjustment discs are available:
Available adjustment discs [thickness in mm]

1.90 2.15 2.65
2.90 3.15
NOTE:  Air gap can be adjusted using upper and lower adjustment discs.
 Remove all adjustment discs, lining discs, outer discs and the corrugated spring washer - 5 - , - 4 - , - 3 - ,
- 2 - and - 1 - from input shaft cylinder - A -.
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CAUTION: This step is necessary because the corrugated spring washer - 2 - is only
installed over the lower adjustment disc - 1 - in order to adjust the input
shaft. When assembling the input shaft, the corrugated spring washer is
installed in the upper position.
 Assemble input shaft Input shaft, assembling.

Left flange shaft seal, replacing


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 Driver 2062
Work procedure
 Remove left flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .

 Pull out flange shaft seal using Extractor lever VW 681.
NOTE:  Do not damage shaft seal seating surfaces.

1. Flange shaft
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3. Spacer ring
4. Circlip
5. Not installed
ring)
 Moisten outer circumference and shaft seal lip with axle oil.
 Installation position: Open side of shaft seal faces transmission.
Cover
 Drive in new left flange shaft seal uniformly with Driver 2062.
 Production drive-in depth 5.5 mm below cover surface.

 If re-using the used flange shaft, repair drive-in depth is 6.5 mm.
NOTE:  Do not angle shaft seal when driving in.
 Install left flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .

 Check gear oil level in front final drive --> 39 - FINAL DRIVE, DIFFERENTIAL .
Right flange shaft seal and grooved ball bearing, replacing
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Fig. 145: Identifying Special Tools - Right Flange Shaft Seal And Grooved Ball Bearing, Replacing

 Punch VW 407
 Punch VW 412

 Driving sleeve 32 - 109
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Fig. 146: Tube 2040

 Tube 2040

 Driver 2062
2:04:29 AM Page 106


Work procedure
 Remove right flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .
Removing shaft seal
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 Pull flange shaft seal out of mounting bracket using Extractor lever VW 681.

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Installing shaft seal
 Coat outer edge and sealing lip of shaft seal with axle oil.
 Installation position: Open side of shaft seal faces transmission.
 Drive in new right flange shaft seal uniformly with Driver 2062.
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 Production drive-in depth 5.5 mm below mounting bracket surface.

 If re-using the used flange shaft, repair drive-in depth is 6.5 mm.
NOTE:  Do not angle shaft seal when driving in.
2:04:29 AM Page 110


 Install right flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .
 Check gear oil level in front final drive --> 39 - FINAL DRIVE, DIFFERENTIAL .
Differential shaft seal, replacing
Fig. 155: Identifying Special Tools - Differential Shaft Seal, Replacing

 Torque wrench V.A.G 1331

 Socket T10023
 Thrust pad T40107
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 Assembly lever
 Cleaning solution D 009 401 04
Work procedure
 The differential shaft seal can be replaced with transmission installed.
 Drain ATF --> ATF, draining for ATF flushing process.

 Remove differential --> Differential, removing and installing
 Remove right flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .
NOTE:  In the case of insufficient accessibility in the vehicle, right flange shaft
must not be completely removed. In that case, it only needs to be pulled
out of transmission housing a little in order to create enough room to
remove and install shaft seal.
CAUTION:  In the following procedures, the differential shaft surface must not
come in contact with hard objects. Even small scratches or damage
to the differential shaft sealing surface cause lack of seal and the
transmission must be replaced completely.
Fig. 156: Placing Punch On Side Hole Of Pinion Shaft Seal And Punch Small Hole To Install Metal Screw
In Shaft Seal
 Place a punch on a side hole of pinion shaft seal and punch a small hole - arrow - to install a metal screw
2:04:29 AM Page 112

in shaft seal.
Fig. 157: Installing Metal Screw With Large Head In Shaft Seal Hole
 Install metal screw with large head in shaft seal hole.
Fig. 158: Using Stable Lever With Center Notch To Install Metal Screw
 Use a stable lever - 1 - with center notch - arrow - to install metal screw.
 Position lever on metal screw.
CAUTION: Lay an appropriate wood or plastic plate - 2 - between lever and

transmission housing to prevent damage.
The housing must not be damaged.
2:04:30 AM Page 113

 Remove shaft seal.
Fig. 159: Cleaning Breather Tube Using Pressurized Air

 Clean breather tube - arrow - using pressurized air and lay a cloth on interior side of breather tube.
Fig. 160: Identifying Differential Shaft Sealing Surface

 Clean differential shaft sealing surface with cleaning solution D 009 401 04 and a soft cloth; to do so turn
differential shaft.
 Selector shaft lever must not be in position "P".
 Remove stubborn deposits with the fingernail, do not use tools at all.
CAUTION:  Do not clean the differential shaft mechanically with tools or

polishing paste under any circumstances. Even small scratches or
damage to the differential shaft sealing surface cause lack of seal
and the transmission must be replaced completely.
2:04:30 AM Page 114

 Coat outside circumference of shaft seal with ATF.

 Check assembly aid T40107/2 for cracks or burrs. Do not use a damaged assembly aid.
Fig. 161: Placing Assembly Aid T40107/2 On Pressure Sleeve T40107/1 And Sliding Shaft Seal Onto
Pressure Sleeve
 Place assembly aid T40107/2 on pressure sleeve T40107/1 and slide shaft seal - 1 - onto pressure sleeve.
 Closed side of shaft seal points towards tool.
 Remove assembly aid T40107/2.

 Connect pressure sleeve T40107/1 with shaft seal - 1 - to differential shaft.
Fig. 162: Bringing Pressure Sleeve T40107/1 Into Correct Position

 Place selector shaft lever in "P" position (all the way back).
 Rotate nuts on spindle T40107/3 all the way back.
 Rotate spindle T40107/3 to stop with open-end wrench.
2:04:30 AM Page 115

NOTE:  This installs spindle securely on differential shaft.
 Bring pressure sleeve T40107/1 into correct position.
 Tabs - arrows - pressure sleeve circumference must engage in notches on transmission housing.
Fig. 163: Pressing Shaft Seal Into Transmission Housing With Pressure Sleeve And Tightening Nut To 17
Nm Using Torque Wrench V.A.G 1331 And Socket T10023
 Press shaft seal into transmission housing with pressure sleeve and tighten nut to 17 Nm using Torque
wrench V.A.G 1331 and Socket T10023.
 Shaft seal must settle for 2 minutes.
 After waiting 2 minutes, remove nut and remove pressure sleeve in driving direction.
Fig. 164: Checking Whether Shaft Seal Lip Visible From Outside Lies On Cylindrical Differential Shaft
Sealing Surface And Not On Chamfer
 Check whether shaft seal lip visible from outside lies on cylindrical differential shaft sealing surface and
not on chamfer - arrow - ; press shaft seal on, if necessary
2:04:30 AM Page 116

 Install right flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .

 Install differential housing and front final drive cover --> Differential, removing and installing.
With transmission removed:
NOTE:  To check for leaks, transmission must be reinstalled in vehicle so that a

road test can be performed.
 Transmission, removing and installing --> 37 - AUTOMATIC
TRANSMISSION - CONTROLS, HOUSING
All:
Fig. 165: Performing An Extended Test Drive And Finally Checking For Leaks On Bleeder Hole On
Front Final Drive Cover
 Perform an extended test drive and finally check for leaks on bleeder hole - arrow A - on front final drive
cover.
NOTE:  The bleeder hole is covered with a protective plate in certain

transmissions.
 On new transmissions, the bleeder hole is placed to the side so a leak is
only visible at side of front final driver cover.
 If oil escapes at the bleeder hole, repair must be repeated.
Front final drive cover (on removed transmission), removing and installing
2:04:30 AM Page 117

Fig. 166: Identifying Special Tools - Front Final Drive Cover (On Removed Transmission), Removing
And Installing

 Puller T10037
 Drift VW 295
Removing
NOTE:  Front final drive cover, removing and installing on installed transmission --
> 39 - FINAL DRIVE, DIFFERENTIAL
 Observe general repair notes --> Repair instructions .
2:04:30 AM Page 118


 Transmission removed and secured to assembly stand --> Transmission,
attaching to assembly stand.

 Tightly thread lower support of puller T10037 on front differential cover - arrow -.

 Remove left flange shaft with Puller T10037.

 Clamp flange shaft in vise, using jaw protectors.
Flange shaft circlip must always be replaced.
2:04:30 AM Page 119

Fig. 168: Pressing Circlip With New Circlip Out Of Flanged Shaft Groove
 Press circlip with new circlip - A - out of flanged shaft groove.
CAUTION: Before removing front final drive cover, ensure that right flange shaft is
installed. Otherwise differential can fall out of transmission housing.
Fig. 169: Tightening Bolts On Front Final Drive Cover In Sequence

 Tighten bolts on front final drive cover - 11 to 1 - in sequence.
CAUTION:  Slowly and carefully remove front final driver cover from
transmission housing. Otherwise differential can fall out of
transmission.
2:04:30 AM Page 120

 A differential that has fallen out can no longer be installed. If

differential falls out, transmission must be replaced.
 Ensure that the differential bearing race and adjustment shims do not
fall out of the transmission housing and front final drive cover.
 Bearing rings and adjustment shims that have fallen out cannot be
relocated with workshop equipment.
Fig. 170: Securing Differential Against Falling Out

 Secure differential - arrow - against falling out.
Installing
Fig. 171: Ensuring That Magnet Under Plastic Cover In Front Final Drive Cover
 Ensure that magnet under plastic cover in front final drive cover is installed.
2:04:30 AM Page 121

Fig. 172: Replacing O-Ring In Front Final Drive Cover & Checking Cover For Secure Seating
 Replace O-ring - 1 - in front final drive cover.

 Check cover for secure seating - 2 -.
Fig. 173: Checking Differential For Correct Seating In Transmission

 Check differential - arrow - for correct seating in transmission.
2:04:31 AM Page 122

Fig. 174: Replacing All Bolts On Front Final Drive Cover & Installing Shield Between Final Drive Cover
And Bolt
 Position front final drive cover on transmission housing.

 Replace all bolts on front final drive cover.
 If present, install shield - B - between final drive cover and bolt - 1 -.
NOTE:  The shield - B - should protect the bleeder hole - arrow A - from dirt and
water.
Fig. 175: Tightening Bolts On Front Final Drive Cover In Sequence

2:04:31 AM Page 123

CAUTION:  The 3 bolts with spacer washers are inserted in the places marked
with the - arrows -.
 Use original bolts .
 Tighten bolts on front final drive cover in 2 stages in sequence shown as follows:
 Stage: Hand-tighten bolts in - 1 to 11 - sequence.
 Stage: Tighten bolts in - 1 to 11 - sequence in several stages to tightening torque.
 Check left flange shaft seal, replace if necessary --> Left flange shaft seal, replacing
 Install left flange shaft --> 39 - FINAL DRIVE, DIFFERENTIAL .

 Fill axle oil and check level in front final drive --> 39 - FINAL DRIVE, DIFFERENTIAL .
CAUTION: The Multitronic 01J or 0AN transmission requires a different axle oil than
shift automatics. Only axle oil for Multitronic which can be obtained as a
replacement part must be used in front final drive .
Component Nm
Front final drive cover on transmission housing 25 1)
Oil filler plug on front final drive cover 20

1) Replace bolts.
Differential, removing and installing
Removing
CAUTION:  Slowly and carefully remove front final driver cover from
transmission housing. Otherwise differential can fall out of
transmission.
 A differential that has fallen out can no longer be installed. If
differential falls out, transmission must be replaced.
 Ensure that the differential bearing race and adjustment shims do not
fall out of the transmission housing and front final drive cover.
 Bearing rings and adjustment shims that have fallen out cannot be
relocated with workshop equipment.
With transmission installed:
 Remove front final drive cover --> 39 - FINAL DRIVE, DIFFERENTIAL .
2:04:31 AM Page 124

 Remove front final drive cover --> Front final drive cover (on removed transmission), removing and
installing.
All:

Installing

With transmission installed:
 Install front final drive cover --> 39 - FINAL DRIVE, DIFFERENTIAL .
2:04:31 AM Page 125

 Install front final drive cover --> Front final drive cover (on removed transmission), removing and
installing.
TRANSMISSION COMPONENTS, EVALUATING WEAR
Input shaft, checking for wear
Fig. 178: Exploded View Of Input Shaft

4 - Piston
 Checking for wear Checking pistons and thrust plate for wear
5 - Pressure plate
 Checking for wear Checking pistons and thrust plate for wear
 Check running and sealing surfaces for wear Check input shaft cylinder running and sealing surfaces
for wear
 Checking for signs of wear caused by coated plate --> Check inner circumference of input shaft
cylinder for scoring from lining discs
13 - Oil pipe
 Checking for wear Checking oil pipe for wear
Checking pistons and thrust plate for wear
2:04:31 AM Page 126

 Remove pistons - 1 - from thrust plate - 2 -.
Check thrust plate - 2 -
 Check thrust plate running and sealing surfaces - arrow A - for wear.
 Check thrust plate running and sealing surfaces - arrow D - for wear.
 If running or sealing surfaces - arrow A - show grooves, scratches or scoring, thrust plate - 2 - must be
replaced.
 If running or sealing surfaces - arrow D - show grooves, scratches or scoring, thrust plate - 2 - and
pistons - 1 - must be replaced.
Checking pistons - 1 -
 Check seal - arrow B - on outer piston circumference - 1 - for damage.

 Check running surface - arrow C - on interior piston circumference - 1 - on shaft.
 If seal - arrow B - is damaged or piston running surface - arrow C - shows grooves, scratches, scoring or
uneven thickness from wear, piston - 1 - must be replaced.
Check input shaft cylinder running and sealing surfaces for wear
2:04:31 AM Page 127

Fig. 180: Checking Input Shaft Cylinder Running And Sealing Surfaces For Wear
 Check input shaft running and sealing surfaces - arrow A - for wear.
NOTE:  Shaft seal in input shaft cover seals at this sealing surface - arrow A -.
 Light scoring from shaft seal is normal.
 Check ball bearing running surface - arrow B - in input shaft cover for wear.
 Check shaft seal - arrow C - for damage.
 If seal - arrow C - is damaged or shaft running surfaces - arrow B - or - arrow A - show deep scoring or
grooves, entire input shaft must be replaced.
Check inner circumference of input shaft cylinder for scoring from lining discs
2:04:31 AM Page 128

Fig. 181: Checking Inner Circumference Of Input Shaft Cylinder For Scoring From Lining Discs
 Check inner circumference of input shaft cylinder for scoring from lining discs - arrows -.
 If there is scoring on interior circumference of input shaft cylinder from lining discs - arrows - , entire
input shaft must be replaced.
Checking oil pipe for wear
Fig. 182: Checking Oil Pipe For Wear

 Check oil pipe seal - 1 - for damage.
 The seal must have a gap - arrow B -.

 If gap - arrow B - is completely closed, oil pipe must be replaced.
2:04:31 AM Page 129

 Check oil pipe running surfaces - arrows - and rotor blades - arrow A - for wear, cracks and damage.
 If seal - 1 - or rotor blades - arrow A - are damaged or running surfaces - arrow - show deep scoring or
grooves, oil pipe must be replaced.
 The O-ring - 2 - must always be replaced.
 Always check oil pipe running surfaces in suction jet pump --> Suction jet pump, checking wear
Suction jet pump, checking wear
 Input shaft removed --> Input shaft, removing and installing
Fig. 183: Checking Oil Pipe Running Surfaces In Suction Jet Pump For Scoring, Scratches Or Damage
 Check oil pipe running surfaces - arrow - in suction jet pump for scoring, scratches or damage.
 The oil pipe running surface in suction jet pump - arrow - must not have any noticeable, cascaded
scoring or scratches.
In case of noticeable, cascaded scoring or damage to the wear surface by the oil pipe, suction jet pump must be
replaced.
 Always check oil pipe Checking oil pipe for wear
Differential shaft, checking for wear
 Differential removed
 Shaft seal removed --> Differential shaft seal, replacing.
2:04:31 AM Page 130

Fig. 184: Identifying Differential Shaft Sealing Surface

 Check differential shaft sealing surface for scratches or damage.
 The differential shaft sealing surface must not be scratched or scored.
NOTE:  Even the smallest scratches or damage on the differential shaft sealing
surface will cause lack of seal, even with a new shaft seal.
2:04:32 AM Page 131

TRANSMISSION Continuously Variable Transmission (CVT) 01J On Board Diagnostic (OBD)
TRANSMISSION
Continuously Variable Transmission (CVT) 01J On Board Diagnostic (OBD)
01 ON BOARD DIAGNOSTIC (OBD)

ON BOARD DIAGNOSTIC (OBD), OPERATION
On Board Diagnostic (OBD), operation
The Multitronic 01J constantly variable automatic transmission is controlled electronically/hydraulically.
The Transmission Control Module (TCM) receives information from components which influence the shifts.
Based on this information, the control module activates the applicable proportioning valves in the valve body.
The three proportioning valves regulate the fluid pressure generated by the ATF pump.
Proportioning valve 1 regulates the opening and closing of the clutches or brakes respectively.
Proportioning valve 2 controls the transmission ratio between the two disc sets, depending on driving
conditions, i.e. it regulates the pressures on the adjusting cylinders of the two disc sets and keeps the chain at a
constant tension.
Proportioning valve 3 regulates ATF cooling of the transmission.
A more precise description and operation of the individual valves can be found in:
Refer to Self-study Program Course No. 951103, Variable Automatic Transmission, Multitronic 01J
Transmission Control Module (TCM) DTC Recognition
The term "On Board Diagnostic" refers to the electrical/electronic part of the controls.
The control module is equipped with a Diagnostic Trouble Code (DTC) memory so that in the event of the
failure of an electrical/electronic component, or in the event of an open circuit, the cause of the malfunction can
be determined quickly.
The potential of the On Board Diagnostic (OBD) system can only be fully exploited with the V.A.G. 5051
Vehicle Diagnostic Measurement and Information System or with the V.A.G. 1551 scan tool, operating mode 1
"Rapid Data Transmission."
For functions which the V.A.G. 5051 Vehicle Diagnostic Measurement and Information System or the V.A.G.
1551 scan tool can cover. Refer to List of Selectable Functions, Overview of Selectable Functions.
Malfunctions are recognized by means of electrical signals. If malfunctions occur in the sensors or components
being monitored, they are stored in the DTC memory indicating the type and location of the malfunctions.
If a malfunction is present, it is saved as a statistical error. If the malfunction occurs only briefly and is then no
2:05:41 AM
2:05:51 Page 1
longer present, it becomes an intermittent malfunction after the ignition is switched off and on again.
Malfunctions occurring sporadically (intermittently, occasionally) are displayed on the screen as "sporadic."
After 40 engine cold starts (followed by transmission warm-up) the sporadic malfunctions are automatically
deleted from the DTC memory
A maximum of 10 trouble codes are stored in the DTC memory. If an eleventh trouble code should be detected
with 10 statistical trouble codes, emergency shutoff takes place.
If 10 trouble codes have already been saved in the DTC memory but they are not all statistical, and an eleventh
trouble code is added, the oldest existing sporadic trouble code is overwritten.
Transmission Control Module (TCM) safety functions
In the event of a failure of individual or several components or sensors, the control module -J217- activates
corresponding substitute functions. This ensures non-destructive operation of the transmission with the
consequent effect on the function and quality of the shifts.
Three conditions can be distinguished which are recognized by multitronic.

1 - The trouble code is stored and a substitute program allows the vehicle to continue to be driven (with some
limitations). The driver is not alerted to this condition, since it is not critical to safety nor for the transmission.
The transmission range display in the instrument cluster indicates as normal the particular range that has been
selected (arrow). The driver may notice a difference in vehicle driveability and contact an authorized dealer.
2:05:41 AM Page 2
Fig. 2: Identifying Fully Illuminated Transmission Range Display

2 - The trouble code is stored and a substitute program allows the vehicle to continue to be driven (with some
restrictions). The fully illuminated transmission range display in the instrument cluster shows the driver a
simple malfunction (arrow). This malfunction is barely noticeable to the driver, but the brightly lighted
transmission range display is intended to indicate that he or she should consult an authorized dealer as soon as
possible to avoid subsequent damage in the transmission.
Fig. 3: Identifying Flashing Transmission Range Indicator

3 - A flashing transmission range indicator in the instrument cluster points to a serious malfunction in the
transmission (arrow). The condition is critical to safety or for the transmission.
CAUTION: A flashing transmission range display indicator in the instrument cluster

means the vehicle could come to an immediate stop or might not continue
operation the next time the vehicle is stopped. This could mean that
stopping at a traffic signal can cause traffic to be obstructed.
The flashing transmission range display is requesting the driver to stop his or her vehicle at the nearest possible
location and to inform an Audi authorized dealer.
2:05:41 AM Page 3
NOTE: In specific cases following a short wait, driving can be resumed by restarting
the engine. In any case, the driver should immediately consult an Audi
authorized dealer.
If the Transmission Control Module (TCM) -J217- fails, for example, due to a loss of the voltage feed, it will
not be possible to continue driving.
Technical Data
DTC memory
 Permanent memory Yes
Data output
Rapid data transmission Yes
Blink code output No
Output Diagnostic Test Mode (DTM) Refer to Output Diagnostic Test Mode (DTM)
Basic setting No
Adaptation Refer to Adaptation
Coding control module Refer to Transmission Control Module (TCM),
coding
Reading Measured Value Block Refer to Measured Value Block, reading
Electrical/Electronic components and component Refer to Electrical/electronic components and
locations locations
Electrical/electronic components and locations
2:05:41 AM Page 4
Fig. 4: Electrical/Electronic Components And Locations

1 - Transmission Control Module (TCM) for multitronic -J217-
 Component location --> Fig. 5

 Control module is tested by the OBD system
Refer to 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS
2 - Hydraulic unit

 Valves are tested by the OBD system
2:05:41 AM Page 5
Refer to 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS
3 - Shift control mechanism cover
Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
4 - Tiptronic Switch -F189-
 Component location: Integral with the printed-circuit board which is located in the cover for the shift
control mechanism
 Consists of 3 Hall sensors which are triggered by a solenoid on the transverse slide of the roll cover
 Can be tested in Measured Value Block. Refer to Measured Value Block, reading
 In the event of Tiptronic switch malfunctions, first check whether the solenoid is properly attached to the
roll cover, if necessary replace the transverse slide. The circuit board must not be replaced until the wiring
connections have been inspected.
5 - Shift lock solenoid -N110-

 Can be tested in the Measured Value Block. Refer to Measured Value Block, reading and Electrical
Testing
 Component location. Refer to Fig. 8
7 - Cruise control switch -E45-

Refer to
 94 LIGHTS, SWITCHES - EXTERIOR
2:05:41 AM Page 6
 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET
8 - Park/Neutral Position (PNP) relay -J226-
9 - Power supply relay terminal 87
10 - Transmission Range (TR) selector lever display -Y6-

 Flashing transmission range display indicates a critical defect. Refer to Transmission Control Module
(TCM) safety functions
 Fully illuminated transmission range display indicates a simple defect. Refer to Transmission Control
Module (TCM) safety functions
 No display points to a wiring fault or a faulty display -Y6-
11 - Kickdown switch -F8-

 No mechanical switch. A specific value from the Throttle position sensors -G79-/-G185- is saved in the
Engine Control Module (ECM)
 Signal transmission from the Engine Control Module (ECM) to the Transmission Control Module (TCM)
over the CAN bus
 Accelerator pedal module removal and installation:
Refer to 20 - FUEL SUPPLY SYSTEM
12 - Brake light switch -F-

Transmission Control Module (TCM) for multitronic -J217-
2:05:41 AM Page 7
Fig. 5: Transmission Control Module (TCM) For Multitronic -J217-

Component location: The Transmission Control Module (TCM) -J217- is mounted at the rear of the
transmission, directly on the hydraulic unit.
The following components are integrated in the control module.
A - Sender for transmission output RPM -G195- and Sender 2 for transmission output RPM -G196-
B - Transmission fluid temperature sensor -G93-
C - Multi-function transmission range (TR) switch -F125-
D - Sensor for transmission RPM -G182-
E - Sender 1 for hydraulic pressure, automatic transmission -G193-
F - Sender 2 for hydraulic pressure, automatic transmission -G194-
CAUTION: Always perform the Adaptation after installing a new Transmission Control
Module (TCM) -J217-: Refer to Adaptation
Hydraulic Unit
2:05:41 AM Page 8
Fig. 6: Hydraulic Unit

Component location: The hydraulic unit is bolted to the rear of the transmission. The Transmission Control
Module (TCM) -J217- is bolted directly to the hydraulic unit.
A - Wiring connector for Pressure control valve 1 for automatic transmission -N215-
A - Wiring connector for Pressure control valve 2 for automatic transmission -N216-
C - Wiring connector for solenoid valve 1 -N88-
The following valves are integral on the hydraulic unit (not shown here):
1 - Pressure control valve 1 for automatic transmission -N215-; clutch solenoid valve
2 - Pressure control valve 2 for automatic transmission -N216-; transmission ratio solenoid valve
3 - Solenoid valve 1 -N88-; clutch cooling/safety cutoff
4 - Clutch cooling valve
5 - Minimum pressure valve
6 - Pressure control valve
7 - Clutch control valve
8 - Control pressure valve
You will find a more precise description and operation of the individual valves in:
Refer to Self-study Program Course No. 951103, Variable Automatic Transmission, Multitronic 01J
Shift lock solenoid -N110-
2:05:41 AM Page 9

Component location: The shift lock solenoid is located in the shift control mechanism (arrow).
Connector (DLC)
Component location: The DLC is located under the knee bolster to the left of the steering wheel.
Cruise control switch -E45-
2:05:41 AM Page 10
Fig. 9: Cruise Control Switch -E45-

Component location: The cruise control switch is located on the steering column switch.
Transmission Range (TR) selector lever display -Y6-

Component location: Integrated in the instrument cluster
NOTE: The transmission range selector lever display can only be replaced together
with the instrument cluster.
Relay for power supply terminal 87 and Park/Neutral Position (PNP) relay -J226-
2:05:41 AM Page 11
Fig. 11: Relay For Power Supply Terminal 87 And Park/Neutral Position (PNP) Relay -J226-
Component location: On the relay carrier in the E-Box plenum.
3 - Relay for power supply terminal 87
Power supply via terminal 87 is handled through the Motronic ECM power supply relay -J271-.
4 - Park/Neutral Position (PNP) relay -J226-
Fig. 12: Brake Light Switch -F-

Component location: The brake light switch -arrow- is located on the pedal cluster.
NOTE: To ensure an adequately tight fit, the switch must only be installed once.
Kickdown switch -F8-
2:05:41 AM Page 12

Component location:
 No mechanical switch. A specific value from the Throttle position sensors -G79-/-G185- is stored in the
Engine Control Module (ECM)
ON BOARD DIAGNOSTIC (OBD), PROGRAM
Safety Precautions
If the use of test and measuring equipment is required during test drives, the following precautions must
be observed:
CAUTION:  The test and measurement equipment must always be secured on the
rear seat and operated from there by a second person.
 If the test and measurement equipment is operated from the

passenger seat, the person sitting there could be injured in an
accident from deployment of the passenger side airbag.
In order to prevent injuries to persons and/or destruction of electrical and electronic components, the
following precautions must be observed:
 Attach measurement and test equipment terminals only with the ignition switched OFF.
 With some tests it may happen that the control module detects and stores a trouble code. For this reason,
the DTC memory must be read and if necessary deleted after completing all tests and repairs.
2:05:41 AM Page 13
 Disconnecting and attaching battery terminals must only be carried out with the ignition switched OFF,
otherwise the Transmission Control Module (TCM) can be damaged.
CAUTION: Observe precautions when disconnecting battery terminals.
Refer to

Performance testing, brake testing and towing
NOTE: It is not possible to tow the vehicle in order to start the engine, for example
when the battery is too weak or the starter is not working.
VAS 5051 Vehicle Diagnosis, Measurement and Information System, connecting and selecting functions
Test requirements
 Parking brake applied.

Refer to Electrical Wiring Diagrams, Troubleshooting and Component Locations binder
 Check battery ground (GND) strap and ground (GND) strap between battery and transmission.
Test procedure
2:05:41 AM Page 14
Connector (DLC)
 Connect VAS 5051 Vehicle Diagnosis, Measurement and Information System with diagnostic lead VAS
5051/1.
NOTE: The Data Link Connector (DLC) is located at the left-side knee bolster.
NOTE: If an error message appears in the display:
Refer to Users Manual for VAS 5051 Vehicle Diagnosis, Measurement and Information System VAS 5051
2:05:41 AM Page 15

Display on VAS 5051
 Touch "Vehicle OBD" button.

Display on VAS 5051
NOTE: By touching "00 Read DTC Memory Complete System" in the selection -1- the
automatic test sequence is performed, i.e. a scan is performed of the DTC
memory for all systems in the vehicle capable of OBD.
Depending on the desired function:
or
 Start engine.
 In selection -1- touch vehicle system "02 Transmission Electronics".
2:05:41 AM Page 16
Fig. 17: Diagnostic System VAS 5051: Display - System In Basic Setting
1 - Control module identification number of the Transmission Control Module (TCM).
Identification number of Transmission Control Module (example)

02 - Transmission electronics Vehicle system
01J927156. Part number; application
V301) 01J2) 3.0l 5V3) USA4) 1) Internal designation for
20405) 2) Continuously Variable
3) Transmission
4) Multitronic 01J
5) Engine version: 3.0 liter 5V
Market, USA and Canada
Control module data status
(software status)
Code 1001 Control module coding check. Refer to Transmission Control
Module (TCM), coding
Plant number 12345 Plant identification of the VAS 5051 with which the last coding was
performed.
LIST OF SELECTABLE FUNCTIONS
List of Selectable Functions
Refer to
02 - Diagnostic Trouble Code (DTC) Diagnostic Trouble Code (DTC)
memory memory, reading
03 - Output Diagnostic Test Mode Output Diagnostic Test Mode
(DTM) (DTM)
05 - Erasing DTC memory Diagnostic Trouble Code (DTC)
memory, erasing
2:05:41 AM Page 17
06 - Ending output
07 - Coding control module Transmission Control Module
(TCM), coding
08 - Reading Measure Value Block Measured Value Block, reading
DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, READING
Diagnostic Trouble Code (DTC) memory, reading
Vehicle Diagnosis, Measurement and Information System, connecting and selecting functions. In
selection touch vehicle system "02 Transmission Electronics". Ignition must be switched on.

Display on VAS 5051
 In selection -1- touch diagnostic function "02 Read DTC memory".
Fig. 19: Identifying Content Of DTC Memory & Identification Of Fault On Diagnostic System VAS 5051
Display
2:05:42 AM Page 18
1 - Contents of the DTC memory:
0 DTC detected
or
X DTCs detected
2 - DTC
DTC
Location of DTC
Type of DTC
A - If DTCs were recognized:
 Print out contents of screen or OBD protocol.

 End function "02 Read DTC memory" by touching <-- button.

Display on VAS 5051
 Repair malfunction(s) using DTC Chart. Refer to Diagnostic Trouble Code (DTC) table.
 In selection touch diagnostic function "02 Read DTC memory" again and delete DTC memory. Refer to
Diagnostic Trouble Code (DTC) memory, erasing.
 Touch "06 End output".
B - If no DTC was detected:
2:05:42 AM Page 19
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
Diagnostic Trouble Code (DTC) table
NOTE:  In the following list all the possible DTCs are shown in ascending order.
These DTCs can be recognized by the Transmission Control Module (TCM)
-J217-. Then they are displayed on the VAS 5051 Vehicle Diagnosis,
Measurement and Information System VAS 5051 or on the V.A.G 1551 scan
tool during reading of the DTC memory content.
 If DTCs occur only occasionally or if the DTC memory was not deleted
after the malfunction was corrected, these DTCs will be displayed for a
predetermined time as "intermittently occurring DTCs". Refer to
Transmission Control Module (TCM) DTC Recognition.
 If faulty components are displayed when the DTC memory is read, make an
additional check of wiring connections to the components for short or
open circuits.
PART 1, UP TO DIAGNOSTIC TROUBLE CODE 18149/P1741
Part 1, up to Diagnostic Trouble Code 18149/P1741
Output at printer Possible cause Corrective action

16889/P0505
Idle speed control  Specified engine  Read Measured
Malfunction idle RPM is lower Value Block.
than the specified Refer to
idle RPM required Measured Value
by the Block, reading;
transmission, display group
which means that number 020.
the required  Read DTC
increase in idle memory for
RPM was not Engine Control
carried out. Module (ECM)
and repair
malfunction.
16987/P0603
Control module faulty  Control module -  Replace
J217- faulty Transmission
Control Module
2:05:42 AM Page 20
(TCM). Refer to
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 Check all
applicable
Technical
Bulletins.

16988/P0604
Control Module
(TCM). Refer to
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
16989/P0605
Control Module
(TCM). Refer to
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
17086/P0702
Control Module
(TCM). Refer to
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
2:05:42 AM Page 21
CONTROLS
 Check all
applicable
Technical
Bulletins.

17087/P0703
Electrical malfunction in circuit  Wiring connection  Read Measured
between brake test Value Block. Refer
switch, Brake light to Measured
switch -F- and Value Block,
Engine Control reading; display
Module (ECM) group number 001.
faulty  Check wiring
connections and
harness connectors
using wiring
diagram.
 Read DTC memory

for Engine Control
Module (ECM) and
repair malfunction.
 Brake light switch -  Replace Brake
F- faulty light switch -F-.
Refer to 46 -
BRAKES -
MECHANICAL
COMPONENTS
 Conditions for DTC recognition: The signals from the brake light switch and the brake test switch are
transmitted over the CAN bus circuit to the Transmission Control Module (TCM) and evaluated there.
After 10 consecutive occurrences of an implausibility between the brake light switch and the brake test
switch (one switch actuated, the other not) this DTC is saved in the Transmission Control Module (TCM).

17090/P0706
Multifunction Transmission Range (TR) switch.
Refer to -F125-
Implausible signal  Selector lever cable  Read Measured
2:05:42 AM Page 22
wrongly adjusted Value Block. Refer

to Measured Value
Block, reading;
display group
number 002.
 Adjust selector
lever cable. Refer to
37 - AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
 Operation of  Clean selector shaft.
selector shaft Refer to 37 -
solenoid 2) for AUTOMATIC
multifunction TRANSMISSION
transmission range - CONTROLS,
switch affected by HOUSING
dirt or metal chips
 Multifunction TR  Replace2)
switch -F125- Transmission
faulty Control Module.
Refer to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
 Selector shaft  Replace
solenoid 1) for transmission. Refer
multifunction TR to 37 -
switch AUTOMATIC
demagnetized by a TRANSMISSION
strong electrical - CONTROLS,
field (welding HOUSING
equipment for
example) or
selector shaft bent
or damaged
1) The solenoid transmits the current position of the selector shaft to the Hall sensors on the multifunction TR
switch -F125-. If the shift control mechanism is correctly adjusted, this position matches the selector lever
position.
2) The multifunction TR switch -F125- is integrated in the Transmission Control Module (TCM) -J217- and can
only be replaced as a unit with the Transmission Control Module (TCM).
2:05:42 AM Page 23

17094/P0710
Transmission fluid temperature sensor -G93-
Electrical malfunction in circuit  Transmission  Read Measured
fluid temperature Value Block.
sensor -G93- Refer to
faulty Measured Value
Block, reading;
display group
number 010 or
011.
 Replace
Transmission
Control Module
(TCM) 3. Refer to
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
17095/P0711
Implausible signal  Transmission  Read Measured
Block, reading;
display group
number 010 or 011
 Replace
Transmission
Control Module
(TCM) 4. Refer to
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
3) The transmission fluid temperature sensor -G93- is integrated in the Transmission Control Module (TCM) -
J217- and can only be replaced as a unit along with the Transmission Control Module (TCM).
2:05:42 AM Page 24
17096/P0712
Signal too low  Transmission  Read Measured
Block, reading;
display group
number 010 or
011.
 Replace
Transmission
Control Module
(TCM) 4. Refer to
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
4) The Transmission fluid temperature sensor -G93- is integrated in the Transmission Control Module (TCM) -
J217- and can only be replaced as a unit along with the Transmission Control Module (TCM).
 Condition for DTC recognition: The temperature reading measured fell below -60°C.

17097/P0713
Signal too high  Transmission  Read Measured
fluid temperature Value Block 5).
Block, reading;
display group
number 010 or
011.
 Replace
Transmission
Control Module
(TCM) 4. Refer to
38 -
AUTOMATIC
2:05:42 AM Page 25
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
4) The transmission fluid temperature sensor -G93- is integrated in the Transmission Control Module (TCM) -
J217- and can only be replaced as a unit with the Transmission Control Module (TCM).
5) The Measured Value Block should be read out when the engine and transmission have cooled (approx. room
temperature). If the temperature reading is then higher than or equal to 160°C, the transmission fluid
temperature sensor -G93- is clearly faulty.
 Condition for DTC recognition: The temperature reading measured has exceeded 160°C.

17100/P0716
Sensor for transmission RPM
-G182-
Implausible signal  Sensor for  Read Measured
transmission RPM Value Block.
-G182- faulty Refer to
Measured Value
Block, reading;
display group
number 007
 Replace
Transmission
Control Module
(TCM) 6. Refer to
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
6) The Sensor for transmission RPM -G182- is integrated in the Transmission Control Module (TCM) -J217
and can only be replaced as a unit along with the Transmission Control Module (TCM).
 Condition for DTC recognition: The Transmission Control Module recognizes short-term drive RPM
which is higher than 7000 RPM.
2:05:42 AM Page 26

17101/P0717
No signal  Sensor for  Read Measured
transmission Value Block.
RPM -G182- Refer to
Block, reading;
display group
number 007.
 Replace
Transmission
Control Module
(TCM) 6. Refer to
37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
 Sensor wheel  Replace
in transmission.
transmission Refer to 37 -
has become AUTOMATIC
detached or TRANSMISSION
is faulty. - CONTROLS,
HOUSING
6) The Sensor for transmission RPM -G182- is integrated in the Transmission Control Module (TCM) -J217-
 Condition for DTC recognition: The Transmission Control Module (TCM) recognizes short-term input
RPM which is less than or equal to 1 RPM and simultaneously an output RPM which is higher than 100
RPM.

17105/P0721
Implausible signal  Sender for  Read Measured
transmission Value Block.
output RPM - Refer to
G195- faulty Measured Value
Block, reading;
display group
2:05:42 AM Page 27
number 004.
 Replace
Transmission
Control Module
(TCM) 7. Refer to
37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
17106/P0722
No signal  Sender for  Read Measured
transmission RPM Value Block.
-G195- faulty Refer to
Measured Value
Block, reading;
display group
number 004.
 The Transmission  Replace
Control Module Transmission
(TCM) is not Control Module
receiving an (TCM) 7. Refer to
indication of 37 -
vehicle direction AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
7) The Sender for transmission RPM -G195- is integrated in the Transmission Control Module (TCM) -J217-

17110/P0726
RPM signal from Engine Control Module
(ECM)
Implausible signal  Malfunction  Read
in Engine Measured
speed RPM Value Block.
diagnosed by Measured
Engine Value
Control Block,
Module reading;
(ECM) display
2:05:42 AM Page 28
 Engine RPM group

too high number 009.
recognized  Read DTC
(engine over memory for
revved) Engine
Control
Module
(ECM) and
repair
malfunction.
 Wiring from  Perform
Engine electrical
Control test. Refer to
Module Electrical
(ECM) to Testing.
Transmission  Check
Control wiring
Module connections
faulty and harness
connectors
using wiring
diagram.
 An implausible RPM signal is being received by the Transmission Control Module (TCM) over the RPM
lead. The cause could be, for example, engine RPM too high or false RPM readings caused by
interference from the ignition system. The substitute engine RPM signal is then transmitted by the Engine
Control Module (ECM) over the CAN bus circuit to the Transmission Control Module.

17111/P0727
RPM signal from Engine Control Module (ECM)
No signal  Open circuit in  Perform electrical
wiring test. Refer to
Electrical Testing.
 Check wiring
connections and
harness connectors
using wiring
diagram.
 Malfunction in  Read DTC memory
Engine Control for Engine Control
Module (ECM) Module (ECM) and
2:05:42 AM Page 29
repair malfunction.
Control Module - Transmission
J217- faulty Control Module
(TCM). Refer to 38
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
17114/P0730
Monitoring gear ratio
Wrong transmission ratio  Transmission  Replace
faulty transmission. Refer
to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
 In the event of an open circuit in the RPM lead, the substitute engine RPM signal is transmitted by the
Engine Control Module (ECM) over the CAN bus circuit to the Transmission Control Module (TCM).

17134/P0750
Shift valve 1. Refer to solenoid valve 1 -N88-
Operational malfunction  Clutch pressure  Replace hydraulic
too high unit. Refer to 38 -
 Solenoid valve 1 - AUTOMATIC
N88- 8) faulty TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
17137/P0753
Shift valve 1. Refer to solenoid valve 1 -N88-
Electrical malfunction in circuit  Wires 9) to  Replace
solenoid valve 1 - Transmission
N88- have a short Control Module
circuit to B+ or (TCM) 9. Refer to
ground 38 -
AUTOMATIC
TRANSMISSION
2:05:42 AM Page 30
- GEARS,
HYDRAULIC
CONTROLS
8) Solenoid valve 1 -N88- is integral in the hydraulic unit and can only be replaced as a unit along with the
hydraulic unit.
9) The wires are integral in the Transmission Control Unit -J217- and can only be replaced as a unit along with
the new Transmission Control Module (TCM).

18031/P1623
Data bus drive 10)
No communication  Open wire in CAN bus  Read Measured Value
circuit Block. Refer to Measured
Value Block, reading;
display group number 125.
 Check CAN bus. Refer to
Data Exchange between
Transmission Control
Module (TCM) and CAN-
Capable Control Modules,
checking.
 Incorrect or faulty Engine  Check Engine Control
Control Module (ECM) Module (ECM)
identification number and
read DTC memory.
 Incorrect or faulty ABS  Check ABS control module
control module identification number and
read DTC memory.
 Transmission Control  Check Engine Control
Module (TCM) does not Module (ECM)
match the Engine Control identification number.
Module (ECM), or the ABS
control module 11)
 Incorrect or faulty  Check instrument cluster
instrument cluster identification number and
read DTC memory.
10) The data bus is also described as a CAN bus.
11) Software status of Engine Control Module (ECM), ABS and Transmission Control Module (TCM) or
instrument cluster do not match, or an incorrect Transmission Control Module could also have been installed.
2:05:42 AM Page 31
Transmission Control Module (TCM) and instrument cluster is carried out over the CAN bus. All
information signals are transmitted over 2 leads.
 The Transmission Control Module (TCM) can send signals and data, but it cannot receive anything.

18112/P1704
Kickdown switch -F8- 13)
Electrical malfunction in circuit  Open wire in  Read
CAN bus Measured
circuit Value Block.
Refer to
Measured
Value Block,
reading;
display group
number 125.
 Check CAN
bus. Refer to
Data
Exchange
between
Transmission
Control
Module
(TCM) and
CAN-
Capable
Control
Modules,
checking.
 Short circuit  Read out
or open DTC memory
circuit for Engine
between Control
accelerator Module
pedal module (ECM) and
and Engine repair
Control malfunction.
Module  Check wiring
(ECM) connections
 Accelerator and harness
pedal module connectors
2:05:42 AM Page 32
faulty using wiring

diagram.
 Replace
accelerator
pedal module.
Refer to 20 -
FUEL
SUPPLY
SYSTEM
13) No mechanical switch. A specific value from the Throttle position sensors -G79-/-G185- is saved in the
Engine Control Module (ECM). Signal transmission from Engine Control Module (ECM) to Transmission
Control Module takes place over CAN bus.
 With the brake pedal depressed and simultaneous full depression of the accelerator pedal as far as
Kickdown (Wide Open Throttle) this DTC can be displayed erroneously.

18113/P1705
Monitoring gear ratio
Adaptation limit reached  Adaptation values  Delete DTC
stored too limited memory, perform
adaptation:
NOTE:
 If transmission is
operating
correctly, delete
DTC memory and
ignore renewed
DTC entry.
 Hydraulic  Replace hydraulic

malfunction unit. Refer to 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS

18132/P1724
Signal for Park/Neutral position
2:05:42 AM Page 33
Short circuit to ground  Park/Neutral  Read Measured

position relay - Value Block.
J226- faulty Refer to
Measured Value
Block, reading;
display group
number 005.
 Replace relay for
Park/Neutral
position relay -
J226-. See Fig.
11.
ground in the connections and
electrical wiring harness
connectors using
wiring diagram.
18137/P1729
Signal for Park/Neutral position
Short circuit to B+  Relay for  Read Measured
Park/Neutral Value Block.
position relay - Refer to
J226- faulty Measured Value
Block, reading;
display group
number 005.
 Replace relay for
Park/Neutral
position relay -
J226-. See Fig.
11.
B+ in the connections and
electrical wiring harness
connectors using
wiring diagram.
 Open circuit cannot be determined by the control module.
 Open circuit cannot be determined by the control module.
2:05:42 AM Page 34

18141/P1733
Tiptronic switch -F189-
Short circuit to ground  Tiptronic switch -  Read Measured
F189- faulty Value Block. Refer
to Measured Value
Block, reading;
display group
number 003.
 Short circuit to  Check wiring and
ground in the harness connectors
electrical wiring using wiring
ground in the
Tiptronic buttons
on the
multifunction
steering wheel or
in the wiring
 Solenoid in the  Replace printed-
masking cover for circuit board14) or
shift mechanism roll cover15) for
has become shift mechanism.
detached Refer to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
14) The Tiptronic switch -F189- consists of switches for recognition, upshift and downshift. It is integrated in
the shift mechanism printed circuit board, i.e. if the Tiptronic switch is faulty, the printed circuit board has to be
replaced.
15) The Tiptronic switch -F189- receives its Tiptronic gate recognition or upshift/downshift information
through the solenoid on the transverse slide of the roll cover. If the solenoid has become detached, the cover
must be replaced.
 In the case of this DTC "Downshift switch" is always displayed in Measured Value Block 003.

18147/P1739
2:05:42 AM Page 35
Short circuit to ground  Tiptronic switch -  Read Measured

F189- faulty Value Block. Refer
to Measured Value
Block, reading;
display group
number 003.
ground in the
Tiptronic buttons
on the
multifunction
steering wheel or
in the wiring
 Solenoid in the roll  Replace printed
cover for shift circuit board14) or
mechanism has rollcover15) for
become detached shift mechanism.
Refer to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
the shift mechanism printed circuit board, i.e. if the Tiptronic switch is faulty, the printed circuit board has to be
replaced.
through the solenoid on the transverse slide of the roll cover. If the solenoid has become detached, the cover
must be replaced.
 In the case of this DTC "Upshift switch" is always displayed in Measured Value Block 003.

18148/P1740
Monitoring clutch temperature  Clutch was  Allow ATF to
overloaded, for cool.
example, as the
result of repeated
hill starts with a
2:05:42 AM Page 36
trailer
18149/P1741
Clutch pressure adaptation
Adaptation limit reached  Hydraulic  Replace hydraulic
malfunction unit. Refer to 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 The DTC is displayed when clutch temperature is too high.

 Engine torque is automatically cut back until the temperature has fallen into the permissible operating
range again.
 If this DTC occurs intermittently (display SP), the DTC memory must be deleted. Afterward, the vehicle
must be taken for a test drive and the DTC memory read again. If the DTC recurs, the hydraulic unit must
be replaced.
PART 2, UP TO DIAGNOSTIC TROUBLE CODE 18270/P1862
Part 2, up to Diagnostic Trouble Code 18270/P1862

18150/P1742
Clutch torque adaptation
Adaptation limit reached  Malfunction in  Read Engine
Module (ECM) (ECM) DTC
memory and repair
malfunction.
 ATF properties are  Change ATF, then
no longer OK perform adaptation.
Refer to
Adaptation. Refer
to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
2:05:42 AM Page 37
faulty transmission. Refer
to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING

18151/P1743
Monitoring clutch slip
Signal too high  Incorrect  Compare code
transmission letters on
installed16) transmission with
code letters in -->
00 - GENERAL,
TECHNICAL
DATA
 ATF properties are  Change ATF, then
no longer OK perform adaptation.
Refer to
Adaptation. Refer
to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
 Clutch faulty  Replace
transmission. Refer
to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
16) This DTC is displayed if an incorrect transmission has been installed, i.e. if a transmission for a 1.8 liter
engine was mistakenly installed in a vehicle with a 3.0 liter engine.

18152/P1744
Short circuit to ground  Tiptronic switch, -  Read Measured
F189-17) faulty Value Block. Refer
to Measured Value
2:05:42 AM Page 38
Block, reading;
display group
number 003.
ground in the
Tiptronic buttons
on the
multifunction
steering wheel or
in the wiring
 Solenoid in roll  Replace printed
cover for shift circuit board14) or
mechanism has roll cover15) for
become detached shift mechanism.
Refer to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
the shift mechanism printed circuit board, i.e. if the Tiptronic switch -F189- is faulty, the printed-circuit board
has to be replaced.
through the solenoid on the transverse slide for the roll cover. If the solenoid has become detached, the cover
must be replaced.
17) If the transmission is shifted into the Tiptronic gate with the selector lever in D this shift procedure is
recognized by the Tiptronic recognition switch -F189- and transmitted to the Transmission Control Module
(TCM).
 DTC is displayed if Tiptronic recognition was detected, although the selector lever is not in the Tiptronic
gate.

18156/P1748
Control module faulty  Transmission  Replace
(TCM) -J217- Control Module
2:05:43 AM Page 39
faulty (TCM). Refer to

38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
18158/P1750
Power supply
Voltage too low  Generator or  Check power
voltage regulator supply for
faulty Transmission
Control Module
(TCM). Refer to
Electrical
Testing.
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 Condition for DTC recognition: Battery voltage was detected as less than or at 10 V.

18159/P1751
Power supply
Voltage too high  Generator or  Check power
voltage regulator supply for
faulty Transmission
Control Module
(TCM). Refer to
Electrical
Testing.
2:05:43 AM Page 40

38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 Condition for DTC recognition: Battery voltage above 16 volts.

 This DTC was also displayed, for example, when jump starting with a 24 volt battery.

18161/P1753
Implausible signal  Individual Hall  With an intermittent
sensors are not DTC: Check adjustment
switching to of selector lever cable.
ground Refer to 37 -
AUTOMATIC
TRANSMISSION -
CONTROLS,
HOUSING
 Read Measured
Value Block.
Refer to
Measured Value
Block, reading;
display group
number 002.
 Replace printed
circuit board14)
for shift
mechanism. Refer
to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
 Connector at the  Check wiring and
shift mechanism harness connectors using
not connected wiring diagram.
 Power supply for
shift mechanism
2:05:43 AM Page 41
missing
 All 3 Tiptronic
wires have an
open circuit
the shift mechanism printed circuit board, i.e. if the Tiptronic switch -F189- is faulty, the printed circuit board
has to be replaced.

18162/P1754
Open circuit/short circuit  Tiptronic switch -  Read Measured
to B+ F189- faulty Value Block. Refer
(upshift) to Measured Value
Block, reading;
display group
number 003.
 Replace printed
circuit board14) for
shift mechanism.
Refer to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
 Open circuit/short  Check wiring and
circuit to B+ in the harness connectors
 Open circuit/short diagram.
circuit to B+ in the
Tiptronic buttons
on the
multifunction
steering wheel or
in the wiring
has to be replaced.

18163/P1755
2:05:43 AM Page 42

(downshift) to Measured Value
Block, reading;
display group
number 003.
 Replace printed
shift mechanism.
Refer to 37 -
AUTOMATIC
TRANSMISSION
- CONTROLS,
HOUSING
Tiptronic buttons
on the
multifunction
steering wheel or
in the wiring
has to be replaced.

18164/P1756
(recognition) to Measured Value
Block, reading;
display group
number 003.
 Replace printed
shift mechanism.
Refer to 37 -
AUTOMATIC
2:05:43 AM Page 43
TRANSMISSION
- CONTROLS,
HOUSING
Tiptronic buttons
on the
multifunction
steering wheel or
in the wiring
has to be replaced.

18165/P1757
Power supply
Open circuit  Open circuit in  Check power
electrical wiring supply for
Transmission
Control Module
(TCM). Refer to
Electrical
Testing.
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS

18169/P1761
Shift locksolenoid -N110-18)
Short circuit to ground  Short circuit to ground in  Perform Output Diagnostic
electrical wiring Test Mode (DTM). Refer to
2:05:43 AM Page 44
 Fuse faulty Output Diagnostic Test

Mode (DTM).
Block. Refer to Measured
Value Block, reading;
display group number 001.

Refer to Electrical Testing.
 Check wiring connections
and harness connectors
 Shift lock solenoid -N110-  Replace Shift lock solenoid
faulty -N110-. . Refer to 38 -
AUTOMATIC
TRANSMISSION -
GEARS, HYDRAULIC
CONTROLS
 Short circuit on shift  Replace shift mechanism
mechanism printed circuit printed circuit board. Refer
board to 38 - AUTOMATIC
TRANSMISSION -
GEARS, HYDRAULIC
CONTROLS
 Transmission Control  Replace Transmission
Module (TCM) -J217- Control Module (TCM).
faulty Refer to 38 -
AUTOMATIC
TRANSMISSION -
GEARS, HYDRAULIC
CONTROLS
18) Shift locksolenoid -N110- is also described as selector lever lock solenoid.

18172/P1764
Monitoring transmission temperature  Clutch was  Allow ATF to cool.
overloaded, for
example, as the
result of repeated
hill starts with a
trailer
18173/P1765
Sender 2 for hydraulic pressure -G194-
2:05:43 AM Page 45
Adaptation limit reached  Ignition switched  Erase DTC

off with vehicle memory, switch
coasting ignition OFF and
ON, read DTC
memory again. If no
other DTC has been
entered, no
malfunction is
present.
faulty (TCM). Refer to 38
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 The DTC is displayed when clutch temperature is too high.

 Engine torque is automatically cut back until the temperature has fallen into the permissible operating
range again.

18181/P1773
Signal too high  Hydraulic unit  Replace hydraulic
contaminated or unit and change
faulty ATF. Refer to 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
18183/P1775
Adaptation limit reached  Ignition switched  Erase DTC
off with vehicle memory, switch
coasting ignition OFF and
ON, read DTC
memory again. If no
other DTC has been
2:05:43 AM Page 46
entered, no
malfunction is
present
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 If DTC 18201/P1793 is displayed in addition, the sensor wheel may be faulty and the transmission must
be replaced.

18185/P1777
Implausible signal  Flow rate in the  Check routing of
ATF lines hoses and lines.
inadequate because  Replace ATF filter.
ATF hoses were Refer to 37 -
installed twisted, AUTOMATIC
ATF filter is TRANSMISSION
clogged or ATF - CONTROLS,
lines are crushed HOUSING
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS

18194/P1786
Signal for back-up light
Open circuit  Park/Neutral  Read Measured
position (PNP) Value Block.
2:05:43 AM Page 47
relay -J226- faulty Refer to

Measured Value
Block, reading;
display group
number 005.
 Replace
Park/Neutral
position (PNP)
relay -J226. See
Fig. 11.
 Open circuit in  Check wiring
the electrical connections and
wiring harness connectors
using wiring
diagram.
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS

18195/P1787
Short circuit to ground  Park/Neutral  Read Measured
Measured Value
Block, reading;
display group
number 005.
 Replace
Park/Neutral
position (PNP)
relay -J226. See
Fig. 11.
ground in connections and
electrical wiring harness connectors
2:05:43 AM Page 48
using wiring
diagram.
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS

18196/P1788
Short circuit to B+  Park/Neutral  Read Measured
Measured Value
Block, reading;
display group
number 005.
 Replace
Park/Neutral
position (PNP)
relay -J226-. See
Fig. 11.
B+ in electrical connections and
wiring harness connectors
using wiring
diagram.
38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
2:05:43 AM Page 49

18198/P1790
Signal for transmission range selector lever
position display
Open circuit  Harness  Read Measured Value
connector not Block. Refer to
connected at Measured Value
instrument cluster Block, reading; display
 Open circuit in group number 002.
electrical wiring  Check wiring
connections and harness
connectors using wiring
diagram.
 Transmission  Replace instrument
Range selector cluster19). Refer to
lever display -Y6-  90
in instrument INSTRUMENTS
cluster faulty
 90
INSTRUMENTS
for
ELECTRICAL
EQUIPMENT,
CABRIOLET
Control Module Control Module (TCM).
(TCM) -J217- Refer to 38 -
faulty AUTOMATIC
TRANSMISSION -
GEARS,
HYDRAULIC
CONTROLS
19) The Transmission Range selector lever display -Y6- is integrated in the instrument cluster and can only be
replaced as a unit with the instrument cluster.

18199/P1791
display
Short circuit to ground  Short circuit to  Read Measured Value
ground in Block. Refer to
electrical wiring Measured Value
Block, reading; display
group number 002.
2:05:43 AM Page 50
 Check wiring
diagram.
cluster faulty
 90
INSTRUMENTS
for
ELECTRICAL
EQUIPMENT,
CABRIOLET
faulty AUTOMATIC
TRANSMISSION -
GEARS,
HYDRAULIC
CONTROLS
 No display in instrument cluster.

18200/P1792
display
Short circuit to B+  Short circuit to  Read Measured Value
B+ in electrical Block. Refer to
wiring Measured Value
Block, reading; display
group number 002.
 Check wiring
diagram.
2:05:43 AM Page 51

cluster faulty
 90
INSTRUMENTS
for
ELECTRICAL
EQUIPMENT,
CABRIOLET
faulty AUTOMATIC
TRANSMISSION -
GEARS,
HYDRAULIC
CONTROLS

18201/P1793
Sender 2 for transmission output RPM -G196-
No signal  Hydraulic unit  Replace hydraulic
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
18203/P1795
Signal for road speed
Open circuit  Open circuit in  Read Measured
electrical wiring Value Block. Refer
to Measured Value
Block, reading;
display group
number 001.
 Check wiring
connections and
harness connectors
using wiring
2:05:43 AM Page 52
diagram.
 Instrument cluster  Read DTC memory
faulty for instrument
cluster.
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 If DTC 18181/P1773 is displayed in addition, the sensor wheel may be faulty and the transmission must
be replaced.

18204/P1796
Short circuit to ground  Short circuit to  Read Measured
ground in electrical Value Block. Refer
wiring to Measured Value
Block, reading;
display group
number 001.
 Check wiring
connections and
harness connectors
using wiring
diagram.
cluster.
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
2:05:43 AM Page 53
CONTROLS

18205/P1797
Short circuit to B+  Short circuit to B+  Read Measured
in the electrical Value Block. Refer
wiring to Measured Value
Block, reading;
display group
number 001.
 Check wiring
connections and
harness connectors
using wiring
diagram.
cluster.
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS

18206/P1798
Sender 2 for transmission output RPM -G196-
Implausible signal  Incorrect  Compare code
transmission letters on
installed16) transmission with
code letters in -->
00 - GENERAL,
TECHNICAL
DATA
 Hydraulic unit  Replace hydraulic
AUTOMATIC
2:05:43 AM Page 54
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
16) This DTC is displayed if an incorrect transmission has been installed, i.e. if a transmission for a 1.8 liter
engine was mistakenly installed in a vehicle with a 3.0 liter engine.

18221/P1813
Pressure control valve 1 -N215-
Electrical malfunction in  Transmission  Replace
circuit Control Module Transmission
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 Pressure control  Replace hydraulic
valve faulty unit. Refer to 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
18226/P1818
Pressure control valve 2 -N216-
Electrical malfunction in  Transmission  Replace
circuit Control Module Transmission
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
CONTROLS
 Pressure control  Replace hydraulic
valve faulty unit. Refer to 38 -
AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
2:05:43 AM Page 55
CONTROLS

18249/P1841
Engine Control Module (ECM)/Transmission
Versions do not match  Incorrect  Check Engine
Control Module (ECM)
(TCM) installed or identification
incorrectly number.
coded20)
Module (ECM) (ECM)
identification
number and read
DTC memory.
20) Code 0000 is displayed in the Transmission Control Module (TCM) identification number.

18258/P1850
Data bus drive10)
Engine Control Module CAN bus circuit Value Block. Refer
(ECM) to Measured
Value Block,
reading; display
group number 125.
 Check CAN bus.
Refer to Data
Exchange between
Transmission
Control Module
(TCM) and CAN-
Capable Control
Modules,
checking.
18259/P1851
Data bus drive10)
ABS control module CAN bus circuit Value Block. Refer
2:05:44 AM Page 56
to Measured
Value Block,
reading; display
group number 125.
 Check CAN bus.
Refer to Data
Exchange between
Transmission
Control Module
(TCM) and CAN-
Capable Control
Modules,
checking.
 Condition for DTC recognition: The Transmission Control Module (TCM) is not receiving a message
from the Engine Control Module (ECM). However, communication with the ABS control module and the
Transmission Control Module (TCM) and instrument cluster is carried out over what is called a CAN bus.
All information signals are transmitted over 2 leads.
 Condition for DTC recognition: The Transmission Control Module (TCM) is not receiving a signal from
the ABS control module. However, communication with the Engine Control Module (ECM) and the

18262/P1854
Data bus drive10)
Faulty  Transmission  Replace
- AUTOMATIC
TRANSMISSION
- GEARS,
HYDRAULIC
2:05:44 AM Page 57
CONTROLS
18263/P1855
Data bus drive10)
Monitoring software  Open circuit in  Read Measured
status CAN bus circuit Value Block. Refer
to Measured Value
Block, reading;
display group
number 125.
 Check CAN bus.
Refer to Data
Exchange between
Transmission
Control Module
(TCM) and CAN-
Capable Control
Modules, checking.
 Incorrect  Check TCM
Control Module number.
(TCM)

18265/P1857
Load signal
Error message from  Error in "Signal for  Read Engine
Engine Control Module Actual Engine Control Module
(ECM) Torque" diagnosed (ECM) DTC
by Engine Control memory and repair
Module (ECM) malfunction.
2:05:44 AM Page 58

Module (ECM) or (ECM)
engine components identification
faulty number and read
DTC memory
 The signal for actual engine torque is transmitted from the Engine Control Module (ECM) over the CAN
bus lead to the Transmission Control Module (TCM).
 Conditions for DTC recognition: The malfunction in the component in question is diagnosed by the
Engine Control Module (ECM). This diagnosis is transmitted over the CAN bus circuit to the
Transmission Control Module (TCM).

18270/P1862
Data bus drive 10)
instrument cluster CAN bus circuit Value Block. Refer
to Measured
Value Block,
reading; display
group number 125.
 Check CAN bus.
Refer to Data
Exchange between
Transmission
Control Module
(TCM) and CAN-
Capable Control
Modules,
checking.
 Condition for DTC recognition: The Transmission Control Module is not receiving a message from the
Engine Control Module (ECM). However, communication with the ABS control module is working.
All information signals are transmitted over 2 wires.
OUTPUT DIAGNOSTIC TEST MODE (DTM)
2:05:44 AM Page 59
Output Diagnostic Test Mode (DTM)
NOTE:  Output DTM can only be performed if the selector lever is in "P" or "N," the
engine is not running and the vehicle is stationary.
 Output DTM is terminated if the engine is started, the vehicle starts to
move or if a switch is not made within about 60 seconds to the next
actuator. It is also terminated if the selector lever is moved to a position
other than "P" or "N."
Triggering sequence
1. Signal for back-up light
2. Shift lock solenoid -N110-
Test sequence
Vehicle Diagnosis, Measurement and Information System, connecting and selecting functions and
select vehicle system "02 Transmission Electronics". Ignition must be switched on.

Display on VAS 5051
 Touch -1- diagnostic function "03 Diagnostic Test Mode".

2:05:44 AM Page 60
Fig. 22: Display On VAS 5051 - (1st Control Element In Test & Evaporative Emission (EVAP) Canister
Purge Regulator Valve-N80-)
A - First actuator being tested
1 - Back-up light signal
 The Park/Neutral Position (PNP) Relay -J226- turns the back-up lights ON and OFF at intervals for about
1 minute unless a switch has been made to the next actuator by pressing the delta button.
If the back-up lights do not illuminate:
 Check Park/Neutral Position (PNP) Relay -J226- and wiring using wiring diagram.
NOTE: Any electrical malfunctions are saved in the DTC memory. Refer to DTC chart
starts on Diagnostic Trouble Code (DTC) table.
Fig. 23: Display On VAS 5051 - (2nd Control Element In Test & Secondary Air Injection (AIR) Solenoid
2:05:44 AM Page 61
Valve -N112-)
A - Second actuator being tested
2 - Shift lock solenoid -N110-
 The shift lock solenoid -N110- is triggered at intervals for about 1 minute (clicks) unless actuator
diagnosis is terminated by touching the delta button.
NOTE: In addition, the brake symbol on the shift mechanism cover must illuminate at
intervals.
If the solenoid is not triggered:
 Perform electrical test. Refer to Electrical Testing.
NOTE: Any electrical malfunctions are saved in the DTC memory. Refer to DTC chart
starts on Diagnostic Trouble Code (DTC) table.
 Touch the delta button.
Fig. 24: Display On VAS 5051 - (Output Diagnostic Test Mode Is Completed)
A - Actuator test is concluded
 End function "03 Diagnostic Test Mode" by touching <-- button.
DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, ERASING
2:05:44 AM Page 62
Diagnostic Trouble Code (DTC) memory, erasing
Requirements
 DTC memory read. Refer to Diagnostic Trouble Code (DTC) memory, reading.
 All DTCs corrected.
After DTC scan has been performed:

Display on VAS 5051
 Touch -1- diagnostic function "05 Erase DTC memory".

1 - No display (before erasing)
2:05:44 AM Page 63
or
DTC memory erased
NOTE: If the message: "DTC memory has not been read yet" appears in display field -1-
, the test procedure was not followed exactly. The DTC memory can only be
erased if the DTC memory was read previously.
2 - you sure you want to do this? will be deleted!
 Touch "OK" button in display -2-.

 End function "05 Erase DTC memory" by touching <-- button.
 After repair read DTC memory again.
NOTE: This erases DTCs which were stored during repair of the malfunction, for
example by removing harness connectors.
 After reading and deleting DTC memory, test drive vehicle and read DTC memory again.
DTC memory must display:
"No DTC recognized"
TRANSMISSION CONTROL MODULE (TCM), CODING
Transmission Control Module (TCM), coding
The Transmission Control Module (TCM) can be coded.
NOTE: Coding can only be performed with the ignition ON and with the selector lever
in position "P" or "N." The accelerator pedal must be in the idle position. The
vehicle must be stationary and the engine must not be started.
Test procedure
2:05:44 AM Page 64

Display on VAS 5051
 Touch -1- diagnostic function "07 Coding control module".

1 - Enter code word
 On keypad -2- enter control module code as given in code chart.

 Confirm entry by pressing Q button.
Coding chart
Code number For vehicles

01001 USA and Canada
00000 Impermissible code
If this code is displayed, an incorrect transmission
2:05:44 AM Page 65
may have been installed or it has been incorrectly

coded. Check control module identification number.
NOTE: After coding, the Transmission Control Module DTC memory is automatically
deleted.

1 - Coding is being carried out
Fig. 30: Diagnostic System VAS 5051: Display - (Coding Of Vehicle System Performed & Control Module
Identification With New Coding)
1 - Coding in the vehicle system completed
2:05:44 AM Page 66
2 - Control module identification number with new coding (previous coding in parentheses)
 Terminate function "07 Coding Control Module" by pressing <-- button.

 Perform adaptation. Refer to Adaptation.
MEASURED VALUE BLOCK, READING
Measured Value Block, reading
Test procedure
or, depending on the desired operation:
 Start engine.

Display on VAS 5051
 Touch -1- diagnostic function "08 Read Measured Value Block".
2:05:44 AM Page 67

1 - Enter display group Max. input value = 255
 On key pad -2- enter desired 3-digit display group number. Refer to List of Selectable Display Groups
and confirm entry by touching Q button.
Example:
 Enter "001" for "Display group number 001" and confirm by touching Q button.
Fig. 33: Identifying VAS5051 Tester Display

Display on VAS 5051 for display group 001 to 255:
1 - Display group X
2 - Display field 1
Display field 2
2:05:44 AM Page 68
Display field 3
Display field 4
NOTE:  If a display field is not being used, there will be no display.

 To switch to another display field, proceed as follows:
Display group VAS 5051

Higher Press s button
Lower Press t button
 End function "08 Read Measured Value Block" by touching <-- button.
List of Selectable Display Groups
NOTE: The legend for the values in the individual display fields can be found under.
Refer to "Test Chart for Measured Value Blocks" starting on Measured Value
Block table.
Display on screen
(example)
Display fields: Display group number Display field Description
1234
||||
Read Measured Value 001 1 Brake light switch
Block --> 2 Brake test switch
Bls.OFF Bts.OFF PN 3 Shift lock solenoid -
active 0 km/h 4 N110-
Speed
Read Measured Value 002 1 Selector lever position
Block --> 2 Hall sensor status of the
D 1 0 1 0 M switch 3 3 multi-function switch
4 Tiptronic recognition
Gear selected
Block --> 2 Tiptronic recognition
D M switch not actuated 3 Upshift switch for
Reverse switch 4 Tiptronic
Reverse switch for
Tiptronic
Block --> 2 Directional display
D Forward 70 RPM 70 3 Output speed 1
RPM 4 Output speed 2
2:05:44 AM Page 69
Display on screen
(example)
1234
||||
Block --> 2 Park/Neutral position
D Terminal 50 OFF 3 ON/OFF
Relay OFF 13.6 V 4 Back-up light ON/OFF
Supply voltage terminal
15
Read Measured Value 006 1 Can be ignored
Block --> 2
P 0.470 A 0.265 A 0.000 3
A 4
Read Measured Value 007 1 Engine RPM
Block --> 2 Transmission input RPM
760 RPM 0 RPM 0 3 Transmission output
RPM AS 4 RPM
Synchronous flag
Read Measured Value 008 1 Accelerator pedal value
Block --> 2 Actual transmission
62 % 310 RPM 2480 3 output RPM
RPM 3240 RPM 4 Specified transmission
input RPM
Actual transmission input
RPM
Display on screen
(example)
1234
||||
Block --> 2 Kickdown switch
100 % Kickdown 234 3 Actual engine torque
Nm 6500 RPM 4 Engine RPM
Read Measured Value 010 1 Adaptation of clutch
Block --> 2 curve driving forward
0.25 A ADP. O.K. 72°C 3 Adaptation of starting
387 Nm 4 from stop characteristics
driving forward
Transmission fluid
temperature
Specified clutch value
2:05:45 AM Page 70
Read Measured Value 011 1 Adaptation of clutch

Block --> 2 curve backing up
0.25 A ADP. O.K. 72°C 3 Adaptation of starting
387 Nm 4 from stop characteristics
backing up
Transmission fluid
temperature
Specified clutch value
Read Measured Value 012 1 Can be ignored at this
Block --> 2 time
0.5 A 0.81 A 0.28 A 3
4
Display on screen
(example)
1234
||||
Read Measured Value 013 1 Clutch pressure
Block --> 2 MF pressure
8.1 bar 3.2 bar 72°C 89°C 3 Transmission fluid
4 temperature
Coolant temperature
Block --> 2 time
0.28 A 0.81 A 0.28 A 3
0.75 A 4
Block --> 2 time
0.091 A 0.813 A 3 bar 3 3
bar 4
Display on screen
(example)
1234
||||
Block --> 2 time
12.2 2.6 83 2.77 3
4
Block --> 2 Engine RPM
0 % 800 RPM 20 Nm 12 3 Engine torque
Nm 4 Specified clutch torque
2:05:45 AM Page 71
(clutch 1)
Block --> 2 time
8.1 bar 129 Nm 3.2 bar 3
0.098 A 4
Block --> 2 time
8.1 bar 0.12 A A/C 3
compressor ON 4
Display on screen
(example)
1234
||||
Read Measured Value 020 1 Engine RPM
Block --> 2 Specified engine RPM at
800 RPM 800 RPM 800 3 idle
RPM 4 Specified transmission
RPM at idle
Block --> 2 time
90 Nm 79 Nm 90 Nm 3
1399 Nm/sec 4
Read Measured Value 022 1 ABS ON/OFF (Anti-lock
Block --> 2 brake system)
ABS act EDS not act 3 EDS ON/OFF (Electronic
ASR not act ESP act 4 Differential Lock)
ASR ON/OFF
(Automatic Traction
Control)
ESP ON/OFF (Electronic
Stability Program)
Block --> to 2 time
124 3
4
Display on screen
(example)
1234
||||
Read Measured Value 125 1 Engine Control Module
Block --> 2 (ECM) is participant on
2:05:45 AM Page 72
Eng 1 ABS 1 Steering 3 the CAN bus

whl 0 Instr cluster 1 4 ABS control module is
participant on the CAN
bus
Steering column
electronics system is
bus
Instrument cluster is
bus
Measured Value Block table
Display Display Description Test conditions Specified Steps in the events

group field value of deviations from
number displayed specified value
001 1 Brake light switch F Brake Actuated Bls ON Brake light switch
and brake test
switch must always
have the same status
(ON or OFF)
Not Bls OFF  Refer to DTC
actuated 17087/P0703
Continued 2 Brake test switch Brake Actuated Bts ON
? Not Bts OFF
actuated

001 3 Shift lock solenoid - In selector lever
N110- position P or N
Brake Actuated PN  Refer to DTC
deactivated 18169/P1761
Not P N active
actuated
4 Speed While driving 1) .km/h The speedometer
display and values
on the tester can
show minor
divergences
 Refer to DTCs
18203/P1795,
2:05:45 AM Page 73
18204/P1796
and
18205/P1797
1) While driving: a second technician is needed to read the specified values.

002 1 Selector lever position Stationary Selector
Multi-function TR lever
switch -F125- position
P P  Compare with
Measured
Value Block
002, display
field 4
Between P ZP  Refer to DTC
and R 17090/P0706
R R
Between R ZN
and N
Continued N N
? D D

002 2 Hall sensor status of Stationary Selector
the Multi-function TR lever
switch -F125- position
P 0101  Refer to DTC
17090/P0706
ZP 0100
R 0110
ZN 0010
Continued N 0011
? D 1010

002 3 Tiptronic switch -F189- Selector lever in the M-switch
2:05:45 AM Page 74
Tiptronic gate  Refer to

DTCs
18152/P1744,
18161/P1753
and
18164/P1756
Selector lever not in Not
the Tiptronic gate actuated
4 Gear selected Stationary Selector  Check
lever conformity
position with selector
lever display
-Y6- in
instrument
cluster
P P
R R
N N
D D
While D and 1, 2, 3, 4,  Refer to
driving 2) shifted 5 or 6 DTCs
into the 18198/P1790,
Tiptronic 18199/P1791
gate and
18200/P1792
Display Display Description Test conditions Specified Steps in the

group field value events of
number displayed deviations from
specified value
003 1 Selector lever position Refer to display group number 002, display field 1
2 Tiptronic switch -F189- Refer to display group number 002, display field 3
(recognition)
3 Tiptronic switch -F189- Selector lever in Not  Refer to
(upshift) Tiptronic gate actuated DTCs
18147/P1739
and
18162/P1754
Upshift 4) Upshift
switch
4 Tiptronic switch -F189- Selector lever in Not  Refer to
(downshift) Tiptronic gate actuated DTCs
2:05:45 AM Page 75
18141/P1733
and
18163/P1755
Downshift 5) Downshift
switch
4) You must activate the upshift switch (+) by tapping the selector lever forward. On vehicles with multi-
function steering wheel the upshift switch has to be activated by additionally tapping the upper left or right
button (+) on the steering wheel.
5) You must activate the downshift switch (-) by tapping the selector lever to the rear. On vehicles with multi-
function steering wheel the downshift switch has to be activated by additionally tapping the lower left or right
button (-) on the steering wheel.

number displayed deviations
from specified
value
2 Directional display Stationary Not
recognized
While Driving Forward  Compare
driving 2) forward with
Measured
Value
Block
004,
display
field 3
and 4
Continued Driving in Backward
? reverse

specified value
004 3 Output RPM from Sender While driving2) 0.... Displays in display
for transmission output 2000 rpm fields 3 and 4 must
RPM -G195- be the same.
 Refer to
2:05:45 AM Page 76
DTCs
17105/P0721
and
17106/P0722
4 Output RPM from Sender While driving2) 0.... Displays in display
for transmission output 2000 rpm fields 3 and 4 must
RPM -G196- be the same.
 Refer to
DTCs
18201/P1793
and
18206/P1798
Notes on display group number 004:
 If "0 RPM" is shown in display field 3 or 4, the corresponding sender is faulty and the Transmission
Control Module (TCM) must be replaced.
 If "0 RPM" is shown in display field 3 and 4, there is a mechanical defect in the transmission, and the
transmission must be replaced.

2 Park/Neutral position Gear
switch selected
Not active P, N Terminal  Refer to DTCs
50 ON 18132/P1724
and
18137/P1729
Active R, D Terminal
50 OFF
3 Back-up light Gear
selected
Continued Off P, N, D Relay OFF  Refer to DTCs
18194/P1786,
18195/P1787
and
18196/P1788
? On R Relay ON
2:05:45 AM Page 77

number displayed deviations
from specified
value
005 4 Supply voltage Stationary min. 10.0 V  Check
Terminal 15 fuses and
wiring
using
wiring
diagram
max. 15.0 V  Perform
electrical
test.
Refer to
starting
on
Electrical
Testing
006 Can be ignored

specified value
007 1 Engine RPM With the engine 0...  Refer to
running 7000 rpm DTCs
17110/P0726
and
17111/P0727
Continued 2 Input RPM from Sensor While driving 2) 0...  Refer to
? for transmission RPM - 7000 rpm DTCs
G182- 17100/P0716
and
17101/P0717

specified value
007 3 Output RPM from While driving 2) 0...  For -G195-.
Sender for transmission 2200 rpm Refer to
2:05:45 AM Page 78
output RPM -G195- and DTCs

Sender 2 for 17105/P0721
transmission output and
RPM -G196- 17106/P0722
 For -G196-.
Refer to
DTCs
18201/P1793
and
18206/P1798
4 Synchronous flag While Synchronous SY Engine and
driving 2) operation transmission input
RPM are the same
Asynchronous AS Engine and
operation transmission input
RPM are different,
for example, when
starting from stop
and accelerating.
2) While driving a second technician is needed to read the specified values.
Note on display group number 007, display field 4:
 If "AS" is always displayed, the clutch is slipping. The ATF must be changed. If "AS" is still displayed
the transmission must be replaced.
Display Display Description Test conditions Specified Steps if deviations

group field value from specified
number displayed value
008 1 Accelerator pedal Stationary Accelerator 0...1% When accelerating
value pedal not from idle to Wide
depressed Open Throttle the %
value increases
steadily
Accelerator 99...100%  Refer to DTC
pedal fully 18269/P1861
depressed
2 Transmission output Refer to display group number 007, display field 3
RPM
3 Specified transmission While driving 2) 0... Specified and actual
input RPM 7000 rpm transmission input
RPM should be
approximately the
same at a constant
speed
2:05:45 AM Page 79
4 Actual transmission While driving 2) 0...  Refer to DTCs

input RPM 7000 rpm 17100/P0716,
17101/P0717
and
17114/P0730

009 1 Accelerator pedal value Refer to display group number 008, display field 1
2 Kickdown switch -F8- Stationary Not Not
actuated actuated
Kickdown Kickdown  Refer to DTC
actuated6) 18112/P1704
3 Engine torque While driving 2) .Nm The signal for actual
engine torque is
transmitted by the
Engine Control
Module (ECM) over
the CAN bus line to
the Transmission
Control Module
(TCM)
Refer to DTC
18265/P1857
4 Engine RPM Refer to display group number 007, display field 1
6) In order to generate the Kickdown signal the accelerator pedal must be depressed to the stop.

010 1 Adaptation of clutch curve Can be ignored
forward
2 Adaptation of start-from- Perform During ADP. is The test conditions
stop behavior forward adaptation adaptation running 7) must be observed.
Refer to
Adaptation
Refer to Following ADP.
2:05:45 AM Page 80
Adaptation successful O.K. 7)

adaptation
3 Transmission fluid max. 160°C  Refer to
temperature DTCs
17094/P0710,
17095/P0711,
17096/P0712
and
17097/P0713
min. -60°C
4 Specified clutch torque Can be ignored
7) "ADP" is the abbreviation for adaptation. Adaptation means adapting to an internal specified value.
Display Display Description Test conditions Specified Steps in

group field value the events
number displayed of
deviations
from
specified
value
011 1 Adaptation of clutch curve in Can be ignored
reverse
2 Adaptation of start-from-stop Perform During ADP. is The test
characteristics in reverse adaptation adaptation running 7) conditions
must be
observed.
Refer to
Adaptation
Refer to Following ADP.
Adaptation successful O.K. 7)
adaptation
3 Transmission fluid temperature Refer to display group number 010, display
field 3
4 Specified clutch torque Can be ignored
7) "ADP" is the abbreviation for adaptation. Adaptation means adapting to an internal specified value.
Display Display Description Test conditions Specified Steps in

group field value the events
number displayed of
deviations
from
specified
value
2:05:45 AM Page 81
012 In each Can be ignored

to instance
016 1 to 4
017 1 Accelerator pedal value Refer to display group number 008, display field 1
2 Engine RPM Refer to display group number 007, display field 1
3 Engine torque Refer to display group number 009, display field 3
4 Specified clutch torque (clutch While driving 2) ... Nm Is
1) calculated
by the
control
module

018 In each Can be ignored
to instance
019 1 to 4
20 2 Engine RPM Refer to display group number 007, display field 1
2 Specified engine RPM at With the engine Up to The value in
idle running about display field 2
1200 RPM must be greater
than or the same as
the value in display
field 3
3 Specified transmission With the engine Up to If the value in
RPM at idle running about display field 3 is
1200 RPM always greater than
in display field 2:
 Read
Transmission
(TCM) and
Engine
Control
Module
(ECM) DTC
memory and
repair
malfunction
021 Can be ignored
2:05:46 AM Page 82

specified value
022 1 ABS system While ABS ABS Is activated when
(Anti-lock Brake System) driving 2) activated active required by the
by panic ABS control
stop module
No panic ABS not  Read ABS
stop active control
module
DTC
memory
and correct
malfunction
2 EDL system While One wheel EDL Is activated when
(Electronic Differential driving 2) spins active required by the
Lock) when ABS control
starting module
from stop
and is
braked.
Continued Not EDL not  Read ABS
? activated active control
module
DTC
memory
and correct
malfunction

022 3 ASR system (Automatic While Wheel ASR Is activated when
Traction Control) driving 2) spin is active required by Engine
braked Control Module
(ECM) and ABS
control module
Not ASR not  Read DTC
activated active memory of
corresponding
control
module and
repair
2:05:46 AM Page 83
malfunction
4 ESP system While When the ESP active Is activated when
(Electronic Stability driving 2) vehicle required by Engine
Program) drifts out Control Module
in a turn (ECM) and ABS
control module
ESP not  Read DTC
active memory of
corresponding
control
module and
repair
malfunction
023 Can be ignored
to
124

125 1 Participant on CAN Stationary Participates Engine 1  Check CAN
bus drive: Engine bus. Refer to
Control Module Data
(ECM) Exchange
between
Transmission
Control
Module
(TCM) and
CAN-Capable
Control
Modules,
checking
Does not Engine 0
participate
2 Participant on CAN Stationary Participates ABS 1  Check CAN
bus drive: ABS control bus. Refer to
module Data
Exchange
between
Transmission
Control
Module
2:05:46 AM Page 84
(TCM) and
CAN-Capable
Control
Modules,
checking
Does not ABS 0
participate
3 Participant on CAN Stationary Participates Steering  Check CAN
bus drive: Control wheel 1 bus. Refer to
module for steering Data
column electronics Exchange
between
Transmission
Control
Module
(TCM) and
CAN-Capable
Control
Modules,
checking
Does not Steering
participate wheel 0
4 Participant on CAN Stationary Participates Instrument  Check CAN
bus drive: Instrument cluster 1 bus. Refer to
cluster Data
Exchange
between
Transmission
Control
Module
(TCM) and
CAN-Capable
Control
Modules,
checking
Does not Instrument
participate cluster 0
Notes on display group number 125
 If "1" is displayed, communication from the corresponding control module to the Transmission Control
Module (TCM) is O.K.
 If "0" is displayed and no trouble code has been set in the DTC memory, the corresponding control
module does not have CAN capability (or is faulty).
ADAPTATION
2:05:46 AM Page 85
Adaptation
Adaptation must be performed after the following operations:
 After replacing the Transmission Control Module (TCM) -J217-

 After coding the Transmission Control Module -J217-
 After reprogramming (flash) the Transmission Control Module -J217-
Requirement:
 No trouble codes in the DTC memory; read DTC memory. Refer to Diagnostic Trouble Code (DTC)
memory, reading.
Adaptation for driving forward
 Read Measured Value Block display group 010, engine at idle. Refer to Measured Value Block,
reading.

Display on VAS 5051
 Check whether transmission fluid temperature in display field 3 is higher than 60°C. A short test drive
may be necessary to reach this temperature.
 Drive forward briefly and then brake to a stop again.
 Check display in display field 2.
 Display must from change "ADP. is running" to "ADP. O.K."
If the display does not come up as described:
 Repeat start from stop and braking procedure until "ADP. O.K." is displayed.
2:05:46 AM Page 86
If the specified value "ADP. O.K." is not obtained:
 Read DTC memory. Refer to Diagnostic Trouble Code (DTC) memory, reading and correct
malfunction. Adaptation must be performed again afterward.
 Perform adaptation for driving in reverse.
Adaptation for driving in reverse:
 Read Measured Value Block display group 011, engine at idle. Refer to Measured Value Block,
reading.

Display on VAS 5051
 Drive backward (in reverse) briefly and then brake to a stop again.
 Check display in display field 2.
 Display must from change "ADP. is running" to "ADP. O.K."
If the display does not come up as described:
 Repeat start from stop and braking procedure until "ADP. O.K." is displayed.
If the specified value "ADP. O.K." is not obtained:
 Read DTC memory. Refer to Diagnostic Trouble Code (DTC) memory, reading and correct
malfunction. Adaptation must be performed again afterward.
ELECTRICAL TESTING
Electrical Testing
2:05:46 AM Page 87
Fig. 36: Special Tool - Multimeter V.A.G 1526 A

 Multimeter V.A.G. 1526 A
Fig. 37: VAG 1598/21 Adapter From VAG 1598 A Test Box
 Test box V.A.G. 1598/21
NOTE:  For testing, use Multimeter V.A.G. 1526 A or VAS 5051 Vehicle Diagnosis,
Measurement and Information System. The charts contain the specific
measurement methods which have to be set up before the corresponding
measurements.
 The specified values given are valid for an ambient temperature of 0°C to
40°C.
 If the values measured deviate from the specified values, determine the
malfunction using the wiring diagram.
 If the values measured show only a minor deviation from the specified
values, clean cavities and plugs on the test equipment and test leads,
repeat test. Before replacing the components in question, check their
wires and connectors. In particular with specified values below 10 ohms
2:05:46 AM Page 88
repeat the resistance measurement on the component.

 The terminal numbers of the connector and the cavity numbers on the
V.A.G. 1598/21 test box match. Refer to Multiple harness connector (25-pin
connector) for Transmission control module -J217- (cavities on V.A.G
1598/21).
CAUTION: In order to avoid destroying electronic components, the specific

measurement range on the measuring equipment must be switched on
before connecting the test leads.
Test requirements:
 Vehicle power supply O.K.

 Power supply and fuses for particular system OK
Refer to Electrical Wiring Diagrams, Troubleshooting and Component Locations
 Check ground connections for corrosion and faulty connection, repair as needed.
Test procedure

2:05:46 AM Page 89
 Undo quick release fasteners -2- and -3- and remove sound deadening at rear. Sound deadening at front
remains installed.
 Loosen cover for vehicle floor and heat shield above exhaust system in rear area of transmission. Push
heat shield a little to one side.

 Where used, remove left inner -2- and right inner -1- vehicle floor covers.
2:05:46 AM Page 90

 Unlock connector -A- in direction of (arrow) and disconnect it from transmission.

 Uncover wiring harness.
 Connect test box V.A.G 1598/21 to wiring harness to control module.
 Perform test as described in specific test chart.
Multiple harness connector (25-pin connector) for Transmission control module -J217- (cavities on V.A.G 1598/21)
1- Not used 15- Engine RPM signal

2- K-wire for diagnosis 16- Not used
3- Park/Neutral position 17- Not used
(PNP) relay -J226-
4- Park/Neutral position 18- Not used
(PNP) relay -J226-
5- Vehicle speed signal 19- Not used
6- Not used 20- Not used
7- Shift lock solenoid - 21- Not used
N110-
8- Supply voltage (terminal 22- Not used
15)
9- Supply voltage (terminal 23- Not used
87)
10- CAN bus (High) 24- Not used
11- CAN bus (Low) 25- Ground for power
consumers (terminal 31)
12- Tiptronic switch -F189-
(upshift)
(recognition)
(downshift)
Component tested Corresponding test step

Supply voltage for Transmission Control Module -  Perform test steps 1, 2 and 3
J217-
Shift lock solenoid -N110-  Perform test step 4
Wire connection to the Engine Control Module  Perform test step 5

(ECM) (engine RPM signal)
Test table
2:05:46 AM Page 91

Test step V.A.G What is  Test conditions
Specified Steps if
1598/21 being tested value deviations
 Additional procedures
from specified
value
1 25 + Plus at Ground  Ignition switched off Approximately  Check
the connection battery voltage wiring
Battery for the routing
Transmission using
Control wiring
Module diagram.
(TCM) -
J217-
2 8 + 25 Supply  Ignition switched on Approximately  Check
voltage for battery voltage fuses.
Transmission
Control  Check
Module wiring
(TCM) - routing
J217- using
(terminal 15) wiring
diagram.
 Ignition switched off About 0 V
3 9 + 25 Supply  Ignition switched on Approximately  Check
voltage for battery voltage fuses.
Transmission
Control  Check
Module wiring
(TCM) - routing
J217- using
(terminal 87) wiring
diagram8)
 Ignition switched off About 0 V
8) Power supply through terminal 87 is managed in different ways: On vehicles with the 2.4 liter engine through
the ignition time delay relay for ignition cut off -J64-; On all other gasoline engines through the Motronic ECM
power supply relay -J271-; On vehicles with diesel engines through the Diesel Direct Fuel Injection (DFI)
system relay -J322-.

Specified Steps if
1598/21 being tested value deviations from
 Additional
specified value
procedures
4 7 + 25 Shift lock  Ignition switched on
Approximately  Check
solenoid - battery voltage
2:05:46 AM Page 92
N110-  Selector lever in wiring

position P or N connections
and fuses
 Brake pedal using
depressed wiring
diagram.
 Check shift
lock
solenoid -
N110-.
Refer to
Shift Lock
Solenoid -
N110-,
checking
 Brake pedal not Approx. 0 V  Check
depressed brake light
switch.

Specified Steps in the
1598/21 being tested value events of
cavities  Additional procedures
deviations
from
specified
value
5 15 + xx 7) Wire  Ignition switched off Less than 1.5  Check
connection to ohms wiring
the Engine  Disconnect Engine
Control Module (ECM) routing
Control using
Module wiring
(ECM) diagram.
(engine RPM
signal)
7) Corresponding terminal pinout on the Engine Control Module (ECM):
Shift Lock Solenoid -N110-, checking
NOTE: This test must be performed if the specified values in the voltage measurement
are not reached.
Additional special tools and equipment
2:05:47 AM Page 93
Fig. 41: Identifying Adapter Set V.A.G 1594 A

 Connector test kit V.A.G 1594 A
Test sequence
 Remove cover for shift control mechanism
Fig. 42: Disconnecting Harness Connector At Shift Lock Solenoid -N110 & Attaching Multimeter For
Resistance Measurement Between Contacts
 Disconnect harness connector at Shift lock solenoid -N110 -A-.

 Attach multimeter for resistance measurement between contacts -B-.
2:05:47 AM Page 94
 Specified value: 22.3 ± 1 ohms
If the specified value is not reached:
 Replace the shift lock solenoid.
Data Exchange between Transmission Control Module (TCM) and CAN-Capable Control Modules, checking
NOTE:  The exchange of data between the individual control modules is carried
out by means of a bus system.
 "CAN Bus" describes a system to carry and distribute data.
 The wiring connections between the control modules, over which the data
are transmitted, are described as data lines.
 Data are transmitted serially, that means in sequence, over these data
lines to the attached control modules (e.g. engine RPM, accelerator pedal
position).
Checking bus system
In the DTC table you were instructed to inspect the exchange of data between the Transmission Control Module
(TCM) and CAN-capable control modules.

Display on VAS 5051
 Touch -1- diagnostic function "08 Read Measured Value Block".
2:05:47 AM Page 95

Display on VAS 5051
1 - Enter display group Max. input value = 255
NOTE: Measured Value Block 125 shows the participants on the data BUS drive.
 On keypad enter -2- "125" for "Display group number 125" and confirm by touching Q button.

Display on VAS 5051
 Check displays in display fields -1- to -4-.
The display shows the control modules which are CAN- capable with the Engine Control Module (ECM):
 Display 1: CAN-capable control module is a participant on data bus

 Display 0 or no display: CAN-capable control module is not a participant on data bus or not CAN-
capable
2:05:47 AM Page 96
 End function "08 Read Measured Value Block" by touching <-- button.

Display on VAS 5051
 In selection -1- touch diagnostic function "00 Read DTC memory complete system".
 DTC memory of all systems in the vehicle capable of On Board Diagnostic (OBD) is read.
If a control module responds and identifies itself, the number of stored DTCs or "No DTC" is displayed on the
screen.
Any stored DTCs in a system are shown in sequence. Then the VAS 5051 sends the next address word.
If a DTC referring to "Data bus drive..." or "...CAN bus" is displayed:
 Check whether correct Engine Control Module (ECM) and other CAN-capable control modules have
been installed (Part No. and Code).
If the correct control modules have been installed:
 Check whether multiple connectors for control module are fully seated.
If the multiple connectors are fully seated:
 Check CAN bus system.
Checking a "Dual Wire Bus System"
Communication takes place between two or more control modules over a "Dual Wire Bus System".
 Analyze DTCs stored in control modules.
2:05:47 AM Page 97
NOTE: The analysis helps to pinpoint the wiring malfunction.
Example 1:
Based on the DTCs entered in the DTC memories, it can be seen that control module 1 is not connected to
control modules 2 and 3.


 Disconnect control modules connected by bus circuit and check whether a bus wiring connection has an
open circuit.
Example 2:
Based on the DTCs entered in the DTC memories, it can be seen that control module 2 is not connected to
control modules 1 and 3.


 Disconnect control modules connected by the bus circuit and check whether a bus wiring connection has
an open circuit.
Example 3:
2:05:47 AM Page 98
Based on the DTCs entered in the DTC memory, it can be seen that no transmission or reception activity is
possible in any of the control modules.

Fig. 47: Checking Bus Wires For Short Circuit To B+ Or Ground

 Disconnect control modules connected by bus circuit wiring and inspect bus wiring for a short circuit to
B+ and to ground.
If you are unable to determine any cause in the bus wiring for the DTC "Data bus drive faulty", check to
see whether one of the control modules is responsible for this DTC.
Test requirement:
 VAS 5051 Vehicle Diagnosis, Measurement and Information System connected and Vehicle OBD
selected. Refer to VAS 5051 Vehicle Diagnosis, Measurement and Information System, connecting
and selecting functions.
All the control modules which use the CAN bus for communication are disconnected. The ignition is switched
OFF.
 Connect one control module.
2:05:47 AM Page 99

Display on VAS 5051

 Touch appropriate vehicle system in Display -1-.
 Read DTC memory of control module just connected and delete it.
 In display touch -1- diagnostic function "06 End output".

 Switch ignition OFF and ON again.
 Leave ignition switched ON for 10 seconds. Then, using scan tool, read DTC memory of control module
just connected.
 If DTC "Data bus drive faulty" is read, control module just connected must be replaced.
 If DTC "Data bus drive not faulty" is read, connect next control module and repeat procedure.
2:05:47 AM Page 100



1 - Transmission Control Module (TCM) J217
 Installed location --> Transmission Control Module (TCM) J217

 Control module is checked with On Board Diagnostics (OBD)
 Removing and installing --> Transmission Control Module (TCM) J217 , removing and installing
2 - Hydraulic control module
2:00:48 AM
2:01:27 Page 1
 Installed location Hydraulic control module

 Valves are checked with On Board Diagnostics (OBD)
 Removing and installing --> Hydraulic control module, removing and installing
3 - Shift mechanism cover
 --> Shift mechanism cover (through VIN 8E_6A156499), removing and installing
 --> Shift mechanism cover (from VIN 8E_6A156500), removing and installing
 Location: Integrated into circuit board in cover of shift mechanism

 Consists of 3 Hall sensors that are controlled by a magnet on the cover strip transverse slide.
is properly secured and replace masking panel if necessary. Before replacing the printed circuit, check
wiring.
 --> Tiptronic Switch F189 (through VIN 8E_6A156499), removing and installing
 --> Tiptronic Switch F189 (from VIN 8E_6A156500), removing and installing
 Installed location --> Shift lock solenoid N110

 Installed location Data Link Connector (DLC)
7 - Cruise Control Switch E45
 Installed location --> Cruise Control Switch E45

 94 LIGHTS, SWITCHES - EXTERIOR
 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET
9 - Power supply relay terminal 87/ Starter Interlock Alarm System Relay J60
2:00:48 AM Page 2
10 - Transmission Range (TR) Display Y6
 Installed location --> Transmission Range (TR) Display Y6

 A fully illuminated gear selection indicator indicates a simple malfunction
 A blinking gear selection indicator indicates a critical malfunction
 No indication on display points to a fault in wiring or a faulty Transmission Range (TR) Display Y6
11 - Kick Down Switch F8
 Not a separate component, it adopts functions of Throttle Position (TP) Sensor G79 and Accelerator Pedal
Position Sensor 2 G185 in vehicles with gasoline engine, both are integrated in accelerator pedal module;
component location --> Kick Down Switch F8
 Installed as one unit with Throttle Position (TP) Sensor G79 in vehicles with Diesel engine, this is
integrated in the accelerator pedal module; component location --> Kick Down Switch F8
 Removing and installing accelerator pedal module --> 20 - FUEL SUPPLY SYSTEM
12 - Brake Light Switch F
 Installed location --> Brake Light Switch F

 Removing and installing --> 46 - BRAKES - MECHANICAL COMPONENTS

2:00:48 AM Page 3
 Location: Transmission Control Module (TCM) J217 is on the back end of transmission, secured directly
to hydraulic control module.
The following components are integrated in the control module:
A - Transmission Output Speed (RPM) Sensor G195 and Transmission Output Speed (RPM) Sensor 2 G196
B - Transmission Fluid Temperature Sensor G93
C - Multi-Function Transmission Range (TR) Switch F125
D - Transmission Input Speed (RPM) Sensor G182
E - Automatic Transmission Hydraulic Pressure Sensor 1 G193
F - Automatic Transmission Hydraulic Pressure Sensor 2 G194
Removing and installing Transmission Control Module (TCM) J217 --> Transmission Control Module
Hydraulic control module

 Location: Hydraulic control module is bolted to back end of transmission. Transmission Control Module
(TCM) J217 is fastened directly to hydraulic control module.
A - Harness connector for Automatic Transmission Pressure Regulating Valve 1 N215
B - Harness connector for Automatic Transmission Pressure Regulating Valve 2 N216
C - Harness connector for Solenoid Valve 1 N88
Following valves are integrated into hydraulic control module (not depicted here).
2:00:48 AM Page 4
 Automatic Transmission Pressure Regulating Valve 1 N215 (clutch solenoid valve)

 Automatic Transmission Pressure Regulating Valve 2 N216 (solenoid valve gear)
 Solenoid Valve 1 N88 (clutch cooling/safety shut-off)
 Clutch cooling valve
 Minimum pressure valve

 Pressure relief valve
 Clutch control valve
 Pressure control valve
NOTE:  Valves are monitored via On Board Diagnostic (OBD).

 Description and functions of individual valves 951103Continuously
Variable Automatic Transmission Multitronic 01J.
Removing and installing hydraulic control module --> Hydraulic control module, removing and installing.

 Location: Shift Lock Solenoid N110 is located in shift mechanism - arrow -.
2:00:48 AM Page 5
Connector (DLC)
 Location: Diagnostic connection is located beneath knee bolster on left of steering wheel.
Cruise Control Switch E45
Fig. 8: Cruise Control Switch E45

 Location: Cruise control switch is located on steering column switch.
2:00:48 AM Page 6
Fig. 9: Transmission Range (TR) Display Y6

 Location: Integrated in instrument cluster.
NOTE:  Transmission Range (TR) Display Y6 can only be replaced as a set with the
instrument cluster.
Power supply relay terminal 87/Starter Interlock Alarm System Relay J60 and Park/Neutral Position (PNP) Relay J226
(up to 10.04) or Starting Interlock Relay J207 (as of 11.04)
Fig. 10: Power Supply Relay Terminal 87/Starter Interlock Alarm System Relay J60 And Park/Neutral
Position (PNP) Relay J226 (Up To 10.04) Or Starting Interlock Relay J207 (As Of 11.04)
 Location: On relay carrier in E-box, plenum chamber.
Voltage is supplied differently via terminal 87:
1 - Starter Interlock Alarm System Relay J60 - only in vehicles with 2.4 L gasoline engine
3 - Motronic Engine Control Module (ECM) Power Supply Relay J271 - in all other vehicles with gasoline
engine
2:00:48 AM Page 7
3 - Power Supply Relay (terminal 30, B+) J317 - in vehicles with Diesel engine
NOTE:  In vehicles as of 11.04, activation of reverse driving lights occurs via CAN-
Bus.
Brake Light Switch F

 Location: Brake light switch - arrow - is located in brake pedal assembly.
NOTE:  Switch is only to be installed once so as to ensure a firm fit.
Kick Down Switch F8
2:00:48 AM Page 8

 Location: In accelerator pedal module - arrow -.
NOTE:  In vehicles with gasoline engine, Kick Down Switch F8 adopts the
functions of Throttle Position (TP) Sensor G79 and Accelerator Pedal
Position Sensor 2 G185.
SHIFT MECHANISM (THROUGH VIN 8E_6A156499), SERVICING
Shift mechanism (through VIN 8E_6A156499), servicing
Shift mechanism (through VIN 8E_6A156499), checking
Overview:
 1. Selector mechanism function test --> Selector mechanism function test

 2. Checking ignition key removal lock --> Check ignition key withdrawal lock
 3. Locking button on selector lever handle, checking --> Check locking button on selector lever handle
2:00:48 AM Page 9
 In selector lever positions "S" , "D" , "R" and "Tiptronic gate" the starter motor will not operate.
 If selector lever position "N" is selected at speeds greater than 5 km/h, the selector lever lock solenoid
must not engage and block selector lever. Selector lever can be shifted into driving gear.
 Up to approx. 08.01: Selector lever is locked and cannot be shifted out of position "N" without pressing
button on selector lever handle. Shift Lock Solenoid N110 blocks selector lever.
 As of approx. 08.01: Selector lever is not locked immediately when rapidly shifting through position
"N" (e.g. from "R" to "D"). This enables e.g. "forward and reverse maneuvers" when vehicle is stuck.
Shift lock engages when selector lever is located in "N" for longer than approx. 1 s with brake not being
pressed.
up.
 The Transmission Range (TR) Display Y6 in instrument cluster must change from "PRND" to "654321"
2:00:48 AM Page 10
or (from VIN 8E_5400001) from "PRNDS" to "7654321" when selector lever is shifted into "Tiptronic
Gate".


 Selector lever cannot be shifted out of position "P" with locking button pressed and foot brake operated.

 After releasing, the locking button must come all the way back out by itself

Function test:
Locking button on selector lever handle must be pressed for the following shifts. If it is not pressed, the selector
2:00:48 AM Page 11

 "D" to "S"
 "R" to "P"

Shift mechanism, through VIN 8E_6A156499, removing and installing
Removing
installing.


2:00:48 AM Page 12

 Disengage locking cable - arrows -.
2:00:48 AM Page 13


 Remove rear cross member for vehicle floor, to do so remove bolts - 1 through 4 -.
2:00:48 AM Page 14
All:
it may be damaged.

2:00:48 AM Page 15


arrow -.
2:00:48 AM Page 16


vehicle.
Installing
 Install selector lever cable --> Selector lever cable, (through VIN 8E_6A156499), removing and
installing.
 Install locking cable --> Locking lever (through VIN 8E_6A156499), removing and installing.
ENGINE CODE(S): BKH
.
2:00:48 AM Page 17
Component Nm
Selector lever handle, shift mechanism cover (through VIN 8E_6A156499), assembly overview
052 142 A2 .
2:00:49 AM Page 18
1 - Selector lever
installing
installing
4 - Cover

5 - Symbol panel

installing
selector lever cable --> Selector lever cable (through VIN 8E_6A156499), adjusting
7 - Cover strip

installing
Selector lever handle (through VIN 8E_6A156499), removing and installing
Removing
2:00:49 AM Page 19


will be damaged.
Installing
2:00:49 AM Page 20
 Remove cable tie - arrow - or assembly aid, thereby button mechanism engages in vertical groove of
selector lever. If necessary press button into selector lever handle.
Shift mechanism cover (through VIN 8E_6A156499), removing and installing
Removing
installing.


2:00:49 AM Page 21
Installing
 Install selector lever handle --> Selector lever handle (through VIN 8E_6A156499), removing and
installing.
Tiptronic Switch F189 (through VIN 8E_6A156499), removing and installing
wiring.
Removing
2:00:49 AM Page 22

Installing
and installing.
Shift mechanism (through VIN 8E_6A156499,), assembly overview
052 142 A2 .
2:00:49 AM Page 23
Fig. 31: Shift Mechanism (Through VIN 8E_6A156499,), Assembly Overview

2 - Bracket
3 - Bushing
5 - Pivot pin
6 - Selector lever
2:00:49 AM Page 24
8 - Operating lever for locking cable
11 - Locking lever
12 - Shift lever guide
NOTE:  If selector lever guide or shift unit is faulty, entire shift mechanism must
be replaced. It is not possible to adjust both components using shop
equipment.
13 - Nut
 10 Nm
14 - Shift unit
15 - Bushing
16 - Retaining bracket for selector lever
17 - Retaining clip
19 - Pivot pin
20 - Nut
 10 Nm
Shift mechanism (through VIN 8E_6A156499), disassembling and assembling
Disassembling
NOTE:  Securing spring for locking cable, removing and installing Retaining
spring for locking cable, removing and installing
2:00:49 AM Page 25
6 - Selector lever

 Remove shift lock solenoid - 7 - --> Shift Lock Solenoid N110 (through VIN 8E_6A156499),
 Unclip selector lever guide - 12 -.
 Release pivot pins - 5 - and - 19 - and pull them out from side.
 Unclip retaining brackets - 2 - and - 16 -.

 Pull selector lever - 6 - with bushings - 3 - and - 15 - as well as Tiptronic locking levers - 4 - and - 18 -
2:00:49 AM Page 26
downward out of shift unit - 14 -.
Assembling
6 - Selector lever
 Check whether selector lever is in position "D".

 Insert selector lever - 6 - from below into shift unit - 14 -.
 Connect locking levers for Tiptronic - 4 - and - 18 - as well as bushings - 3 - and - 15 - on selector lever.
 Press selector lever - 6 - with bushes into shift unit and position it with retaining clip - 17 -.
2:00:49 AM Page 27
 Engage retaining brackets - 2 - and - 16 - on shift unit.

 Push pivot pins - 5 - and - 19 - into selector lever - 6 - until they engage.
 Check whether mounting pins in Tiptronic locking lever engage.
 Install shift lock solenoid - 7 - --> Shift Lock Solenoid N110 (through VIN 8E_6A156499), removing
and installing.
 Clip in selector lever guide - 12 -.
Retaining spring for locking cable, removing and installing
Fig. 34: Retaining Spring For Locking Cable, Removing And Installing
Removing:
 To remove locking cable, slightly lift spring at top - arrow B -.

 Unhook spring at retaining tab - arrow C - and remove toward top.
Installing:
 Insert spring - arrow B - from top and hook in at retaining clip - arrow C -.
 Align spring so that it is seated evenly in groove - arrow A -.
Shift Lock Solenoid N110 (through VIN 8E_6A156499), removing and installing
Removing
2:00:49 AM Page 28
Fig. 35: Releasing Lugs And Removing Shift Lock Solenoid Forward
 Release lugs and remove shift lock solenoid forward - arrows -.
Installing
 Press shift lock solenoid into guide until it engages; operating lever - 2 - of solenoid must engage in
locking lever - 1 - on shift mechanism.
and installing.
Selector lever cable and locking cable (through VIN 8E_6A156499), assembly overview

2:00:49 AM Page 29
Fig. 37: Selector Lever Cable And Locking Cable (Through VIN 8E_6A156499), Assembly Overview
1 - Nut
 23 Nm
 Removing and installing --> Selector lever cable, (through VIN 8E_6A156499), removing and
installing
 Adjusting --> Selector lever cable (through VIN 8E_6A156499), adjusting
2:00:49 AM Page 30
3 - Lock nuts
 13 Nm
4 - Boot for selector lever cable
 To be buttoned into selector mechanism bottom cover
5 - Retaining clip
 with ignition key removal lock
7 - Locking cable

 Removing and installing --> Locking lever (through VIN 8E_6A156499), removing and installing
 Adjusting --> Locking lever (through VIN 8E_6A156499), adjusting
8 - Bolt
 9 Nm
9 - Clamping screw
 13 Nm
10 - Pin

 To remove selector lever cable, move plastic retaining spring at selector mechanism forward slightly and
put screws upward, only as far as necessary.
13 - Bolt
 23 Nm
2:00:49 AM Page 31
Selector lever cable, (through VIN 8E_6A156499), removing and installing

Removing

2:00:49 AM Page 32

 Remove rear cross member for vehicle floor, remove bolts - 1 through 4 - to do so.
All:
2:00:49 AM Page 33

it may be damaged.
2:00:49 AM Page 34
2:00:49 AM Page 35


arrow -.
2:00:49 AM Page 36
 Loosen lock nuts - 6 - and remove selector lever cable - 5 - from support bracket - 4 -.
Installing

2:00:49 AM Page 37
 Slide selector lever cable into shift mechanism and secure it with retaining clip - 1 -.
 Installation position: Angled end of retaining clip points toward rear.

 Press pin - 3 - downward - arrow -.
 Check whether plastic securing spring - 2 - has locked the pin.
 Button selector lever cable boot into lower cover.

 Bolt lower cover securely to shift mechanism - arrows -.
2:00:49 AM Page 38
 Tightly bolt selector lever cable - 5 - to support bracket - 4 - , tighten lock nuts - 6 - to 12 Nm.
engages.
carefully onto lever for selector shaft - 7 -.
2:00:49 AM Page 39
properly.
ENGINE CODE(S): BKH
.
Component Nm
Bracket to transmission 23
Support bracket to mounting base 23
Selector lever cable (through VIN 8E_6A156499), adjusting
2:00:50 AM Page 40

model year 2005).
 In vehicles with "PRND" shift mechanisms (through model year 2004),
selector lever cable adjustment is performed in selector lever position "D".
 In vehicles with "PRNDS" shift mechanisms (from model year 2005),
selector lever cable adjustment is performed in selector lever position "S".
2:00:50 AM Page 41

seat - arrow A -.
2:00:50 AM Page 42
 Loosen rear clamping screw on selector lever cable through the hole in shift mechanism approx. one turn
NOTE:  Loosen clamping screw only 1 turn. Do not remove.

 The selector lever must remain in position "S" with clamping bolt
loosened, otherwise the setting is not correct.
 Carefully move selector lever forwards and backwards slightly without shifting to a different selector
lever position.
 Pull selector lever completely toward rear once more until it stops in position "S" and release selector
lever.
and installing.
2:00:50 AM Page 43

 Bring selector lever cable into basic setting --> Selector lever cable (VIN through 8E_6A156499),
Component Nm
Selector lever cable (VIN through 8E_6A156499), bringing into basic setting
2:00:50 AM Page 44

Work procedure
model year 2005).
"D" using socket and key T40031.
2:00:50 AM Page 45
"S" using socket and key T40031.

2:00:50 AM Page 46

2:00:50 AM Page 47


Component Nm
Locking lever (through VIN 8E_6A156499), removing and installing
2:00:50 AM Page 48

1 - Locking cable
Removing

2:00:50 AM Page 49

.
.

.
2:00:50 AM Page 50

1 - Locking cable
Installing
 Route locking cable kink-free behind instrument panel strut - arrow -.

 Bring ignition/starter switch into locking position ("ignition off").
2:00:50 AM Page 51

 Engage locking cable eye into pin - 3 -.
 Lift securing spring - 4 - slightly.
 Slide locking cable support bracket - 5 - from right into shift mechanism until securing spring - 4 -
engages.

.
Locking lever (through VIN 8E_6A156499), adjusting

 Safety glasses
Work preparations
center console.
2:00:50 AM Page 52

grinder.
Work procedure
2:00:50 AM Page 53
 Check ignition key removal lock after every adjustment of locking cable --> Shift mechanism (through
Component Nm
SHIFT MECHANISM (FROM VIN 8E_6A156500), SERVICING
Shift mechanism (from VIN 8E_6A156500), servicing
Shift mechanism (from VIN 8E_6A156500), checking
Overview:
 1. Selector mechanism function test Selector mechanism function test

 2. Checking ignition key removal lock Check ignition key withdrawal lock
 3. Locking button on selector lever handle, checking Check locking button on selector lever handle
 In selector lever positions "S" , "D" , "R" and "Tiptronic gate" starter motor will not operate.
 If selector lever position "N" is selected at speeds greater than 5 km/h, selector lever lock solenoid must
not engage and block selector lever. Selector lever can be shifted into driving gear.
2:00:50 AM Page 54
 Selector lever is not locked immediately when rapidly shifting through position "N" (e.g. from "R" to
"D"). This enables e.g. "forward and reverse maneuvers" when vehicle is stuck. Shift lock engages when
selector lever is located in "N" for longer than approx. 1 s with brake not being pressed.
up.
 The Transmission Range (TR) Display Y6 in instrument cluster should switch from "PRNDS" to
"7654321" when selector lever is shifted into "Tiptronic gate".

2:00:50 AM Page 55

 Selector lever cannot be shifted out of position "P" with locking button pressed and parking brake
operated.

 After releasing, locking button must come all the way back out by itself

Function test:
Locking button on selector lever handle must be pressed for the following shifts. If it is not pressed, selector

 "D" to "S"
 "R" to "P"

2:00:50 AM Page 56
Selector lever handle, shift mechanism cover (from VIN 8E_6A156500), assembly overview
052 142 A2 .
1 - Selector lever
2:00:50 AM Page 57
4 - Cover

5 - Symbol panel

installing
selector lever cable --> Selector lever cable (from VIN 8E_6A156500), adjusting
7 - Cover strip

installing
Selector lever handle (from VIN 8E_6A156500), removing and installing
Removing
2:00:51 AM Page 58


will be damaged.
Installing

2:00:51 AM Page 59
 Remove cable tie - arrow - or assembly aid, thereby the button mechanism engages in the vertical groove
of the selector lever. If necessary press button into selector lever handle.
Shift mechanism cover (from VIN 8E_6A156500), removing and installing
Removing
installing.


2:00:51 AM Page 60
 Disconnect connector from the side of the guide plate.
Installing
 Install selector lever handle --> Selector lever handle (from VIN 8E_6A156500), removing and
installing.
Tiptronic Switch F189 (from VIN 8E_6A156500), removing and installing
 If malfunctions at Tiptronic Switch F189 occur, first check whether magnet at control slide masking panel
wiring.
To replace Tiptronic switch, circuit board must be replaced.
Removing
and installing.
2:00:51 AM Page 61

Installing
2:00:51 AM Page 62
installing.
Shift mechanism (from VIN 8E_6A156500), assembly overview
052 142 A2 .
Fig. 78: Shift Mechanism (From VIN 8E_6A156500), Assembly Overview

1 - Rubber seal
2 - Press tube
3 - Bolt, 2 Nm
2:00:51 AM Page 63
 Qty. 4
4 - Selector mechanism function unit
 Not installed on all vehicles
7 - Lock washers
 Qty. 4, always replace

 For securing sound insulation on selector mechanism function unit
8 - Retaining clip
 Secures selector lever cable on selector mechanism function unit
 --> Selector lever cable (from VIN 8E_6A156500), removing and installing
10 - O-Ring
 Always replace
Shift mechanism (from VIN 8E_6A156500), removing and installing
2:00:51 AM Page 64

Removing
installing.
2:00:51 AM Page 65

 Raise retaining tab - A - and remove locking lever in direction of - arrow -.



2:00:51 AM Page 66



it may be damaged.

2:00:51 AM Page 67

All:
Mechanism

2:00:51 AM Page 68


vehicle.
Installing
 Install selector lever cable --> Selector lever cable (from VIN 8E_6A156500), removing and
installing.
 Install locking cable --> Locking lever (from VIN 8E_6A156500), removing and installing.
ENGINE CODE(S): BKH
.
2:00:51 AM Page 69
Component Nm
Shift Lock Solenoid N110 (from VIN 8E_6A156500), removing and installing
Removing
and installing.
 Press retaining hooks - A - into shift mechanism - arrow - and hold it down.
NOTE:  If retaining hook - A - is broken off, selector mechanism function unit must
be replaced.
2:00:51 AM Page 70
Fig. 90: Disengaging Ball Head From Operating Lever On Shift Mechanism
 Tip Shift Lock Solenoid N110 down and out in direction of - arrow - so that ball head - 1 - disengages
from operating lever on shift mechanism.
 Remove Shift Lock Solenoid N110.
Installing
 Rotate ball head - 1 - to correct installation position.

 Guide Shift Lock Solenoid N110 diagonally from above into shift mechanism.
 Tip Shift Lock Solenoid N110 down in opposite direction of - arrow -.
 Ball head - 1 - must be completely engaged in operating lever on shift mechanism.

 Secure Shift Lock Solenoid N110 on retaining hook - A -.
installing.
Selector lever cable and locking cable (from VIN 8E_6A156500), assembly overview

2:00:51 AM Page 71
Fig. 92: Selector Lever Cable And Locking Cable (From VIN 8E_6A156500), Assembly Overview
 Removing and installing --> Selector lever cable (from VIN 8E_6A156500), removing and installing
2 - Lock nuts
 13 Nm
2:00:51 AM Page 72
3 - Retaining clip
5 - Locking cable

 Removing and installing --> Locking lever (from VIN 8E_6A156500), removing and installing
 Adjusting --> Locking cable (from VIN 8E_6A156500), adjusting
6 - Bolt
 9 Nm
7 - Clamping screw
 13 Nm
8 - O-Ring
 Always replace
10 - Bolt
 20 Nm
 For securing bracket to selector lever cable bracket
12 - Bolt
 20 Nm
 Qty. 3
 For securing selector lever cable bracket to transmission
2:00:52 AM Page 73
Selector lever cable (from VIN 8E_6A156500), removing and installing


Removing
installing.
and installing.
2:00:52 AM Page 74

Removing

2:00:52 AM Page 75


it may be damaged.


2:00:52 AM Page 76

All:
Mechanism

Installing
2:00:52 AM Page 77
Torque specifications --> Selector lever cable and locking cable (from VIN 8E_6A156500), assembly
overview


 Slide noise insulation - A - over opening on selector lever cable.
All:
Fig. 102: Replacing O-ring on selector lever cable & Slide selector lever cable into shift mechanism
 Replace O-ring - 1 - on selector lever cable.
2:00:52 AM Page 78
 Slide selector lever cable into shift mechanism - arrow -.
Mechanism
 Secure selector lever cable - 2 - to shift mechanism with retaining clip - 1 -.
 Installation position: Angled end of retaining clip faces toward shift mechanism.

 Secure sound insulation to shift mechanism with four new lock washers - arrows -.
All:
2:00:52 AM Page 79
 Tightly bolt selector lever cable - 5 - to support bracket - 4 - , tighten lock nuts - 6 -.
engages.
 Then press selector shaft forward 3 detents, so transmission is in "D" position.

 Ensure selector lever in vehicle is also in "D" position.
2:00:52 AM Page 80
 Carefully press selector lever cable ball socket - 5 - onto selector shaft lever - 7 - in this position.
properly.
seat - arrow A -.
2:00:52 AM Page 81
 Tighten clamping screw with Socket T40031 through hole in shift mechanism while in this position,
without touching selector lever.
ENGINE CODE(S): BKH
.
Selector lever cable (from VIN 8E_6A156500), adjusting

2:00:52 AM Page 82
and installing.

seat - arrow A -.
2:00:52 AM Page 83
installing.

 Bring selector lever cable into basic setting --> Selector lever cable, from VIN 8E_6A156500),
Component Nm
Selector lever cable, from VIN 8E_6A156500), bringing into basic setting
2:00:52 AM Page 84

Work procedure
and installing.
tightened. It is accessible through hole in shift mechanism in position "D"
2:00:52 AM Page 85


2:00:53 AM Page 86


Component Nm
Selector lever cable to bracket (lock nut, qty. 2) 13
2:00:53 AM Page 87
Locking lever (from VIN 8E_6A156500), removing and installing
Overview
Fig. 119: Locking Lever (From VIN 8E_6A156500), Removing And Installing Overview
1 - Locking cable
2 - Retaining clip
3 - Locking cable eye pins
4 - Locking cable bracket
2:00:53 AM Page 88
5 - Bolt, 10 Nm
 For adjusting locking cable
Removing


.
.

.
and installing.
2:00:53 AM Page 89

 Raise retaining tab - A - and remove locking lever in direction of - arrow - from locking cable eye pins.
Installing
2:00:53 AM Page 90
Fig. 122: Routing Locking Cable Without Kinks Under Wiring Harness And Behind Instrument Panel
Brace
 Route locking cable without kinks under wiring harness - arrow A - and behind instrument panel brace -
arrow B -.

 Bring ignition/starter switch into locking position "ignition off".
2:00:53 AM Page 91

 Slide locking cable in opposite in direction of - arrow - onto locking cable eye pins.
 The retaining tab - A - must engage over locking cable

.
Locking cable (from VIN 8E_6A156500), adjusting
2:00:53 AM Page 92
 Safety glasses
Work preparations
center console.

grinder.
Work procedure
and installing.
.
2:00:53 AM Page 93

 Check ignition key removal lock after every adjustment of locking cable --> Shift mechanism (from
Component Nm
Overview:
 --> Transmission (vehicles with 1.8 L turbo engine, also Audi Cabriolet), removing
 --> Transmission (vehicles with 2.0 L normally-aspirated engine, also Audi Cabriolet), removing
 --> Transmission (vehicles with 2.0 L TFSI engine, also Audi Cabriolet), removing
 --> Transmission (vehicles with 6-cyl. 3.0 L gasoline engine, also Audi Cabriolet), removing
 --> Transmission (vehicles with 6-cyl. 3.2 L FSI gasoline engine, also Audi Cabriolet), removing
 --> Installing transmission
Transmission (vehicles with 1.8 L turbo engine, also Audi Cabriolet), removing
2:00:53 AM Page 94
Fig. 128: Identifying Special Tools - Transmission (Vehicles With 1.8 L Turbo Engine, Also Audi

 Engine/Gearbox Jack V.A.G 1383 A
2:00:53 AM Page 95

Work procedure

2:00:53 AM Page 96


2:00:54 AM Page 97

2:00:54 AM Page 98


2:00:54 AM Page 99


2:00:54 AM Page 100

 Remove bolts - 1 through 4 - and remove rear cross member for vehicle floor:
 Remove bolts - 1 to 6 - and remove front cross member for vehicle floor.

2:00:54 AM Page 101

it may be damaged.

Jack
2:00:54 AM Page 102




2:00:54 AM Page 103

 Remove bolts - arrows - for front exhaust pipe/catalytic converter.
it may be damaged.



2:00:54 AM Page 104



2:00:54 AM Page 105




2:00:54 AM Page 106


All:
2:00:54 AM Page 107




2:00:55 AM Page 108


 Set Template 3282/30 on to transmission support 3282 (template only installs in one position).
2:00:55 AM Page 109

Audi Cabriolet:

performed:

2:00:55 AM Page 110

All:

Audi Cabriolet:

All:

Transmission (vehicles with 2.0 L normally-aspirated engine, also Audi Cabriolet), removing
2:00:55 AM Page 111

Fig. 162: Identifying Special Tools - Transmission (Vehicles With 2.0 L Normally-Aspirated Engine, Also

2:00:55 AM Page 112


Work procedure

2:00:55 AM Page 113



Fig. 167: Disconnecting Air Guide Hose Between Mass Air Flow (MAF) Sensor And Intake Manifold
2:00:55 AM Page 114

 Disconnect air guide hose between Mass Air Flow (MAF) sensor and intake manifold - arrows -.

2:00:55 AM Page 115




2:00:55 AM Page 116



2:00:55 AM Page 117


2:00:56 AM Page 118

it may be damaged.

Jack
2:00:56 AM Page 119




2:00:56 AM Page 120


 Remove bolts front exhaust pipe/catalytic converter - arrows -.
it may be damaged.

2:00:56 AM Page 121





2:00:56 AM Page 122


All:
2:00:56 AM Page 123



2:00:56 AM Page 124



2:00:56 AM Page 125



Transmission (vehicles with 2.0 L TFSI engine, also Audi Cabriolet), removing
2:00:57 AM Page 126

Fig. 193: Identifying Special Tools - Transmission (Vehicles With 2.0 L TFSI Engine, Also Audi

2:00:57 AM Page 127


Work procedure

2:00:57 AM Page 128




2:00:57 AM Page 129

 Position engine support bridge 10-222 A with adapters 10-222/3 on to bolted flanges of fender.
 Position engine support bridge 10-222 A with adapters 10-222 A/3 on to bolted flanges of fender.
 Pre-tension engine slightly using spindles on engine support bridge.
2:00:57 AM Page 130




 Loosen quick-release screws - 1 to 3 - and remove front and rear noise insulation.
2:00:57 AM Page 131



2:00:57 AM Page 132


it may be damaged.

2:00:57 AM Page 133

Jack

2:00:58 AM Page 134




it may be damaged.
2:00:58 AM Page 135




 Remove bolts - arrows - for front exhaust pipe/catalytic converter connection.

 Remove nut - 1 - on front exhaust pipe bar and remove front exhaust pipe.
2:00:58 AM Page 136






2:00:58 AM Page 137




 Move wiring harness - arrows - to clear engine.
NOTE:  For the sake of illustration, shown with transmission removed.
2:00:58 AM Page 138

2:00:58 AM Page 139




2:00:58 AM Page 140



2:00:58 AM Page 141

Audi Cabriolet:

performed:
Fig. 224: Removing Bolts And Torque Supports From Oil Pan
 Remove bolts - arrows - and remove torque support.
2:00:59 AM Page 142


All:

Audi Cabriolet:

All:

Transmission (vehicles with 6-cyl. 3.0 L gasoline engine, also Audi Cabriolet), removing
2:00:59 AM Page 143

Fig. 227: Identifying Special Tools - Transmission (Vehicles With 6-Cyl. 3.0 L Gasoline Engine, Also Audi

2:00:59 AM Page 144


Work procedure

2:00:59 AM Page 145



2:00:59 AM Page 146



 Remove left cover - 1 - in engine compartment.

 Remove coolant reservoir - arrow -.

 Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant
expansion tank.
 Tie coolant expansion tank with connected coolant hoses - 1 to 3 - to side.
 If present, remove connector heat shield at left of bulkhead.
2:00:59 AM Page 147


 Remove electrical connectors - 1 through 4 - from bracket at left of bulkhead.


 Remove nut - 2 - which is accessible from top for left exhaust pipe/exhaust manifold.
2:00:59 AM Page 148



2:01:00 AM Page 149


 Remove bolts for holding plate - 3 - for solenoid valves - arrows -.

 Disconnect electrical harness connector at Mass Air Flow (MAF) Sensor G70.
 Disconnect crankcase ventilation hose - 4 - from air guide - 2 -.
 Remove bolt - arrow - and disconnect air guide - 2 - from throttle valve control module.
 Disconnect hose - 1 - from air guide.
NOTE:  For sake of illustration, air guide is shown from rear with engine removed.
2:01:00 AM Page 150

Fig. 242: Removing Harness Connectors From Bracket At Right Of Bulkhead

 Remove electrical connectors - 1 through 4 - from bracket at right of bulkhead.

 Remove nut - 2 - which is accessible from top for right exhaust pipe/exhaust manifold.
2:01:00 AM Page 151


2:01:00 AM Page 152

 Position engine support bridge 10-222 A onto bolted flange of fenders; spindle stands at front.


2:01:00 AM Page 153




2:01:00 AM Page 154

it may be damaged.
Jack

2:01:00 AM Page 155


 Remove bolt - 1 - for noise insulation cover over left and right drive axle.
2:01:00 AM Page 156



Fig. 256: Removing Bracket For Left Front Exhaust Pipe

 Remove bracket for left front exhaust pipe - arrow -.


 Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/left exhaust manifold.
2:01:01 AM Page 157

Fig. 258: Removing Bracket For Right Front Exhaust Pipe

 Remove bracket for right front exhaust pipe - arrow -.

 Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/right exhaust
manifold.
2:01:01 AM Page 158



2:01:01 AM Page 159





2:01:01 AM Page 160


All:
2:01:01 AM Page 161



2:01:01 AM Page 162


 Mount transmission support 3282 on the Engine/Transmission Jack V.A.G 1383 A.

2:01:01 AM Page 163

Audi Cabriolet:

performed:

2:01:02 AM Page 164

sides) make contact on from below.
All:

 Remove bolts - 1 - and - 9 through 11 - on engine/transmission flange.
Audi Cabriolet:

All:

Transmission (vehicles with 6-cyl. 3.2 L FSI gasoline engine, also Audi Cabriolet), removing
2:01:02 AM Page 165

Fig. 274: Identifying Special Tools - Transmission (Vehicles With 6-Cyl. 3.2 L FSI Gasoline Engine, Also

2:01:02 AM Page 166



 Drip tray for VAS 6100 VAS 6208
Work procedure

2:01:02 AM Page 167



2:01:02 AM Page 168



2:01:02 AM Page 169

Flanges
 Position engine support bridge 10-222 A with two adapters 10 - 222 A/3 on to bolted flanges of fender.

2:01:02 AM Page 170




2:01:03 AM Page 171


it may be damaged.
2:01:03 AM Page 172

Jack


2:01:03 AM Page 173

 If installed, remove bolt - 1 - for noise insulation cover over left and right drive axle.


 Remove left and right front exhaust pipe with catalytic converter -->
ENGINE CODE(S): BKH
.
2:01:03 AM Page 174



 Place drip tray for workshop crane VAS 6208 under transmission.

2:01:03 AM Page 175



 Seal openings with clean cover caps.

 Loosen bolts - arrows - at torque support stop approx. two rotations each.
2:01:03 AM Page 176


 Remove left and right stabilizer mounts - 1 - and - 2 -.

 Swing stabilizer downward.
 Raise engine using spindles of engine support bridge 10-222 A far enough until both nuts - 3 - (on left
and right sides) make contact on from below.
 Place plunger of Engine/Transmission Jack V.A.G 1383 A with a block of wood - 1 - inserted in between
transmission at bottom.
NOTE:
2:01:04 AM Page 177

 Lower connecting bolts on engine/transmission flange are accessible by

doing this.

 Remove bolts - 8, 9 and 10 - on engine/transmission flange.

 Lower engine again using spindles of engine support bridge 10-222 A.

2:01:04 AM Page 178




 Loosen bolts - 1 - and - 7 - only and then tighten by hand.
2:01:04 AM Page 179



2:01:04 AM Page 180


 Remove last mounting bolts - 1 - and - 7 - on engine/transmission flange.

 Press transmission off bushings - A - and carefully lower it far enough until selector lever cable is
accessible.

 Mark installation position of support bracket for selector lever cable.

 Remove bolt - 1 - support bracket for selector lever cable.
 Press selector lever cable ball joint - 2 - off from selector shaft lever.
2:01:04 AM Page 181

 Slowly lower transmission.

 Pay attention to clearance of drive axles when lowering transmission.
Installing transmission
NOTE:  Before installing a replacement transmission, clean ATF lines and ATF
cooler --> ATF lines and ATF cooler, cleaning.
 When performing repairs, replace self-locking nuts and bolts.
 Always replace bolts that are secured with tightening torque as well as
seals, gaskets and O-rings.
 Clean input shaft splines of transmission and damper unit splines on
flywheel, remove corrosion and apply only a very thin coating of lubricant
G 000 100 on splines. Excess grease must be removed.
 Secure all hose connections with hose clamps of the same type as those
equipped by the factory .
 When installing, bring all cable ties back to same positions.
 Check if alignment sleeves for centering engine/transmission are in cylinder block, and install if
necessary.
 Before installing transmission, tie electrical wiring to one side so that it cannot be trapped between engine
and transmission.
 Raise engine far enough until selector lever cable can be installed.
engages.
2:01:04 AM Page 182


 Carefully press ball socket of selector lever cable - 2 - onto lever for selector rod.
properly.
If bracket for selector lever cable - 3 - was removed from transmission:
 Tighten bolts - 2 - on bracket - 3 - for selector lever cable to 23 Nm on transmission.
2:01:04 AM Page 183


 Lightly grease ball socket of selector lever cable with polycarbamide
grease G 052 142 A2 before installing.

 Install support bracket for selector lever cable - 1 - according to marking on bracket.
 Place intermediate panel or intermediate plate onto bushings.
 Carefully raise transmission and bring into installation position using transmission support 3282.
2:01:05 AM Page 184

greased, oiled, covered with a thin coat of phosphate or blackened,
tightening torques Securing engine/transmission (transmission flange
pattern).
 Do not use degreased parts.
 Tolerance for torque specification ± 15%.
 Tighten connecting bolts on engine/transmission flange to tightening torque (tables Securing

engine/transmission (transmission flange pattern)).
 Tighten nuts for left and right engine mounts - 3 - -->

ENGINE CODE(S): AMB
CODE(S): AVK, BGN

(S): BNS
(S): BHF
.
 Tighten stabilizer bolts - 2 - --> 40 - FRONT SUSPENSION .
 Tighten bolts of torque support or torque support stop to engine -->
2:01:05 AM Page 185

ENGINE CODE(S): AMB

CODE(S): AVK, BGN
(S): BNS
(S): BHF
.

 Bolt transmission mount - 1 - onto transmission with bolts - 2 - --> Transmission mount, transmission
support and tunnel cross member, removing and installing
 Install ATF lines with new sealing rings --> ATF lines, ATF cooler and auxiliary ATF filter, servicing.
 Install exhaust system -->
ENGINE CODE(S): BKH
2:01:05 AM Page 186

.
 Install heat shield for left and right drive axle.

ENGINE CODE(S): BKH
.
 Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component
Locations.


.
 Check adjustment of selector lever cable --> Selector lever cable (through VIN 8E_6A156499),
adjusting.
 Check oil level in front final drive --> Gear oil level in front final drive, checking.
Securing engine/transmission (transmission flange pattern)
2:01:05 AM Page 187


Vehicles with 1.8 L turbo engine:
Item Bolt Nm
2, 3, 4, 6, 11 M12x67 65 * See note
5 M12x100 65 * See note
8 10 M10x45 45 * See note
*Replace bolts.

Vehicles with 2.0 L normally aspirated engine:
Item Bolt Nm
2:01:05 AM Page 188


3, 4 M12x75 65 * See note
5 M12x110 65 * See note
8 10 M10x45 45 * See note
11 M12x90 65 * See note
*Replace bolts.

Vehicles with 2.0 L TFSI engine:
Item Bolt Nm
2, 3, 4, 6 M12x75 65 * See note
5 M12x100 65 * See note
8 10 M10x45 45 * See note
11 M12x67 65 * See note
*Replace bolts.
2:01:05 AM Page 189


Vehicles with 3.0 L 6-cyl. gasoline engine:
Item Bolt Nm
1, 10, 11 M10x60 45 * See note
2 M10x90 65 * See notes
3 M12x110 65 * See note
5, 6 M12x90 65 * See note
7 M10x100 45 * See note
*Replace bolts.
*Bolt strength rating 10.9
2:01:06 AM Page 190


Vehicles with 3.2 L FSI 6-cyl. gasoline engine:
Item Bolt Nm
1, 7 M10x115 65 * See note
2 M12x130 65
3, 4, 5, 6 M12x110 65
8, 9, 10 M10x80 45
*Bolt strength rating 10.9.
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Mounting base for selector lever cable to gearbox 23
Automatic transmission, transporting
2:01:06 AM Page 191

Fig. 319: Lifting Tackle T40013

Fig. 320: Identifying Transmission Lift Hook T40013 Used To Transporting The Transmission
Work procedure
The transmission lift hook T40013 can be used when transporting the transmission and for aligning
 Mount and secure transmission lift hook T40013 on upper rib of transmission housing as shown in the
illustration.
2:01:06 AM Page 192




2:01:06 AM Page 193

Fig. 322: Securing Transmission To Assembly Stand With Bolts & Installing Transmission Support VW
353 Onto Holding Plate VW 309
 Secure transmission to assembly stand with bolts - 1 - and - 2 -.


2:01:06 AM Page 194




Transmission mount, transmission support and tunnel cross member, removing and installing


 Wooden block
Removing
2:01:06 AM Page 195



it may be damaged.
2:01:07 AM Page 196

Jack
2:01:07 AM Page 197


 Remove nuts - arrows - and slide tunnel cross member slightly toward rear.

Installing
Installation is in reverse order of removal.
2:01:07 AM Page 198


Transmission mount - 1 - to transmission
 Bolts M8 - 2 - , tightening torque: 23 Nm

Transmission mount to tunnel cross member
 Nuts M8 - arrows - , tightening torque: 23 Nm
2:01:07 AM Page 199

Jack
Tunnel cross member to chassis
 Always replace bolts M12 - 3 - and - 4 - , tightening torque: 110 Nm plus an additional 90° (corresponds
to one-quarter turn)
 Bolts M10 - 1 - and - 2 - , tightening torque: 65 Nm

ENGINE CODE(S): BKH
.
ATF IN PLANETARY GEARING
ATF in planetary gearing
2:01:07 AM Page 200

ATF level, checking and topping off
 Vehicle Diagnosis, Testing and Information System VAS 5051 A with Diagnostic cable VAS 5051/5A


 Safety glasses
 Oil receptacle

the planetary gear. ATF specifications --> Capacities.
2:01:07 AM Page 201

NOTE:  The illustration on the reservoir for Atf Filler System F/CVT Transmission
VAS5162 in upper left graphic refers to the use of special ATF for CVT
transmissions.
performed.
Test conditions
 Transmission not in emergency operating mode.

 Engine idling.
 Air conditioner and heating must be switched off.
2:01:08 AM Page 202


 Vehicle Diagnostic, Testing and Information System VAS 5051 A connected, Vehicle Self-Diagnosis and
vehicle system "02 - Transmission electronics" selected.
 ATF temperature must not be higher than 30°C at start of test, allow transmission to cool down if
necessary.
NOTE:  The ATF level will vary according to the temperature of the ATF.
 Checking ATF level at too low ATF temperature leads to overfilling.
 If the ATF level is checked when the ATF temperature is too high, this will
result in under filling.
 Over and under filling lead to impaired functioning of transmission.
 ATF temperature is read off on the Vehicle Diagnosis, Testing and
Information System VAS 5051 A.
2:01:08 AM Page 203


 In selection - 1 - , click on diagnostic function "08 - Read measuring value block".

 In button field - 2 - , enter "10" for "Display group 10" and confirm input by pressing Q button.
2:01:08 AM Page 204


 Read off ATF temperature indicated in display field - 3 -.
Checking ATF level and topping off

 The ATF level is checked at the ATF inspection plug.
between 35°and 45°C (50°C for hot countries) ATF temperature (dependent
on the fluid level when warming up).
other ATF oils!
2:01:08 AM Page 205

Possible On Vehicle
 Secure filled reservoir of ATF filler system F/CVT transmission VAS 5162 as high as possible on
vehicle.
NOTE:  The shut-off valve on ATF filler system F/CVT transmission VAS 5162 must
be closed.
 While brake pedal is depressed, shift through all selector lever positions ("P" , "R" , "N" , "D" , "S") let
each position remain shifted at idle for approx. 2 seconds.

2:01:08 AM Page 206


 If an ATF temperature of 35°C is reached, remove ATF check plug - B -.
NOTE:  Approx. 5 cl of ATF will always drain initially from the internal oil level pipe
when the plug is removed.
If ATF continues to flow out of the ATF filler plug hole over the overflow tube before the ATF reaches
40°C, the ATF level is OK.
NOTE:  At the latest at 45°C (50°C for hot countries) the ATF check plug must be
installed again.
The ATF check is now completed.
Add ATF if no ATF has escaped from the ATF check plug hole by 40°C Filling ATF.
2:01:08 AM Page 207

Filling ATF

 Hold a suitable container beneath outlet of ATF filler system F/CVT transmission VAS 5162.
2:01:09 AM Page 208

Fig. 347: Checking Atf Level By Rotating Shut-Off Valve In Direction Of Outlet
 Check ATF level by rotating shut-off valve in direction of outlet - lower arrow -.
ATF level is correct when ATF drips out only lightly from outlet before 45°C is reached.
NOTE:  Approx. 5 cl of ATF will initially drain from the internal oil level pipe. This
is normal.
 If no additional ATF flows out, rotate shut-off valve back in direction of filler hose and fill with more
ATF; repeat check of ATF level.
 After reaching correct ATF level, remove shut-off valve again.
NOTE:  After removing shut-off valve, ATF drips out lightly.
2:01:09 AM Page 209


NOTE:  At the latest at 45°C (50°C for hot countries) the ATF check plug - B - must
be installed again.
ATF, changing or filling after repairs

2:01:09 AM Page 210



 Safety glasses
Work procedure
 Observe disposal regulations!
transmission --> Additional ATF filter.
other ATF oils!
2:01:09 AM Page 211

Possible On Vehicle
 Secure filled reservoir of ATF filler system F/CVT transmission VAS 5162 as high as possible on the
vehicle.
NOTE:  The shut-off valve on the ATF filler system F/CVT transmission VAS 5162
must be closed.


2:01:09 AM Page 212



2:01:10 AM Page 213

 Fill at least 4.5 to liters ATF into transmission.
For vehicles as of model year 2005:
 Selector lever in position "P"
 Let engine run at high speed at a minimum of 2500 RPM by depressing accelerator pedal.
CAUTION: It is necessary to run engine at high speed so that ATF pump is ventilated
after performing repairs on the transmission.
All model years:
topping off".
ATF LINES, ATF COOLER AND AUXILIARY ATF FILTER, SERVICING
ATF lines, ATF cooler and auxiliary ATF filter, servicing
transmission --> ATF lines and ATF cooler, cleaning. If extremely dirty ATF
flows out when blowing with compressed air, ATF cooler and ATF lines
must also be flushed with clean ATF.
 Check ATF level --> ATF level, checking and topping off after replacing
ATF lines.
ATF lines, ATF cooler and auxiliary ATF filter (vehicles with 1.8 L turbo engine)
Part 1
2:01:10 AM Page 214

Engine) Part 1
2 - O-Ring
 Replace
 Insert with ATF
3 - O-Ring
 Replace
 Insert with ATF
2:01:10 AM Page 215

Part 2
Engine) Part 2
1 - Bracket
2:01:10 AM Page 216


7 - Clamp
11 - Clamp
13 - Bracket
14 - Clamp
17 - Clamp
19 - O-Ring
 Replace
 Insert with ATF
20 - ATF line
21 - ATF line
2:01:10 AM Page 217

ATF lines, ATF cooler and auxiliary ATF filter (vehicles with 2.0 L normally aspirated engine)
Fig. 357: ATF Lines, ATF Cooler And Auxiliary ATF Filter Overview (Vehicles With 2.0 L Normally
Aspirated Engine)
1 - Bolt, 20 Nm
2 - ATF lines
3 - O-Ring
 Replace
 Insert with ATF
4 - ATF line
2:01:11 AM Page 218

5 - O-Ring
 Replace
 Insert with ATF

10 - O-Ring
 Replace
 Insert with ATF
11 - ATF line
15 - Bracket
17 - Clamp
ATF lines, ATF cooler and auxiliary ATF filter (vehicles with 2.0 L TFSI engine)
2:01:11 AM Page 219

Fig. 358: ATF Lines, ATF Cooler And Auxiliary ATF Filter Overview (Vehicles With 2.0 L TFSI Engine)
1 - Socket head cap screw, 21 Nm
2 - ATF lines
 To auxiliary ATF filter and to ATF cooler
3 - O-Ring
 Replace
 Insert with ATF
2:01:11 AM Page 220

5 - Bracket

11 - Clamp
15 - Clamp
17 - O-Ring
 Replace
 Insert with ATF
18 - ATF line
19 - ATF lines
20 - O-Ring
 Replace
 Insert with ATF
23 - Clamp
2:01:11 AM Page 221

25 - ATF lines
ATF lines, ATF cooler and auxiliary ATF filter (vehicles with 6-cyl. gasoline engine)
Fig. 359: ATF Lines, ATF Cooler And Auxiliary ATF Filter Overview (Vehicles With 6-Cyl. Gasoline
Engine)
2 - ATF lines
2:01:11 AM Page 222

3 - O-Ring
 Replace
 Insert with ATF
4 - ATF line
5 - O-Ring
 Replace
 Insert with ATF

10 - O-Ring
 Replace
 Insert with ATF
11 - ATF line
 Not installed on 3.2 L FSI engine
15 - Bracket
16 - 10 Nm
 Combination nut for 3.0 L engines

 Bolt for 3.2 L FSI engines
2:01:12 AM Page 223

18 - Clamp

 Hose diameter approx. 18 mm
 Compressed air gun, commercially available
 Safety glasses
Work procedure
 Before installing a replacement transmission, always blow into ATF cooler and ATF lines with
compressed air (max. 10 bar).
 Before installing a replacement transmission, always replace auxiliary ATF filter.
NOTE:  If extremely dirty ATF flows out when blowing with compressed air, ATF
cooler and ATF lines must also be flushed with clean ATF.
 ATF lines, removing and installing --> ATF lines, ATF cooler and auxiliary
ATF filter, servicing.
Additional ATF filter
transmission. If extremely dirty ATF flows out when blowing with
compressed air, ATF cooler and ATF lines must also be flushed with clean
ATF.
Auxiliary ATF filter, removing and installing (vehicles with 1.8 turbo and 2.0 L TFSI)
2:01:12 AM Page 224

 Oil receptacle
Removing


2:01:12 AM Page 225





 Remove clamp for ATF-lines - arrow -.
2:01:12 AM Page 226


 Remove auxiliary ATF filter on transmission - arrows -.
Installing
Component Nm
ATF auxiliary filter bracket to transmission 40
ATF lines to transmission 21
Line clamp to engine 5
Auxiliary ATF filter, removing and installing (vehicles with 2.0 L normally aspirated- and 6-cyl. gasoline engine)
 Oil receptacle
Removing
NOTE:  Removal and installation is here described for vehicles with 6-cyl. gasoline
engine in the following. On vehicles installed with 2.0l engines
components inside the vehicle possibly look different from the ones
shown in the illustrations.
2:01:12 AM Page 227



 Loosen bolts or quick-release screws - 1 - and - 2 - and remove front noise insulation.

2:01:12 AM Page 228

Fig. 367: Removing Union Nut And Disconnecting Atf-Line To Auxiliary Atf Filter
 Remove union nut - arrow - and disconnect ATF-line to auxiliary ATF filter.
Fig. 368: Disconnecting Air Hoses At Secondary Air Injection (AIR) Pump
 Disconnect air hoses - 1 - and - 2 - at Secondary Air Injection (AIR) pump.
NOTE:  Electrical harness connector - 3 - remains connected.
2:01:13 AM Page 229

Fig. 369: Removing Bolts At Auxiliary Atf Filter Bracket

 Remove bolts - 1 - at auxiliary ATF filter bracket - 2 -.


2:01:13 AM Page 230


Fig. 373: Disconnecting ATF-Lines At Top And Bottom Of Radiator

 Disconnect upper ATF line - arrow - from cooler.

 Remove auxiliary ATF filter.
Installing
Component Nm
2:01:13 AM Page 231

ATF line to cooler 5

ATF BREATHER PIPE
ATF breather pipe
Removing

2:01:13 AM Page 232

NOTE:  If ATF leak is determined from check hole behind ATF breather pipe - A - ,
slightly below bolt - B - , transmission is malfunctioning and must be
replaced.
Installing

Component Nm
2:01:14 AM Page 233


End cover, removing and installing
Fig. 375: Identifying Special Tools - End Cover, Removing And Installing

2:02:33 AM
2:02:37 Page 1
 Oil receptacle
Removing
CAUTION: Do not run engine with the end cover removed or without ATF filling and
do not tow vehicle.
Jack
 Remove tunnel cross member --> Transmission mount, transmission support and tunnel cross
member, removing and installing.
2:02:33 AM Page 2

All:
2:02:33 AM Page 3
2:02:33 AM Page 4

Fig. 382: Removing Bolts And End Cover

Installing
NOTE:  Replace sealing rings, seals and bolts for end cover.
2:02:33 AM Page 5
Module (TCM) J217.
2:02:33 AM Page 6
Module (TCM) J217.
All:

 If bushings were installed in transmission housing or in cover, they must be remounted in same location.
Module (TCM) J217.
 Put on end cover and make sure seal does not slip.
2:02:33 AM Page 7
Fig. 386: Tightening New Bolts First Hand-Tight And In Diagonal Sequence
 Tighten new bolts - arrows - first hand-tight and in diagonal sequence, and then to tightening torque
(table Torque specifications).
 Check installation position of twin lip oil seal - A - :
 Twin lip oil seal must fit flush (sealing lips must not be twisted).
 Check installation position of twin lip oil seal - A - : It must fit flush (sealing lips must not be twisted).
2:02:33 AM Page 8
 Tighten bolts - 2 - of bracket for selector lever cable - 3 - on transmission.

engages.

carefully onto lever for selector shaft.
2:02:33 AM Page 9

properly.

 Bolt transmission mount - 1 - onto transmission - 2 - --> Transmission mount, transmission support
and tunnel cross member, removing and installing.
ENGINE CODE(S): BKH
.
 Fill with ATF --> ATF, changing or filling after repairs.
Component Nm
End cover to transmission, replace bolts 15 + 90°* See note
2:02:33 AM Page 10
Mounting base for selector lever cable to 23

transmission
* 90° is a quarter turn.
The corresponding description for Transmission Control Module (TCM) J217 , removing and installing
can be found in --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS .
 Transmission Control Module (TCM) J217 removed
Work procedure

2:02:33 AM Page 11
NOTE:  Make sure that spring - A - and roller - B - are secured properly.


 Always replace hydraulic control assembly if it has collected dirt or if it is
defective.
The corresponding description for removal and installation of the hydraulic control unit can be found in --> 38 -
damaged.
2:02:33 AM Page 12

The corresponding description for removal and installation of the input shaft can be found in --> 38 -
Input shaft, servicing
The corresponding description, along with disassembling and assembling input shaft, can be found in --> 38 -
2:02:34 AM Page 13

GEAR OIL IN FRONT FINAL DRIVE
Gear oil in front final drive

Gear oil level in front final drive, checking
NOTE:  The specified oil level must be maintained exactly; the transmission reacts
very sensitively to over-filling.
Test sequence
 Take vehicle for a short test drive to heat gear oil to approx. 60°C.
 Move vehicle onto a lifting platform or over a work pit so that it is absolutely level.
 Switch off engine and allow 5 minutes for gear oil to settle back into transmission case.

2:03:09 AM
2:03:16 Page 1
Fig. 395: Removing Inspection Plug

 Remove inspection plug - arrow -.

 Check oil level using a tool created in the workshop, e.g. an angled section of wire.
 Specified value: Oil level 8.5 mm below bottom of filler hole.
 If necessary, top off gear oil level.
 Axle oil specification --> Capacities.
NOTE:  When servicing at the workshop the oil can also be filled up to the lower
edge of the oil filler hole. In this case it is necessary to draw off 0.2 ltr. to
attain the correct oil level.
2:03:09 AM Page 2
 Tighten new screw plug.
Component Nm
Screw plug to transmission 20 * See note
*Replace screw plug.

Left flange shaft, removing and installing
Fig. 396: Drift VW 295

 Drift VW 295
2:03:09 AM Page 3

 Puller T10037
 Oil receptacle
Removing

2:03:10 AM Page 4

 Where installed, remove heat shield for left drive axle.
 Remove left drive axle.
2:03:10 AM Page 5

 Tightly thread lower support of puller T10037 on cover for differential - arrow -.

 Pull left flange shaft using puller T10037 only far enough out until bearing on shaft is pulled out of
Installing
 Replace securing ring for flange shaft, to do this, clamp flange shaft in a vise with protective pads.
2:03:10 AM Page 6

 Press old securing ring out of groove of flange shaft with new securing ring - A -.
 A damaged sealing ring must be replaced --> Left flange shaft oil seal, replacing.
 Drive in flange shaft using needle bearing drift VW 295.
 Install left drive axle --> 40 - FRONT SUSPENSION .

Component Nm
Right flange shaft, removing and installing
 Oil receptacle
Removing
2:03:10 AM Page 7


2:03:10 AM Page 8

 Where installed, remove bolt - 1 - for noise insulation cover over right drive axle.
 Remove right drive axle --> 40 - FRONT SUSPENSION .

 Remove mounting bracket for flange shaft - arrows -.

 Pull out right flange shaft together with mounting bracket.
Installing

 A damaged sealing ring must be replaced --> Sealing ring for right flange shaft and grooved ball
bearing, replacing.
Fig. 407: Replacing O-Ring, Sliding Spring With Cap Outward Into Hole On End Of Flange Shaft &
2:03:10 AM Page 9
Inserting Flange Shaft Into Transmission Housing

 Replace O-ring - arrow A - in mounting bracket for flange shaft.

 Slide spring - C - with cap outward into hole on end of flange shaft - arrow -.
 Insert flange shaft - B - into transmission housing.
NOTE:  While sliding in the flange shaft, make sure that spring - C - remains in the
flange shaft and does not fall into transmission.

 Tightly bolt mounting bracket for flange shaft - arrows -.

 Install right drive axle --> 40 - FRONT SUSPENSION .
Component Nm
Bearing bracket for right-hand flange shaft to 25
transmission
2:03:10 AM Page 10


 Driver 2062
Work procedure
 Remove left flange shaft --> Left flange shaft, removing and installing.
2:03:10 AM Page 11

 Pull out sealing ring for flange shaft using extractor lever VW 681.
NOTE:  Do not damage seating surfaces for oil seal.

1. Flange shaft
3. Spacer ring
4. Circlip
5. Not installed
2:03:10 AM Page 12
ring)
Cover
 Drive in new sealing ring for left flange shaft uniformly using driver 2062 5.5 mm below surface of
cover, do not cant when doing so.
seal.
 Install left flange shaft --> Left flange shaft, removing and installing.
Sealing ring for right flange shaft and grooved ball bearing, replacing
2:03:10 AM Page 13
Fig. 414: Identifying Special Tools - Sealing Ring For Right Flange Shaft And Grooved Ball Bearing,
Replacing

 Punch VW 407
 Punch VW 412

2:03:10 AM Page 14
Fig. 415: Tube 2040

 Tube 2040

 Driver 2062
Work procedure
 Remove right flange shaft --> Right flange shaft, removing and installing.
Seal, removing
2:03:10 AM Page 15

 Pull sealing ring for flange shaft out of mounting bracket using extractor lever VW 681.
2:03:10 AM Page 16

Sealing ring, installing
2:03:10 AM Page 17

 Drive in new sealing ring for right flange shaft uniformly using driver 2062 5.5 mm below surface of
mounting bracket, do not cant when doing so.
seal.
2:03:10 AM Page 18


 Install right flange shaft --> Right flange shaft, removing and installing.
 ATF breather pipe must be replaced if leaking --> ATF breather pipe.
2:03:10 AM Page 19


Work procedure
2:03:10 AM Page 20
Shaft Sea
tighten puller with an open-end wrench.
 You can pull out oil seal a short distance by screwing in rear bolt of puller.
 Re-tighten extractor using open-end wrench so that extractor again grasps the shaft seal tightly and pull
out sealing ring further by tightening the screw.
NOTE:  Input shaft must be installed to install the shaft seal.
 Coat new shaft seal with ATF.
 Slide shaft seal - A - onto input shaft with open side facing transmission.
NOTE:  Slide sealing ring as far as possible into cover so that it cannot bend when
driving in.
2:03:10 AM Page 21
 Drive in sealing ring until it stops using thrust piece T40015.

 Tube VW 418 A
Work procedure
2:03:10 AM Page 22
 Carefully pry out sealing ring for selector shaft lying underneath using a screwdriver.
 Coat outer circumference of new sealing ring with ATF.

 Slide on new sealing ring over selector shaft and press in.
 Drive in sealing ring until it stops using tube 31.5 mm dia. VW 418 A.
Component Nm
2:03:10 AM Page 23
TRANSMISSION 6-speed manual transmission 0A3, All wheel drive
30 CLUTCH
CLUTCH MECHANISM, SERVICING
Clutch mechanism, servicing
CAUTION:  Follow steps required when disconnecting battery -->


Cabriolet
.
 On vehicles equipped with a telematics system, activate the
telematics control module service mode before disconnecting the
battery. -->

Cabriolet
NOTE:  Lubricate all bearings and contact surfaces with polycarbamide grease
G052142A2 .
 Before working on pedal cluster, remove storage compartment on drivers
side -->
 68 - INTERIOR EQUIPMENT for Cabriolet
.
 Make sure brake fluid does not leak into footwell, plenum chamber or onto
transmission below. If it does, area affected must be thoroughly cleaned.
 When working in footwell, use cloths to protect floor covering against
brake fluid spillage.
2:54:21 AM
2:54:25 Page 1
Fig. 11: Exploded View Of Pedal Cluster And Exploded View Of Hydraulic System
I - Pedal cluster - exploded view --> Pedal cluster, assembly overview
II - Pedal cluster (RHD vehicles) - exploded view
Not applicable for North American market
III - Hydraulics - exploded view --> Hydraulic system, assembly overview
Pedal cluster, assembly overview
2:54:21 AM Page 2
Fig. 12: Pedal Cluster, Assembly Overview

1 - Mounting bracket
 Removing and installing --> Clutch master cylinder, removing and installing
2 - Pivot pin for clutch and brake pedal
3 - Retaining clip
4 - Hexagon socket head bolt, 25 Nm
5 - Brake pedal
 Maintenance-free bearing, do not grease
2:54:21 AM Page 3
6 - Clutch Pedal Switch F36
 Removing and installing --> Clutch Pedal Switch F36, removing and installing
 Can only be installed once
 Replace
 Secures clutch and brake pedal pivot pin
8 - Clutch pedal
9 - Retaining clip
10 - Retaining clip
12 - Clutch master cylinder
 Gasket - arrow - must not be removed
13 - Over-center spring
 Black side points towards clutch pedal

 Removing and installing --> Over-center spring, removing and installing
14 - Clutch Pedal Starter Interlock Switch F194
 Only for USA vehicles

 Engine can only be started when clutch is fully depressed (Clutch Pedal Starter Interlock Switch F194
activated).
 Removing and installing
 Replace
 Do not re-install
15 - Torx bolt, 25Nm
 For securing brake master cylinder/brake servo to mounting bracket
Clutch Pedal Switch F36, removing and installing
2:54:21 AM Page 4
NOTE:  Clutch Pedal Switch F36 may only be installed once so as to ensure a firm
fit.
Removing

Fig. 13: Identifying Pedal Assembly And Clutch Pedal Switch F36
 Disconnect electrical connector - 1 - on clutch pedal switch.
 The clutch pedal - 3 - is in the normal position (i.e. not pressed down). The operating rod - arrow - of the
Clutch Pedal Switch F36 should then rest against the clutch pedal.
 Release Clutch Pedal Switch F36 - 2 - by turning 45° counterclockwise and take out of guide.
Installing
2:54:21 AM Page 5
Fig. 14: Pulling Out Switch Plunger & Identifying Retainer Tabs On Switch
Installation is performed in reverse of removal; note the following:
 Pull out operating rod - arrow - all the way before installing Clutch Pedal Switch F36.
Fig. 15: Identifying Clutch Pedal Switch F36, Plunger

 The clutch pedal should be in the normal position (i.e. not pressed down).
 Guide Clutch Pedal Switch F36 through mounting hole, press against clutch pedal and attach by turning
45° clockwise.
 Connect connector for Clutch Pedal Switch F36.
Clutch Pedal Starter Interlock Switch F194, removing and installing
NOTE:  To ensure a secure fit, the Clutch Pedal Starter Interlock Switch F194 must
not be installed more than once.
Removing

2:54:21 AM Page 6
Fig. 16: Installing and Adjusting Clutch Pedal Starter Interlock Switch F194
 Disconnect electrical connector - 3 - on clutch pedal switch for engine start.

 Press clutch pedal - 1 - all the way down and hold it in this position.
 At the same time, release Clutch Pedal Starter Interlock Switch F194 - 2 - by turning it 45° in the
direction indicated - arrow - and pull it out of the guide.
Installing
 Pull out operating rod - arrow - all the way before installing clutch pedal switch.
2:54:21 AM Page 7
Fig. 18: Pressing Clutch Pedal All The Way Down And Pushing Operating Rod Against Clutch Pedal
 When installing Clutch Pedal Starter Interlock Switch F194, press clutch pedal - 1 - all the way down -
arrowA -. Hold clutch pedal in this position.
 Guide Clutch Pedal Starter Interlock Switch F194 - 2 - through opening in retainer, and at the same time
push operating rod against clutch pedal and secure switch by turning it 45° in the direction indicated -
arrowB -.
 Attach electrical connector - 3 - on clutch pedal switch for engine start.
Over-center spring, removing and installing
2:54:21 AM Page 8
Fig. 19: T40025 Installation Clamp

 Assembly clip T40025
Removing
Fig. 20: Installation Clamp T40025 Installed On Over-Center Spring


.
 Tension over-center spring with clutch pedal, at the same time pressing on assembly clamp T40025.
 Move clutch pedal to rest position and take out over-center spring together with assembly clamp T40025
downwards.
Installing
2:54:21 AM Page 9

 Pull clutch pedal into the passenger compartment.
 Installation position of over-center spring: black side of over-center spring faces clutch pedal.
 Install over-center spring with assembly clamp T40025, operate clutch pedal and remove assembly
clamp.
Hydraulic system, assembly overview
2:54:21 AM Page 10
Fig. 22: Hydraulic System, Assembly Overview

1 - Brake fluid reservoir
2 - Supply hose
 For clutch master cylinder
3 - Line/hose assembly
 For plug-in connections on clutch master cylinder and slave cylinder

 Disconnecting from clutch master cylinder and installing --> Clutch master cylinder, removing and
installing
 Disconnecting from clutch slave cylinder Disconnecting clutch slave cylinder from hose/line assembly
2:54:21 AM Page 11
4 - Grommet
6 - Clutch pedal
 Do not remove clip - arrowA - or seal - arrowB -.
 To remove line/hose assembly, pull out clip - arrowA - , but only as far as limit stop Clutch master
cylinder, removing and installing.
9 - Retaining clip
 Only replace when clutch master cylinder has been removed

 Pry off to remove Removing retaining clip - A - in direction of - arrow -
 Push in to install Pressing master cylinder operating rod into retaining clip - A - (in direction of -
arrow -).
10 - Transmission
11 - Clutch slave cylinder
 Do not operate clutch pedal after slave cylinder has been removed.
 Removing and installing --> Clutch slave cylinder on vehicles with 4.2 Liter V8 engine (S4),
 Bleed clutch slave cylinder after working on hydraulic clutch mechanism --> Hydraulic clutch system,
bleeding
 Disconnecting hose/line assembly Disconnecting clutch slave cylinder from hose/line assembly
 Do not allow brake fluid to come into contact with transmission.
12 - Bleeder valve
 Tighten to 4.5 Nm
 Follow correct procedure when bleeding --> Hydraulic clutch system, bleeding.
 If bleeder valve has broken off, it can be removed with 3 mm Allen key
13 - Dust cap
14 - Clip
2:54:21 AM Page 12
 To remove line pull out clip as far as limit stop Disconnecting clutch slave cylinder from hose/line
assembly
15 - Bracket
 For line/hose assembly

 Attached to transmission together with slave cylinder
 Clutch slave cylinder to transmission

 Self-locking
 Replace
17 - Retaining clip
18 - Seal
19 - Securing bolt
 For brake fluid reservoir
Removing retaining clip - A - in direction of - arrow -
Fig. 23: Removing Retainer By Prying

Pressing master cylinder operating rod into retaining clip - A - (in direction of - arrow -).
2:54:21 AM Page 13
Fig. 24: Installing Clutch Master Cylinder Operating Rod In Retainer

Disconnecting clutch slave cylinder from hose/line assembly
Fig. 25: Removing Hydraulic Line From Slave Cylinder

Removing
 To remove hose/line assembly, use a screwdriver to pry off clip - A - as far as the stop. Only then can the
hose/line assembly be pulled out.
Installing
 Press retaining clip - A - in as far as it will go.

 Push hose/line assembly into clutch slave cylinder until it engages audibly.
 Pull on line/hose assembly to check it is secure.
Clutch master cylinder and slave cylinder, notes on removing and installing
 Before replacing the clutch master cylinder or slave cylinder on the assumption that it is defective you
must first perform a function check.
2:54:21 AM Page 14
 If slave cylinder is removed from transmission with hose/line assembly still attached, make sure you do
not press clutch pedal. Otherwise, the piston will be pressed out of the slave cylinder and be destroyed.
 After installing the slave cylinder, carefully press the clutch pedal. If you feel an unusually strong point of
resistance when depressing the clutch pedal, you must not press it down further. The operating rod of the
slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be
destroyed once pedal force exceeds approx. 300 N.
Clutch master cylinder and slave cylinder, function check
Before replacing the master and/or slave cylinder, perform the appropriate checks in the case of the following
errors:
Noises when operating the clutch:
 First check the over-center spring/clutch pedal switch for noise.

 If you hear a noise, remove over-center spring and repeat check.
 Replace faulty component.
After releasing clutch pedal it still remains depressed/does not return to its initial position.
 Check whether clutch pedal returns all the way to its initial position, thereby uncovering the vent opening
in the master cylinder.
 The ventilation opening must be uncovered, otherwise permanent self-ventilation for the hydraulic clutch
system cannot function.
 The self-ventilation function of the clutch system can be impaired if the footwell trim or foot mats get
trapped, if the clutch pedal switch jams or if the driver rests his foot on the clutch pedal for long periods
of time.
Check the complete hydraulic system for external or internal leaks.
 Check brake fluid level in brake fluid reservoir.

 Check master and slave cylinder as well as the line-hose assembly including connecting points for
external leaks (visual check).
 If leaks are identified replace the leaking component.
 Bleed clutch system --> Hydraulic clutch system, bleeding.
High pedal force:
 Clutch plate is worn (except for SAC)

 Mechanically defective pressure plate/clutch plate --> Clutch, servicing
Pedal forces:
Conventional clutch:
2:54:21 AM Page 15
 - Clutch lining when new: approx. 115 N

 - Clutch lining at wear limit: approx. 160 N
SAC clutch:
 - approx. 140 N higher for complete service life of the clutch
Clutch does not disengage or does not disengage fully:
 Air in hydraulic system: bleed clutch system --> Hydraulic clutch system, bleeding and check hydraulic
system for external and internal leaks.
 Clutch plate does not run smoothly on input shaft splines
 Needle bearing in flywheel (centering bearing for input shaft) defective, replace needle bearing -->
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for BHF
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for BPG
.
 Foreign material in clutch system

 Wrong components used or components forgotten when performing repair work (e.g. intermediate plate).
Clutch master cylinder, removing and installing
Fig. 26: Identifying Hose Clamps 3094

 Hose clamps, up to Ø 25 mm 3094
2:54:21 AM Page 16
Fig. 27: Identifying Spark Plug Connector Pliers V.A.G 1922

 Pliers V.A.G 1922
Removing


Cabriolet
.
battery -->

Cabriolet
2:54:21 AM Page 17
 Pull off rubber seal on plenum chamber in direction of - arrow -.

 Remove cover - 1 - from plenum chamber.
 With the ignition switched off, disconnect battery ground (GND) strap -->
 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet

 Pry off the two caps - 3 -.

 Remove nuts - 4 - and remove the two wiper arms - 2 -.
 Remove clips - 1 - and disconnect cowl panel grille - 5 -.
Remove the electronics box from the plenum chamber as follows:
2:54:22 AM Page 18
 Unscrew bolts - arrows - and take off the cover.
 Use screwdriver to carefully pry off retaining strap - arrow -.

 Lay aside engine control module with connectors attached.
Fig. 32: Connector At Connector Rail And Wire

 Disconnect connectors - 2 - at connector console.

 Remove electrical wiring connection - 1 -.
2:54:22 AM Page 19
Fig. 33: Locating Auxiliary Relay Carrier Catches

 Release catches - arrows - and lift auxiliary relay carrier out of electronics box.
 Pull engine wiring harness together with rubber grommet out through opening in electronics box.
Fig. 34: Electronics Box Nuts

 Remove nuts - arrows - and lift out electronics box - 1 -.
NOTE:  In the following steps make sure that no brake fluid escapes into the
plenum chamber or onto the transmission below. If this does happen,
clean the affected area thoroughly.
 When performing work in the footwell, put cloths on the carpet to protect it
from possible brake fluid spills.
2:54:22 AM Page 20
Fig. 35: Identifying Brake Fluid Reservoir Return Hose Grommet

 Pinch off supply hose - A - from brake fluid reservoir using hose clamp 3094. Disconnect hose from
clutch master cylinder and plug hose.
 Remove rubber grommet from bulkhead above connection line for supply hose.
 Lever out retaining clip - C - using a screwdriver and then pull out line/hose assembly - B - slightly.
Fig. 36: Location Of Brake Fluid Reservoir Dowel Bolt

 Remove bolt for brake fluid reservoir - 1 - and disconnect connector for Brake fluid level warning contact
downwards.
NOTE:  The brake fluid reservoir does not have to be removed.
2:54:22 AM Page 21
Fig. 37: Location Of Brake Servo Securing Bolts

 Remove vacuum line to brake servo - 1 -.

 Remove the two TORX bolts - arrows -.
NOTE:  To simplify the illustration, the brake fluid reservoir has not been included.
 Brake fluid reservoir must be moved slightly to the side in order to
unscrew upper Torx bolt.

.
 Removing over-center spring --> Over-center spring, removing and installing.
Fig. 38: Brake Pedal At Brake Servo

 Disconnect brake pedal from brake servo --> 47 - BRAKES - HYDRAULIC COMPONENTS .
2:54:22 AM Page 22
Fig. 39: Locating Steering Column At Steering Gear And Disconnecting Connector On Clutch Pedal
Switch, Brake Pedal Switch And On Accelerator Pedal Module
 Disconnect steering column from steering box - arrowA - --> 48 - STEERING .

 Disconnect connectors at clutch pedal switch - 1 - , brake pedal switch - 2 - and at accelerator pedal
module - 3 -.
 If installed, disconnect connector from Clutch Pedal Starter Interlock Switch F194.
 Remove securing bolt for mounting bracket - arrowB - and remove entire pedal cluster.
Fig. 40: Pressing Retainer Together And Detaching Clutch Pedal From Master Cylinder Using VAG
1922
Release master cylinder operating rod from clutch pedal as follows:
2:54:22 AM Page 23
NOTE:  When releasing the operating rod, make sure that clutch pedal does not
collide with mounting bracket for clutch pedal switch - arrow -. The
mounting bracket could otherwise break off.
 Insert pliers V.A.G 1922 in recesses on clutch pedal, press on sides of retaining clip and Disconnect
clutch pedal from master cylinder.
Fig. 41: Identifying Retaining Clip, Clutch Pedal, Bolts And Master Cylinder
 Disconnect retaining clip - 1 - and remove clutch pedal - 2 -.

 Remove bolts - 3 - and remove clutch master cylinder - 4 -.
Installing
Installation is performed in reverse sequence; note the following:
 Install clutch master cylinder - 4 - and tighten bolts - 3 - to 20Nm.
2:54:22 AM Page 24
Fig. 43: Pushing Clutch Pedal To Lock Into Place, While Making Sure Mount Is Properly Secured In
Clutch Pedal
 Install retaining clip - 1 - in clutch pedal.

 Lock clutch pedal in position by pressing in direction of - arrow -. Make sure retaining clip - 1 - engages
correctly in clutch pedal.
Fig. 44: Location Of Clutch Pedal Switch F36 And Pedal Assembly Securing Bolt
A second technician is required for the next step.
 Insert entire pedal cluster and tighten bolt - 1 - by hand. The second technician should guide hose/line
assembly into clutch master cylinder from plenum chamber.
2:54:22 AM Page 25

 Tighten bolts for brake servo - arrows - to 25Nm.
Fig. 46: Installing Rubber Grommet And After-Run Hose

 Press in retaining clip - C - as far as it will go.

 Insert hose/line assembly - B - in clutch master cylinder and make sure that it engages audibly.
 Install rubber grommet - D - onto connecting line for supply hose - A - at bulkhead.
 Push supply hose - A - from brake fluid reservoir on as far as it will go.
 Remove hose clamps 3094.
2:54:22 AM Page 26

 Screw in securing bolt - 1 - for brake fluid reservoir and Connect connector at brake fluid level warning
contact.
 Tighten hexagon socket head bolt - arrowB - for securing pedal cluster to instrument panel carrier to
25Nm.
 Connect connectors - 1 - , - 2 - and - 3 -.
 If installed, attach connector for Clutch Pedal Starter Interlock Switch F194.
 Connect brake pedal to brake servo --> 47 - BRAKES - HYDRAULIC COMPONENTS .
 Secure steering column to steering box - arrowA - --> 48 - STEERING .
2:54:22 AM Page 27
 Install over-center spring Installing.

.
 Bleed clutch system --> Hydraulic clutch system, bleeding.

 Install electronics box and tighten nuts -arrows- to 4Nm.

 Route engine wiring harness and Connect connector in connector console.
 Install engine control module --> 24 MULTIPORT FUEL INJECTION (MFI) .
 If applicable, install auxiliary relay carrier and auxiliary fuse carrier -->
 97 WIRING
 97 WIRING for Cabriolet
 Press on cover (hand-tight) and tighten bolts in diagonal sequence to 4Nm.

NOTE:  Upon re-connecting the battery, remember to check and activate the
vehicle equipment (radio, clock, convenience electrics etc.).
Hydraulic clutch system, bleeding
2:54:22 AM Page 28
Fig. 50: Identifying Brake Filler And Bleeder Unit VAS 5234
 Brake filling and bleeding equipment VAS 5234 or brake filling and bleeding equipment V.A.G 1869
 Brake fluid specification --> 47 - BRAKES - HYDRAULIC COMPONENTS .
Procedure
NOTE:  Open the bleeder valve before switching on the bleeding appliance.
 When performing the following steps, make sure that no brake fluid
escapes onto the transmission.
 The clutch system must be bled after performing work on the hydraulic
clutch mechanism.
 Before bleeding the clutch system, pull back the clutch pedal to the
normal position and top off brake fluid to "Max" marking on brake fluid
reservoir.
 The clutch system should be bled at the same intervals as the brake system.
 Connect brake charge and bleed equipment V.A.G1869 or VAS 5234, but do not switch on at this stage.
2:54:22 AM Page 29
 If installed, remove rear part of noise insulation - 2 to 3 -.
Fig. 52: Axle Shaft Noise Insulation Retainers

 If installed, remove noise insulation cover - arrows - in wheel housing (left-side).

 Remove heat shield - arrows - for driveshaft (left-side).
2:54:22 AM Page 30
Fig. 54: Connecting Bleeder Hose To Clutch Slave Cylinder

 Connect bleeder hose - A - to slave cylinder - arrow - and open bleeder valve.
 Connect bleeder hose to pressure hose of fluid collector bottle.
 Switch on bleeder appliance and allow about 100cm3 of brake fluid to drain out.
 Operating pressure 2.5 bar
NOTE:  Ensure bleeder hose is correctly installed during bleeding operation.
 Close bleeder valve and tighten to4.5Nm.

 Depress clutch pedal several times after bleeding process is completed.
 Repeat bleeding procedure if necessary.
 Bolt heat shield for drive shaft onto transmission.
Tightening torque
Component Nm
CLUTCH RELEASE MECHANISM, SERVICING
Clutch release mechanism, servicing
2:54:22 AM Page 31
Fig. 55: Identifying Special Tools - Clutch Release Mechanism, Servicing


 Press tool VW 412
 - 1 - Internal puller Kukko 21/5

 - 4 - Counter-support Kukko 22/1
 Sealing grease G 052 128 A1
 Copper grease Z 381 351 TE
2:54:22 AM Page 32
 Adhesive AMV 195 KD1 01
Fig. 56: Clutch Release Mechanism Remove/Install Components

 Removing and installing on vehicles with 8-cylinder engine --> Clutch slave cylinder on vehicles with
4.2 Liter V8 engine (S4), removing and installing
 Tighten bleeder valve to 4.5Nm.
 When installing, push in until the securing bolt can be installed.
2:54:22 AM Page 33

 Self-locking
 Replace
3 - Bracket

 Bolt to transmission with clutch slave cylinder
4 - Operating rod
 Lubricate end of operating rod with copper grease Z381351TE .
5 - O-ring
 Always replace Replacing O-ring

 Lubricate with gear oil before installing
6 - Oil seal
 For input shaft

 Removing Removing input shaft oil seal
 Installing Installing input shaft oil seal
 Pack space between sealing lip and dust lip half full with sealing grease G 052 128 A1 .
7 - Guide sleeve
 Removing Removing and installing guide sleeve
8 - Clutch release lever
 Removing Clutch release lever, removing and installing

 Before installing, lubricate area which makes contact with operating rod of slave cylinder with copper
grease Z381351TE .
9 - Release bearing
 Do not wash out; wipe clean only

 Replace bearings if noisy
 Servicing release bearing with glued plastic ring Checking and servicing release bearing with glued
plastic ring
 Checking release bearing with mechanically attached plastic ring Checking release bearing with
2:54:22 AM Page 34
mechanically attached plastic ring
 Replace if groove worn on plastic ring is too deep Checking release bearing with mechanically
attached plastic ring
 Retainer lugs on release bearing must engage in release lever
10 - Bolt, 24 Nm
 Self-locking
 Replace
11 - Leaf spring
12 - Bolt, 24 Nm
 2x
 Self-locking
 Replace
13 - Retaining piece
 For guide sleeve
14 - Intermediate piece
15 - Transmission
Clutch release lever, removing and installing
Fig. 57: Clutch Release Lever Remove/Install Components

2:54:22 AM Page 35
Removing
 Loosen bolt - 1 - and remove leaf spring - 2 -.

 Remove clutch release lever - 3 - with release bearing.
 Disengage retaining tabs of release bearing at release lever.
Installing
 Before installing clutch release lever, apply a thin coat of copper grease Z381351TE to contact surface
for operating rod of clutch slave cylinder.
 Install clutch release lever - 3 - with release bearing onto guide sleeve.
 Install leaf spring - 2 - and tighten new bolt - 1 - to 24Nm.
Checking and servicing release bearing with glued plastic ring
Fig. 58: Servicing Release Bearing With Plastic Ring

Identification: inner side of plastic ring has three lugs - arrows -.
The plastic ring - arrows - may come loose from the release bearing when the transmission or release bearing is
removed. The release bearing does not have to be replaced if this happens.
 Before installing the transmission, glue the loose plastic ring back onto the bearing with adhesive
AMV195KD101 .
The three square lugs - arrows - on the plastic ring engage in the recesses of the bearing ring.
 The release bearing must be replaced if the groove worn on the plastic ring is deeper than 0.8mm.
Checking release bearing with mechanically attached plastic ring
2:54:22 AM Page 36
Fig. 59: Checking Release Bearing With Plastic Ring Attached

Identification: retaining tabs around plastic ring - arrows -.
 The release bearing must be replaced if the plastic ring - 1 - has come loose.
 The release bearing - 3 - must be replaced if the groove - arrow2 - worn on the plastic ring - 1 - is deeper
than 0.8mm.
Removing and installing guide sleeve
Fig. 60: Guide Sleeve Remove/Install Components

Removing
 Unscrew bolts - arrows - and remove retaining piece - 1 -.

 Pull guide sleeve - 2 - out of transmission housing.
Installing
 Replace O-ring in transmission housing Replacing O-ring.

 Install a thin insulating hose tightly over splines of input shaft.
2:54:22 AM Page 37
 Pack space between sealing lip and dust lip with sealing grease G 052 128 A1 .
 Lightly oil outer circumference of guide sleeve.
 Push guide sleeve - 2 - over input shaft and into transmission housing.
 Remove insulating hose.
 Secure retaining piece - 1 - with new bolts - arrows -.
Replacing O-ring
Fig. 61: O-Ring Remove/Install Components

 Remove O-ring - arrow - using a small screwdriver.

 Lubricate new O-ring with gear oil before installing.
Removing input shaft oil seal
Fig. 62: Removing Input Shaft Oil Seal

A - Counter support, e.g. - Kukko 22/1 -
B - Internal puller 30 to 37 mm, e.g. - Kukko 21/5 -
2:54:22 AM Page 38
Installing input shaft oil seal
Fig. 63: Installing Input Shaft Oil Seal

 Lightly lubricate outer circumference of seal with gear oil.

 Press in oil seal for input shaft as far as it will go.
 The open side of seal faces towards press tool VW 454.
 Pack space between sealing lip and dust lip half-full with sealing grease G 052 128 A1 .
Clutch slave cylinder on vehicles with 4.2 Liter V8 engine (S4), removing and installing
Observe the notes on removing and installing clutch master cylinder and slave cylinder --> Clutch master
cylinder and slave cylinder, notes on removing and installing.

2:54:22 AM Page 39

Removing
 Release quick release fasteners - 1 - , unscrew bolts - 2 - and remove noise insulation.

NOTE:  The flexible pipe connection (de-coupling element) in the front exhaust
2:54:22 AM Page 40
Fig. 67: Supporting Tunnel Cross Member Using VAG1383A Engine/Transmission Lift And A Piece Of
Wood
 Remove universal mounting V.A.G 1359/2 from engine and transmission jack V.A.G 1383 A and place a
wooden block - arrow - on the lifting column in its place.
 Support the rear cross member with engine and transmission jack V.A.G 1383 A.
 First unscrew bolts - 1 - and - 2 - , then bolts - 3 - and - 4 -.
Fig. 68: Identifying Distance Between Cross Member And Body Reaches Dimension
 Lower rear cross member slowly with engine and transmission jack V.A.G 1383 A until distance between
rear cross member and body reaches dimension - x -.
 Dimension - x - = 60 mm
2:54:22 AM Page 41

 Remove heat shield - arrows - for drive shaft (left-side).

 Unbolt drive shaft - 1 - from flange shaft and move clear to the front.
Fig. 70: Slave Cylinder Bracket And Fastener

 Remove bolt - arrow - and take out clutch slave cylinder from the rear.
NOTE:  Do not depress clutch pedal after removing slave cylinder. The slave
cylinder would then be destroyed once pedal force exceeds approx. 300 N.
2:54:22 AM Page 42

 To remove hose/line assembly, use a screwdriver to Pry off clip - A - as far as the stop. Only then can the
Installing
NOTE:  Do not allow brake fluid to come into contact with the transmission. If
necessary, clean the transmission housing.
 If the clutch slave cylinder is inserted at an angle, there is a danger that
the operating rod will be guided past the clutch release lever.
 To facilitate assembly, engage 6th gear before fitting slave cylinder.
 When installing, press in slave cylinder so that securing bolt can be
installed easily.
 Always replace securing bolt.
Fig. 72: Identifying Slave Cylinder Hose/Line Assembly

2:54:22 AM Page 43
 To connect line to clutch slave cylinder, press in retaining clip - A - as far as it will go.
 Push line - B - into clutch slave cylinder until it engages audibly.
Fig. 73: Coat Boot Area Of Clutch Slave Cylinder With Lithium Grease
 Before inserting slave cylinder in transmission housing, lubricate area - a - of sleeve with lithium grease
G052150A2 .
 Lightly lubricate surface where operating rod and clutch release lever make contact with copper grease
Z381351TE .
Fig. 74: Clutch Slave Cylinder, Bracket And Hose/Line Assembly

 Engage bracket for hose/line assembly - 3 - at slave cylinder - 4 -.
2:54:22 AM Page 44
Fig. 75: Guiding Slave Cylinder Into Bore Of Transmission Housing

 Guide slave cylinder - 1 - into opening in transmission housing keeping it as straight as possible (without
tilting operating rod - arrow A -) and insert in recess - arrow B - on clutch release lever - 3 -.
 Use new hexagon socket head bolt - 2 - to secure to transmission.
NOTE:  If the slave cylinder - 1 - is inserted at an angle, there is a danger that the
operating rod - arrow A - will be guided past the clutch release lever - 3 -.

 Tighten bolt - arrow - to specified torque.

 If the line-hose assembly was disconnected at the slave cylinder, the clutch system has to be bled after
installing slave cylinder --> Hydraulic clutch system, bleeding.
2:54:22 AM Page 45
CAUTION: After installing the slave cylinder carefully press the clutch pedal. If you
feel an unusually strong point of resistance when depressing the clutch
pedal, you must not press it down further. The operating rod of the slave
cylinder is likely to have been guided past the clutch release lever. The
slave cylinder would then be destroyed once pedal force exceeds approx.
300 N.
 Bolt drive shaft to flange shaft --> 40 - FRONT SUSPENSION


 Install tunnel cross member --> 40 - FRONT SUSPENSION
 Install exhaust system so it is free of stress --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS .
Tightening torques
Component Nm
Clutch slave cylinder to transmission 23 * See note
* Replace bolt
CLUTCH, SERVICING
Clutch, servicing
NOTE:  Refer to general repair instructions --> General repair instructions.

 Before replacing the clutch plate and pressure plate Fault-finding No.9 -
Defects on the clutch and clutch mechanism.
 Observe the notes on removing and installing clutch master cylinder and
slave cylinder --> Clutch master cylinder and slave cylinder, notes on
 On vehicles with SAC pressure plate (self-adjusting clutch) an adjuster
ring has to be reset when only the clutch plate is replaced--> Resetting
adjuster ring in SAC clutch pressure plate.
 To avoid damaging SAC pressure plate when removing and installing, observe assembly instructions for
SAC pressure plate --> Clutch with SAC pressure plate, removing and installing.
 Check that SAC pressure plate is not distorted Check SAC pressure plate for distortion, cracks and
burns.
 Replace clutch plate and pressure plate if riveted fastening is damaged or loose.
 Select the correct clutch plate and pressure plate according to engine code
2:54:22 AM Page 46
 To avoid damaging dual-mass flywheel during removal, please observe instructions for removal
Removing dual-mass flywheel.
 Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and
apply only a very thin coating of grease for clutch plate splines G000100 to the splines. Then move
clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to
remove excess grease.
 Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned,
otherwise the service life of the clutch will be considerably reduced.
 If the clutch has burnt out, thoroughly clean the bell housing, flywheel and parts of the engine facing the
transmission in order to prevent odors.
Clutch with SAC pressure plate (LuK version), servicing
NOTE:  "SAC" stands for "Self-Adjusting Clutch".
 Please refer to notes --> Clutch, servicing.
2:54:22 AM Page 47
Fig. 77: Clutch With SAC Pressure Plate

 The transmission has to be removed before working on the clutch --> Transmission, removing and
installing.
2:54:22 AM Page 48

1 - Dual-mass flywheel
 Ensure that dowel pins fit tightly

 Contact surface for clutch lining must be free of grooves, oil and grease
 Observe instructions for removal Removing dual-mass flywheel
 Removing and installing --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
2 - Needle bearing
3 - Bolt for flywheel
2:54:22 AM Page 49
 Replace
 Bolt length: 22.5 mm; 60 Nm + 90° further
 Bolt length: 43 mm; 60 Nm + 180° further
4 - Clutch plate
 Installation position: Clutch lining must make full contact with flywheel
 The marking "Transmission end" (transmission side), if provided, faces towards pressure
plate/transmission.
 Coil springs (damper assembly) point towards pressure plate and transmission
 Clutch plate diameter --> Code letters, assignment of mechanical units, transmission ratios,
capacities
5 - SAC pressure plate
 Removing and installing --> Clutch with SAC pressure plate, removing and installing
 Resetting adjuster ring --> Resetting adjuster ring in SAC clutch pressure plate
 Check ends of diaphragm spring Checking ends of diaphragm spring
 Check that pressure plate is not distorted Check SAC pressure plate for distortion, cracks and burns
 Check spring connection and rivets Checking spring connection and rivet
6 - Bolt, 22 Nm
 Observe instructions for installation --> Clutch with SAC pressure plate, removing and installing
Checking ends of diaphragm spring
Fig. 79: Checking Ends Of The Diaphragm Spring

2:54:22 AM Page 50
 Wear up to half the thickness of the diaphragm spring is permitted.
NOTE:  Important: When performing repairs, always select the correct clutch
pressure plate and clutch plate by checking engine code.
Checking spring connection and rivet
Fig. 80: Checking Spring And Rivet Connections

 Check spring connections - arrowsA - for damage and make sure riveted fastenings - arrowsB - are
seated tightly.
NOTE:  Replace pressure plate if spring connections are broken or badly bent, or
if riveted fastenings are loose.
Check SAC pressure plate for distortion, cracks and burns
Fig. 81: Check SAC Pressure Plate For Warpage, Cracks And Burns
A - Straightedge
2:54:22 AM Page 51
B - Feeler gauge
 Pressure plate distortion up to 1.0 mm is allowed
Removing dual-mass flywheel
Fig. 82: Identifying Dual-Mass Flywheel & Bolts

NOTE:  Do not use an impact wrench or pneumatic wrench to remove bolts - B - :

this would severely damage the dual-mass flywheel. Bolts - B - must
always be removed by hand.
 Rotate flywheel - A - so that bolts - B - are aligned centrally behind the holes - arrows -.
 When unscrewing bolts - B - , make sure the bolt heads do not contact the flywheel - arrows - because
this would damage the flywheel when the bolts are turned further.
Removing and installing dual-mass flywheel --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
Clutch with SAC pressure plate, removing and installing
2:54:22 AM Page 52
Fig. 83: Counter-Holder Tool 10-201

 Counterhold tool 10-201
Fig. 84: Identifying Centering Mandrel 3176

 Centring mandrel 3176

 Grease for clutch plate splines G000100
Fig. 85: Counter-Hold Tool 10 - 201 Attached Before Loosening Clutch Bolts
Removing
 Attach counter-hold tool 10-201 before loosening bolts.
To prevent the pressure plate from becoming distorted during removal (causes clutch grab when driving off),
always adhere to the following procedure when unbolting the pressure plate:
 Loosen all 6 bolts consecutively in clockwise direction and in steps of 90° (1 /4 turn) until the pressure
plate is released.
2:54:22 AM Page 53
Installing
NOTE:  Before you re-install the SAC pressure plate check that it is not distorted
Check SAC pressure plate for distortion, cracks and burns.
 When only the clutch plate is replaced, the adjuster ring in the SAC
pressure plate has to be reset before assembly --> Resetting adjuster ring
in SAC clutch pressure plate.
 Installation position of clutch plate: coil springs (damper assembly) or
marking "transmission side" point towards pressure plate and
transmission.
Fig. 86: Identifying 3176 And Counterhold Tool 10-201 On Clutch Plate
 Use centering mandrel 3176 to centralize clutch plate.

 Re-position counterhold tool 10-201 to tighten bolts.
To prevent the pressure plate from becoming distorted during installation (causes clutch grab when driving off),
always adhere to the following procedure when installing the pressure plate:
 Position pressure plate on dowel pins.

 Screw in all 6 bolts evenly by hand until bolt heads make contact with pressure plate.
 Tighten all six bolts consecutively in clockwise direction and in steps of 90° (1 /4 turn) until the housing
makes contact with flywheel.
 Tighten all 6 bolts to final torque (22Nm) consecutively in clockwise direction.
Resetting adjuster ring in SAC clutch pressure plate

 When fitting a new clutch plate in conjunction with a used SAC pressure
plate, the adjuster ring in the pressure plate has to be reset by turning it
back as far as it will go. If you do not reset the adjuster ring in the
2:54:22 AM Page 54
pressure plate, the SAC pressure plate will operate with reduced clamping
force, which will cause excessive wear, especially of the clutch plate
(clutch will then slip).
 If the clutch plate is not replaced, it is not necessary to reset the adjuster
ring.
 New SAC pressure plates are pre-set accordingly, and do not have to be
reset.
Fig. 87: Thrust Disc VW 412

 Press tool VW412
Fig. 88: Identifying Thrust Pad 3062

 Thrust pad 3062
2:54:22 AM Page 55
Fig. 89: Inserting Securing Bolts Into Mounting Holes On Pressure Plate
Procedure
 Insert 3 securing bolts for pressure plate - A - into the mounting holes on the pressure plate at 120° (1 /3
turn) intervals, as shown in the illustration.
 Screw 3 nuts - B - M8 onto bolts - A - and tighten nuts lightly.
Fig. 90: Placing SAC Pressure Plate Onto Press

 Place the SAC pressure plate onto the press tool so that only the 3 bolt heads - arrows - make contact.
 Position thrust pad 3062 in the center of the pressure plate.
Do not use force when performing the following steps, as this could cause the forks on the adjuster ring to break
off.
2:54:22 AM Page 56
Fig. 91: Turning The Adjuster Ring Evenly Using Both Screwdrivers Until It Reaches The Limit Stop
 Apply two screwdrivers to the forks on the adjuster ring. Use the press tool to apply pressure to the
pressure plate until it is just possible to move the adjuster ring.
 Using the two screwdrivers, turn back the adjuster ring evenly in direction of - arrows - until it reaches
the stop - arrowA -.
 Hold the adjuster ring against the stop and reduce the pressure applied by the press tool so that the
adjuster ring is held in this position.
2:54:22 AM Page 57
TRANSMISSION 5 Spd. Manual Transmission 01A All Wheel Drive
30 CLUTCH
CLUTCH MECHANISM COMPONENTS (ON CHASSIS)
Clutch mechanism components (on chassis)

 On vehicles equipped with Audi Telematics by OnStar ® , switch-off
the emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery. Refer to

Cabriolet
.
according to article and/or Owner's Manual.

Telematics by OnStar ® , switch-on the emergency (back-up) battery
for the Telematic/Telephone Control Module. Refer to

Cabriolet
.
Clutch mechanism components (on chassis), servicing
2:21:40 AM
2:21:44 Page 1
I - Exploded view of pedal cluster. Refer to Pedal cluster, assembly overview
II - Exploded view of hydraulic system. Refer to Hydraulic system, component overview
NOTE:  Lubricate all bearing and contact surfaces with polycarbamide grease G
052 142 A 2.
 Remove cover panel under instrument panel before carrying out work on
pedal cluster:
Refer to
2:21:40 AM Page 2
 Make sure brake fluid does not escape into footwell or plenum chamber or
onto transmission below. If it does, clean affected area thoroughly.
 When working in footwell, cover carpet with cloths to protect it from brake
fluid spillage.

 Removing and installing. Refer to Master cylinder, removing and installing
2 - Mounting pin for clutch and brake pedal
2:21:40 AM Page 3
3 - Locking element
4 - Hex socket-head bolt, 25 Nm
5 - Brake pedal
 Attachment maintenance-free, do not lubricate
6 - Clutch pedal switch
 Do not install more than one time

7 - Hex socket-head bolt, 5Nm
2:21:40 AM Page 4
 For securing mounting pin for clutch and brake pedal
8 - Clutch pedal
9 - Locking element
10 - Mount
 Removing and installing. Refer to Hydraulic system, component overview
12 - Master cylinder

 Do not remove gasket (arrow)
2:21:40 AM Page 5

 Black side facing clutch pedal

 Removing and installing. Refer to Over-center spring, removing and installing
 Assignment
14 - Clutch pedal starter interlock switch -F194-
15 - TORX bolt, 25 Nm
 For attaching brake master cylinder/brake booster to mounting bracket
2:21:41 AM Page 6

 T40025 Mounting clip
Removing
 Remove driver's storage compartment:
Refer to

 Tension over-center spring with clutch pedal and press on mounting clip T40025.
 Move clutch pedal to home position and pull over-center spring together with mounting clip T40025
2:21:41 AM Page 7
downward to remove.
Installing
 Pull clutch pedal into passenger compartment.
Installation position of over-center spring:
 Black side of over-center spring faces clutch pedal.

 Install over-center spring with mounting clip T40025, press clutch pedal and remove mounting clip.
Hydraulic system, component overview
2:21:41 AM Page 8

2 - Supply hose
 For master cylinder
3 - Hose/line assembly
 For push-on connections on master/slave cylinder

 Separating from master cylinder and installing. Refer to Master cylinder, removing and installing
 Separating from slave cylinder. See Separating slave cylinder from hose/pipe assembly
4 - Grommet
2:21:41 AM Page 9
6 - Clutch pedal

7 - Master cylinder

 Do not remove clip (arrow A) or gasket (arrow B)
 To remove hose/pipe assembly pull out clip (arrow A) as far as it will go.
9 - Mount
2:21:41 AM Page 10
 Only replace when master cylinder removed

 Detaching. See Prying off mount
 Pressing on. See Pressing master cylinder operating rod into mount
10 - Transmission

11 - Slave cylinder
 Do not press clutch pedal after removal

 Removing and installing. Refer to Lubricating clutch slave cylinder with grease before installing
 Bleed slave cylinder after working on hydraulic clutch mechanism. Refer to Clutch system, bleeding
 Separate from hose/line assembly. See Separating slave cylinder from hose/pipe assembly
2:21:41 AM Page 11
 Brake fluid must not escape onto transmission
12 - Bleeder valve
 Follow work sequence for bleeding. Refer to Clutch system, bleeding
13 - Dust cap
14 - Clip
 To remove tube pull out clip as far as it will go. Refer to Separating slave cylinder from hose/pipe
assembly.

2:21:41 AM Page 12
15 - Bracket
 For hose/pipe assembly

 Slave cylinder to transmission

 Self-locking
 Always replace
17 - Holding clip
18 - Gasket
19 - Bolt
Prying off mount

Pressing master cylinder operating rod into mount
2:21:41 AM Page 13

Separating slave cylinder from hose/pipe assembly

Removing
To remove the hose/pipe assembly use a screwdriver to pry out clip -A- as far as it will go. Only then can the
hose/pipe assembly be pulled out.
Installing
 Push in clip -A- as far as it will go.

 Insert hose/pipe assembly in slave cylinder until it clicks into position.
 Check proper installation by pulling hose/pipe assembly.
Master cylinder, removing and installing
Special tools, testers and other items required
2:21:41 AM Page 14

 3094 Hose clamp

 VAG 1922 Pliers
Removing
 Pull off gasket on plenum chamber in direction of arrow.
2:21:41 AM Page 15
Fig. 27: Removing Cover Over Plenum Chamber

 Remove cover -1- on top of plenum chamber.

 First check if a coded radio is installed. In this case obtain anti-theft code.
See Caution for disconnecting Telematics battery. Refer to Clutch mechanism components (on chassis)
 Disconnect battery Ground strap with ignition switched off.

 Pry off two covers -3- with a screwdriver.

 Remove nuts -4- and two wiper arms -2-.
 Pull off clips -1- and remove cowl panel grille -5-.
Remove electronics box in plenum chamber as follows:
2:21:41 AM Page 16
Fig. 29: Electronics Box Sealing Cover

 Remove bolts (arrows) and take off cover lid.
 Carefully pry off mount bar with screwdriver (arrow).
Fig. 31: Releasing Connector Latches And Pulling Off Connectors On Engine Control Module
2:21:41 AM Page 17
 Loosen connector locks (arrows) and unplug connectors -1- and -2- from engine control module.

 Remove connectors -2- from connector strip.

 Disconnect electrical connection -1-.

 Release locks (arrows) and pull auxiliary relay carrier in electronics box upward and off.
 Pull engine wiring harness together with grommet out of recess in electronics box.
2:21:41 AM Page 18

 Remove nuts (arrows) and lift out electronics box -1-.
NOTE:  During the following steps make sure that brake fluid does not escape into
plenum chamber or onto transmission below. If it does, clean affected area
thoroughly.
fluid spillage.

 Disconnect supply hose -A- to brake fluid reservoir with special tool 3094, disconnect from master
cylinder and seal with plug.
 On bulkhead remove grommet above connecting tube for supply hose.
 Pry out securing clip -C- with screwdriver and then pull tube -B- out slightly.
2:21:41 AM Page 19

 Remove bolt for brake fluid reservoir -1- and unplug connector for monitoring fluid level by pulling
downward.
NOTE: Do not remove brake fluid reservoir.
NOTE:  Brake fluid reservoir not shown for purpose of clearer illustration.
 To remove the top TORX bolt; swivel brake fluid reservoir sideways
slightly.

 Remove two TORX bolts (arrows).

 Remove vacuum tube to brake booster -1-.
 Remove driver's storage compartment.
Refer to
2:21:41 AM Page 20

 Separate brake pedal from brake booster.
Refer to 47 - BRAKES - HYDRAULIC COMPONENTS
 Separate steering column from steering box (arrow A).
Refer to 48 - STEERING
2:21:41 AM Page 21
 Disconnect connectors from clutch pedal switch -1-, brake pedal switch -2- and accelerator pedal module
-3-.
 Remove bolt for mounting bracket (arrow B) and remove pedal cluster assembly.
 Remove over-center spring. Refer to Over-center spring, removing and installing.
NOTE:
Fig. 40: Pressing Retainer Together And Detaching Clutch Pedal From Master
Cylinder Using VAG 1922
 When releasing make sure clutch pedal does not bounce against clutch
pedal switch mount (arrow). Otherwise the mount might break.
 In order to assure sufficiently secure fitting of clutch pedal switch. Refer to
Pedal cluster, assembly overview Item 6- as well as Clutch pedal starter
interlock switch -F194-. Refer to Pedal cluster, assembly overview Item 14-
in pedal cluster, these switches must not be installed more than once.
 Insert pliers VAG 1922 into recesses in clutch pedal, compress mount (arrows) and separate clutch pedal
from master cylinder.
2:21:41 AM Page 22
 Remove securing clip -1- and clutch pedal -2-.

 Remove bolts -3- and master cylinder -4-.
Installing
Install in reverse order, paying attention to the following:
 Insert master cylinder and tighten bolts -3- to 20 Nm.
Clutch Pedal
 Insert mount -1- in clutch pedal.

 Push clutch pedal in direction of arrow to lock into place, while making sure mount -1- is properly
secured in clutch pedal.
 Installing over-center spring. Refer to Over-center spring, removing and installing.
2:21:41 AM Page 23
For the next step a second technician is required.
 Insert pedal cluster assembly and tighten bolt -1- hand-tight. Simultaneously, second technician feeds
tube from plenum chamber side into master cylinder.

 Tighten brake booster bolts (arrows) to 25 Nm.
2:21:41 AM Page 24

 Push in securing clip -C- as far as it will go.

 Insert tube -B- in master cylinder until it clicks into position.
 Install grommet -D- over connecting tube/supply hose -A- and into bulkhead.
 Push on supply hose -A- to brake fluid reservoir as far as it will go.
 Remove special tool 3094.

 Screw in brake fluid reservoir bolt.
Fig. 47: Locating Connectors

 Tighten hex socket-head bolt (arrow B) which secures pedal cluster to instrument panel carrier to 25 Nm.
 Attach connectors -1-, -2- and -3-.
 Connect brake pedal to brake booster.
 Attach steering column to steering box (arrow A).
2:21:41 AM Page 25
 Install driver's storage compartment:
Refer to
 Bleed clutch system. Refer to Clutch system, bleeding.

 Insert electronics box and tighten nuts (arrows) to 4 Nm.

 Route engine wiring harness and attach connection in connector station.
 Install engine control module plus auxiliary relay carrier and auxiliary fuse holder, if installed.
Refer to 97 WIRING r.
 Push on cover lid by hand and tighten bolts diagonally - 4 Nm.
See Caution for connecting Telematics battery. Refer to Clutch mechanism components (on chassis)
NOTE: If the battery is reconnected remember to check and activate vehicle equipment
(radio, clock, convenience electronics etc.).
Refer to
 01 - MAINTENANCE for Cabriolet
Clutch system, bleeding
2:21:41 AM Page 26
Fig. 49: Identifying Brake Filler And Bleeder Unit V.A.G 1869
 Brake system brake filler and bleeder unit VAS 5234
Brake fluid specification:
NOTE:  Open bleeder valve before switching on bleeding equipment.

 Make sure no brake fluid escapes onto transmission when performing
subsequent work.
 Bleed system after working on hydraulic clutch mechanism.
 Before bleeding the system pull out clutch pedal and fill brake fluid
reservoir with brake fluid up to "max".
 Connect brake system brake filler and bleeder unit VAS 5234, but do not switch on at this point.
 Remove sound insulation below transmission, if installed.
2:21:41 AM Page 27
 Attach bleeder hose -A- to slave cylinder (arrow) and open bleeder valve.
 Connect bleeder hose to pressure hose of collecting bottle.
 Then switch on bleeding appliance and allow approx. 100 cm3 of brake fluid to drain out.
 Working pressure 2.5 bar
NOTE: Make sure bleed hose is correctly installed when bleeding.
 Tighten bleeder valve to 4.5 Nm.

 Press clutch pedal several times following completion of bleeding process.
 Bleed system again if necessary.
CLUTCH RELEASE MECHANISM COMPONENTS (ON TRANSMISSION), SERVICING
Clutch release mechanism components (on transmission), servicing
2:21:41 AM Page 28
Fig. 51: Clutch Release Mechanism Components (On Transmission), Servicing

1 - Transmission
2 - Ball pivot, 25 Nm
 Lubricate with MoS2 grease
4 - Dished washer
 Small diameter (convex side) facing guide sleeve
5 - O-ring
2:21:41 AM Page 29
 Always replace
6 - Oil seal for input shaft
 Available together with guide sleeve -item 7 as one part

7 - Guide sleeve
 Available together with oil seal -item 6 as one part

 Installation position: Oil drain hole facing downward
 To protect oil seal -item 7 place shrink down tube over input shaft splines
8 - Retaining spring
2:21:41 AM Page 30
 Attach to clutch release lever
9 - Internal TORX head bolt, 35 Nm
 Self-locking
 Always replace
 Before installing lubricate locating recess for plunger of clutch slave cylinder with copper paste e.g. Z
381 351 TE

11 - Release bearing
2:21:41 AM Page 31
 With or without plastic ring. See Servicing release bearing with plastic ring, depending on design
 Glue on detached plastic ring. See Servicing release bearing with plastic ring
 Never wash out bearing; only wipe
 Replace noisy bearings
 Lock retaining tabs on release bearing in release lever
12 - Slave cylinder

 Separating from hose/pipe assembly. See Separating slave cylinder from hose/pipe assembly
 Installing. See Lubricating clutch slave cylinder with grease before installing and see Installing
clutch slave cylinder
 Pre-load slave cylinder so that securing bolt can be installed easily
 Tighten bleeder valve to 4.5 Nm

 Bleed clutch system. Refer to Clutch system, bleeding
2:21:41 AM Page 32


 Self-locking
 Always replace
14 - Bracket

 Installing. See Installing clutch slave cylinder
2:21:41 AM Page 33
15 - Plunger
 Lubricate end of plunger with copper paste, e.g. Z 381 351 TE

Removing
To remove hose/pipe assembly use a screwdriver to pry out clip -A- as far as it will go. Only then can the
Installing

Lubricating clutch slave cylinder with grease before installing
2:21:41 AM Page 34
 Apply a thin layer of copper paste, e.g. Z 381 351 TE, to contact surface for plunger on clutch release
lever
 Before installing slave cylinder in transmission housing lubricate area -a- of boot with lithium base grease
G 052 150 A2.
Installing clutch slave cylinder

 Lock bracket for hose/pipe assembly -3- on slave cylinder -4- and bolt onto transmission together with
slave cylinder.
 Insert clutch slave cylinder into hole of transmission housing without major lateral deviation from
direction of motion of plunger.
NOTE:  If clutch slave cylinder -4- is not kept straight during insertion there is a
risk that the plunger might move past the clutch release lever.
 Pre-load clutch slave cylinder so that securing bolt can be installed easily.
 Replace securing bolt -2-.
Servicing release bearing with plastic ring
2:21:41 AM Page 35

In the case of release bearings with plastic ring, the latter may become detached from the release bearing
during the removal of the transmission or the release bearing. This does not mean that the release
bearing has to be replaced.
 Before installing transmission glue loose plastic ring onto bearing ring with adhesive AMV 195 KD1 01.
Three square lugs (arrows) of plastic ring locate in recesses of bearing ring.
NOTE: If running face of plastic ring is worn by more than 0.5 mm, replace the release
bearing.
CLUTCH, SERVICING
Clutch, servicing
2:21:41 AM Page 36
Fig. 59: Identifying Special Tools - Clutch, Servicing

 3067 Counterhold
 3176 Centering mandrel
 VAG 1331 Torque wrench
NOTE:  Follow general repair instructions. Refer to General repair instructions.

 Replace clutch plates and pressure plates where riveted joint is damaged
or loose.
 Assign clutch plate and pressure plate by way of engine code.
 Clean input shaft splines and - in the case of used clutch plates - hub
2:21:41 AM Page 37
splines, remove corrosion and apply extremely thin layer of grease G 000
100 to splines. Then move clutch plate back and forth on input shaft until
hub moves freely on shaft. Excess grease must be removed.
 Pressure plates have an anti-corrosion coating and are greased. Only the
contact surface may be cleaned, as otherwise the clutch service life will be
considerably shortened.
 To reduce the odor nuisance of a scorched clutch, thoroughly clean bell
housing, flywheel and parts of engine facing transmission.
Fig. 60: Clutch Remove/Install Components

For servicing the clutch first remove the transmission. Refer to Transmission, removing and installing.
A - Paint dot on dual-mass flywheel
2:21:41 AM Page 38
 If present, white paint dot -A- on dual-mass flywheel must be aligned with white paint dot -B- on
pressure plate
B - Paint dot on pressure plate
pressure plate

 Make sure centering pins are a tight fit

 Locating face for clutch lining must be free from grooves, oil and grease
2:21:41 AM Page 39
Refer to 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
 Always replace
 Bolt length 22.5 mm: 60 Nm 1/4turn (90 ° )
 Bolt length 43 mm: 60 Nm plus 1/2 turn (180 ° )

3 - Clutch plate
 Installation position:
 Damping set (coil springs) toward pressure plate or transmission
2:21:41 AM Page 40
 Lining of clutch plate must be located against flywheel

 Writing "Getriebeseite", if present, toward pressure plate or transmission
 Do not lubricate
 Diameter of clutch plate. Refer to Code letters, assignment of mechanical units, transmission ratios
and capacities onward
 Centering. See Centering clutch plate and removing/installing pressure plate
 Slightly lubricate splines

4 - Pressure plate
 Removing and installing. See Centering clutch plate and removing/installing pressure plate
2:21:41 AM Page 41
 Checking ends of diaphragm spring. See Checking ends of diaphragm spring

 Checking spring attachment and rivet attachments. See Checking spring attachment and rivet
attachments
 If present, line up white paint dots on flywheel -A- and pressure plate -B-, with one another during
assembly.
5 - Bolt, 25 Nm
 Loosen and tighten gradually in diagonal sequence
6 - Needle bearing
Centering clutch plate and removing/installing pressure plate
Fig. 64: Centering Clutch Plate And Removing And Installing Pressure Plate
 Loosen and tighten bolts gradually in diagonal sequence, 25 Nm.
NOTE:  Reverse position of counterhold 3067 when removing.

 Installation position of clutch plate: Damping set (coil springs) or writing
"Getriebeseite" must face pressure plate or transmission.
 Only install attachment bolts once contact surface of pressure plate and
lining of clutch plate are located completely on flywheel.
 Use centering mandrel 3176 to center clutch plate.
 During assembly ensure that white paint dots, if present, on dual-mass
flywheel -A- and pressure plate -B- are lined up with one another.
2:21:41 AM Page 42
Fig. 65: Checking Ends Of Diaphragm Spring

 Wear down to half the diaphragm spring thickness is permissible.
NOTE: When performing repairs, always assign clutch pressure plate and clutch plate
by way of engine code.
Checking spring attachment and rivet attachments
Fig. 66: Checking Spring Connections And Rivet Connections

 Check spring attachment between pressure plate and cover for cracks, check rivet attachments are secure.
 Replace clutches showing damaged springs or loose rivet attachments (arrows).
2:21:41 AM Page 43
TRANSMISSION 6 Spd. Manual Transmission 01E All Wheel Drive
30 CLUTCH


Cabriolet
.


Cabriolet
.
See Caution before beginning repairs on the electrical system. Refer to Clutch mechanism, servicing
Refer to

NOTE:  Disconnect battery Ground strap with the ignition switched off.
 Lubricate all bearings and contact surfaces with polycarbamide grease G
052 142 A 2.
2:27:02 AM
2:27:07 Page 1
 Before working on pedal cluster, remove cover below dash panel:
Refer to
 Ensure that no brake fluid escapes into the footwell, plenum chamber or
onto the transmission below. If this does happen, clean the affected areas
thoroughly.
Pedal cluster assembly, overview
2:27:02 AM Page 2
1 - Bracket
 Removing and installing:
3 - Securing clip
4 - Hex socket-head bolt - 25 Nm
5 - Brake pedal
 Maintenance-free mount, do not grease
6 - Clutch Vacuum Vent Valve Switch -F36-
 In order to assure sufficiently secure installation, switch must not be installed more than once
2:27:02 AM Page 3

7 - Hex socket-head bolt - 5Nm
8 - Clutch pedal
9 - Securing clip
10 - Mount
 Removing and installing. Refer to Hydraulic system, exploded view
2:27:02 AM Page 4

 Seal -arrow- must not be removed

 Black side faces clutch pedal

 Removing and installing. Refer to Over center spring, removing and installing
 Allocation
2:27:02 AM Page 5
14 - Clutch Pedal Position (CPP) Switch -F194- (Interlock switch)
15 - TORX-screw - 25 Nm
 For fastening brake master cylinder/brake servo to mounting bracket
Over center spring, removing and installing
Special tools and workshop equipment required

 T40025 retaining clamp
Removing
 Remove driver's side tray:
Refer to
2:27:02 AM Page 6

 Tension over-center spring with clutch pedal and press on retaining clamp T40025.
 Bring clutch pedal to rest position and remove over-center spring downward together with retaining
clamp T40025.
Installing

 Install over-center spring with retaining clamp T40025, operate clutch pedal and remove retaining clamp.
Hydraulic system, exploded view
2:27:02 AM Page 7

2 - Supply hose
3 - Hose assembly
 For plug connections on master/slave cylinders

 Detaching from master cylinder and installing. Refer to Master cylinder, removing and installing
 Detaching from slave cylinder. See Detaching slave cylinder from hose/pipe assembly
4 - Grommet
2:27:02 AM Page 8
5 - Bracket

6 - Clutch pedal
7 - Master cylinder

 Clips (arrow A) and seal (arrow B) must not be removed
 To remove the hose/pipe assembly, pull out the clip (arrow A) up to the stop. Refer to Fig. 34
9 - Mount
2:27:02 AM Page 9
 Replace only with master cylinder removed

 Prying off. See Lever off mount
 Pressing on. See Press master cylinder operating rod into mount

10 - Transmission
11 - Slave cylinder
 Removing. See Removing clutch slave cylinder

 Installing. See Installing clutch slave cylinder and see Coat clutch slave cylinder with grease before
installing
2:27:02 AM Page 10
 After working on hydraulic clutch mechanism, bleed slave cylinder. Refer to Clutch system, bleeding
 Detach from hose/pipe assembly. See Detaching slave cylinder from hose/pipe assembly
12 - Bleeder valve
 Follow correct work sequence when bleeding. Refer to Clutch system, bleeding
 A broken bleeder valve can be screwed out with a 3mm hex socket wrench

13 - Dust cap
14 - Clamp
2:27:02 AM Page 11
 To remove the line, pull out the clamp to the stop. See Detaching slave cylinder from hose/pipe
assembly
15 - Bracket

 Fastened together with slave cylinder to transmission

 Self-locking
 Always replace
17 - Retaining clip
18 - Gasket
19 - Bolt
Lever off mount

Press master cylinder operating rod into mount
2:27:02 AM Page 12

Detaching slave cylinder from hose/pipe assembly

Removing
 To remove the hose/pipe assembly, lever out the clip -A- up to the stop using a screwdriver. Only then
can the hose/pipe assembly be pulled out.
Installing
 Press in clip -A- to stop.

 Push hose/pipe assembly into slave cylinder until it engages audibly.
 To check, pull on the hose/pipe assembly.
Special tools, testers and auxiliary equipment required
2:27:02 AM Page 13

 3094 Hose clip

 V.A.G 1922 Pliers
Removing
WARNING: Observe safety precautions when disconnecting the battery.
Refer to

Cabriolet
 With the ignition switched off disconnect the battery Ground strap.
2:27:02 AM Page 14
 Pull the rubber gasket off plenum chamber in direction of arrow.
 Remove cover -1- above plenum chamber.

 Lever off both trim caps -3- with a screwdriver.

 Unscrew nuts -4- and remove both wiper arms -2-.
 Pull off clips -1- and remove cowl grille -5-.
2:27:02 AM Page 15
 Unscrew the bolts -arrows- and pull off the sealing cap.
 Carefully lever off the retainer bar with a screwdriver -arrow-.
2:27:02 AM Page 16
 Release the connector catches -arrows- and detach connectors -1- and -2- of engine control unit.

 Detach connectors -2- on connector console.

 Unscrew the electrical wiring connection -1-.

 Release catch -arrow- and detach additional relay carrier in electronics box upward.
 Pull engine wiring harness together with rubber grommet through opening in electronics box.
2:27:02 AM Page 17

 Remove nuts -arrows- and lift out electronics box -1-.
clean the affected areas thoroughly.

 Clamp supply hose -A- leading to brake fluid reservoir using special tool 3094. Pull hose off at master
cylinder and plug it.
 Remove rubber grommet from cross panel above connection pipe for supply hose.
 Pry out retaining clip -C- with a screwdriver and then pull out pipe -B- slightly.
2:27:02 AM Page 18

 Unscrew bolt for brake fluid reservoir -1- and detach fluid level connector downward.
NOTE: The brake fluid reservoir is not removed.
NOTE:  For the sake of clarity, the brake fluid reservoir is not shown here.
 To remove the upper Torx bolt, the brake fluid reservoir must be swivelled
slightly to one side.

 Remove the two Torx bolts -arrows-.

 Detach vacuum pipe from brake servo -1-.
 Remove driver's side storage compartment.
Refer to
2:27:03 AM Page 19

 Detach brake pedal from brake servo.
 Detach steering column from steering box -arrow A-.
Refer to 48 - STEERING .
 Detach connectors from clutch pedal switch -1-, brake pedal switch -2- and from accelerator pedal
module -3-.
2:27:03 AM Page 20
 Unscrew retaining bolts for mounting bracket -arrow B- and remove the complete pedal cluster.
Separate master cylinder operating rod from clutch pedal as follows:
 Removing over-center spring. Refer to Over center spring, removing and installing.
NOTE:  In order to assure sufficiently secure installations of Clutch Vacuum Vent

Valve Switch -F36- -Item 6-: Refer to Pedal cluster assembly, overview and
of Clutch Pedal Position (CPP) Switch -F194- -Item 14-: Refer to Pedal
cluster assembly, overview (Interlock switch) in the pedal assembly, these
switches must not be installed more than once.
Fig. 39: Pressing Retainer Together And Detaching Clutch Pedal From
Master Cylinder Using VAG 1922
 When releasing, make sure that the clutch pedal does not knock against
the mount for the clutch pedal switch -arrow-. The mount could break off.
 Position pliers VAG 1922 in the clutch pedal recesses, press the mount together -arrow- and detach clutch
pedal from master cylinder.
2:27:03 AM Page 21
 Release securing clip -1- and remove clutch pedal -2-.

 Screw out bolts -3- and remove master cylinder -4-.
Installing
Installation is carried out in the reverse order, when doing this note the following:
Clutch Pedal
 Install mount -1- in clutch pedal.

 Press the clutch pedal in direction of arrow until it engages; ensure correct locking of the mount -1- in the
clutch pedal.
 Installing over-center spring. Refer to Over center spring, removing and installing.
2:27:03 AM Page 22
A second mechanic is required for the next step.
 Insert complete pedal cluster and tighten bolt -1- finger tight. The second mechanic should guide the pipe
into the master cylinder starting from the plenum chamber.

 Tighten the retaining bolts for the brake servo -arrows- to 25 Nm.
2:27:03 AM Page 23

 Press retaining clip -C- home.

 Push pipe -B- into master cylinder until it audibly locks in place.
 Insert rubber grommet -D- over connection pipe/supply hose -A- into the cross panel.
 Slide supply hose -A- for the brake fluid reservoir on as far as its stop.

 Screw in securing bolt for brake fluid reservoir.
 Tighten the hex socket head bolt -arrow B- for securing pedal cluster to dash panel crossmember to 25
2:27:03 AM Page 24
Nm.
 Plug in connectors -1-, -2- and -3-.
 Connect brake pedal to brake servo.
 Attach steering column to steering box -arrow A-.
 Install storage compartment for driver's side:
Refer to
 Bleed the clutch system. Refer to Clutch system, bleeding.

 Insert the electronics box and tighten nuts -arrows- to 4 Nm.

 Route the engine wiring harness and join the connector in the connector station.
 Install the engine control unit and, if removed, also the auxiliary relay carrier and the auxiliary fuse box.
Refer to
 97 WIRING
 Press on sealing cap hand-tight and tighten bolts in diagonal sequence - 4 Nm.
See Caution for disconnecting Telematics battery. Refer to Clutch mechanism, servicing
2:27:03 AM Page 25
 Observe safety precautions after connecting the battery.
Refer to

 VAS 5234 Brake filler and bleeder unit
 Brake fluid specification.
NOTE:  Open the bleeder valve before switching on the bleeder unit.
clutch mechanism.
 Before bleeding, pull out clutch pedal and fill brake fluid reservoir with
brake fluid up to "max." marking.
 Connect VAS 5234 Brake filler and bleeder unit, but do not switch on at this stage.
 If installed, remove noise insulation beneath transmission.
2:27:03 AM Page 26

 Connect bleeder hose -A- to slave cylinder (arrow) and open bleeder valve.
 Switch on the bleeder appliance and allow about 100 cm3 of brake fluid to drain out.
NOTE: Ensure bleeder hose is correctly installed during bleeding operation.
 Close bleeder valve and tighten to 4.5 Nm.

 Depress clutch pedal several times after completion of bleeding process.
 Bleed again if necessary.
2:27:03 AM Page 27
Fig. 50: Identifying Clutch Release Mechanism Components

1 - Transmission
 Replace, if damaged
3 - Shaft seal
 For input shaft

 Removing. See Removing shaft seal for input shaft
 Installing. See Installing shaft seal for input shaft
 Standard insertion depth: 3.5 mm, insertion depth for repairs: 4.5 mm
2:27:03 AM Page 28
4 - Locating sleeve
5 - Bolt -15 Nm
 3 pieces

 Removing. See Removing clutch release lever

 Must engage in lugs in intermediate piece when installed. See Installing clutch release lever
 Before installing, coat contact surface of clutch slave cylinder push rod with copper grease, e.g. Z 381
351 TE.
2:27:03 AM Page 29
7 - Leaf spring
8 - Release and tighten bolt - 25 Nm
 Self-locking
 Always replace
9 - Release bearing
 With or without plastic ring, depending on version. See Repairing release bearing with plastic ring
 Cement detached plastic ring. See Repairing release bearing with plastic ring
 Do not wash out, wipe clean only
 Engage retaining latches at the release bearing in contact release lever
2:27:03 AM Page 30

 Tighten bleed valve to 4.5 Nm

installing
 When installing, push on until the securing bolt can be fitted
2:27:03 AM Page 31

 Self-locking
 Always replace

12 - Bracket

 Fastened together to transmission with slave cylinder
 Bolt onto transmission with clutch slave cylinder
2:27:03 AM Page 32
13 - Push rod
 Lubricate end of push rod with copper grease, e.g. Z 381 351 TE
Removing shaft seal for input shaft
Fig. 54: Removing Shaft Seal For Input Shaft

 Lever out seal carefully with a screwdriver.
NOTE: Do not damage bearing surface on input shaft for shaft seal.
Installing shaft seal for input shaft
Fig. 55: Installing Shaft Seal For Input Shaft

 Lightly oil outer circumference of seal.

 Fill space between sealing and dust lips with sealing grease G 052 128 A1.
 Pull a thin protective hose tightly onto splines of input shaft.
 Tapping in input shaft seal.
2:27:03 AM Page 33
 Standard insertion depth: 3.5 mm

 Remove protective hose.
Removing clutch release lever
Fig. 56: Removing Clutch Release Lever

 Release bolt -1-, remove leaf spring - 2- and press back the detent -arrow-.
 Remove clutch release lever -4- together with release bearing -3-.
 Disengage the retaining latches of the release bearing at release lever.
Installing clutch release lever
Fig. 57: Installing Clutch Release Lever

 Before installing the clutch release lever, the contact surface of clutch slave cylinder push rod must be
coated with a thin layer of copper paste.
 Insert clutch release lever -A- into the intermediate piece -C- and allow it to engage (detent -B- becomes
visible).
2:27:03 AM Page 34
 Insert leaf spring -Item 7: Refer to Clutch release mechanism, servicing, tighten retaining bolt -Item :
Refer to 8 Clutch release mechanism, servicing to 25 Nm.

Removing
 To remove the hose/pipe assembly, lever out clip -A- to the stop using a screwdriver. Only then can the
Installing

Removing clutch slave cylinder
Fig. 59: Removing/Installing Slave Cylinder Bolt

2:27:03 AM Page 35
 Remove bolt -arrow-, remove clutch slave cylinder rearward.
NOTE: Do not depress clutch pedal after removing slave cylinder.

 Coat clutch slave cylinder with lithium grease G 052 150 A2. See Coat clutch slave cylinder with
grease before installing.
 Engage bracket for hose/pipe assembly -3- at the slave cylinder -4-.
 When inserting the clutch slave cylinder into the mounting hole of the transmission housing, keep it as far
as possible in line with the direction of operation of the push rod.
NOTE:  If the clutch slave cylinder -4- is inserted off-line there is a danger that the
push rod will be guided past the clutch release lever.
 When installing, press in the clutch slave cylinder far enough so that the
securing bolt can be fitted easily.
 Tighten bracket for hose/line assembly together with slave cylinder on transmission.
Coat clutch slave cylinder with grease before installing
2:27:03 AM Page 36
 Lightly lubricate contact surface for push rod at clutch release lever with copper grease, e.g. Z 381 351
TE.
 Before installing slave cylinder into transmission housing, lubricate area -a- on boot with lithium grease
G 052 150 A2.
Repairing release bearing with plastic ring

In the case of release bearings with plastic ring it is possible that the plastic ring detaches from the
release bearing during removal of the transmission. This does not signify that replacement of the release
bearing is necessary.
 Cement the loose plastic ring to the bearing ring the with adhesive AMV 195 KD1 01 before installing
the transmission.
Three rectangular lugs -arrows- on the plastic ring engage into recesses in the bearing ring.
NOTE: If the plastic ring has become embedded deeper than 0.5 mm in the bearing
2:27:03 AM Page 37
surface, the bearing ring must be replaced.
CLUTCH, SERVICING
Clutch, servicing

 Retainer 10-201
 Thrust pad 3062
 Centering mandrel 3176
 Grease G 000 100
2:27:03 AM Page 38
NOTE:  Observe the general repair instructions. Refer to General repair

instructions.
 The adjuster ring for the SAC-clutch pressure plate (self-adjusting clutch
pressure plate) must be reset before assembly when the clutch ring is
replaced exclusively. Refer to SAC clutch pressure plate adjuster ring,
resetting onward.
 Replace clutch plates and pressure plates with damaged or loose rivets.
 Select the correct clutch plate and pressure plate according to engine
code.
 Clean input shaft splines and (in the case of used clutch plates) the hub
splines. Remove corrosion and apply only a very thin coating of grease G
000 100 to the splines. Then move clutch plate to and for on input shaft
until hub moves freely on shaft. Excess grease must be removed.
 Pressure plates are protected against corrosion and greased. Only the
contact surface may be cleaned, otherwise the service life of the clutch
will be considerably reduced.
 If the clutch has burnt out, thoroughly clean the bell housing, flywheel and
parts of the engine facing the transmission in order to reduce the smell.
Clutch with SAC pressure plate
2:27:03 AM Page 39

 Remove transmission to work on clutch. Refer to Transmission, removing and installing.
 Make sure that centering pins are a tight fit.

Refer to
2:27:03 AM Page 40

2 - Needle bearing
 Driving off and on
Refer to
2:27:03 AM Page 41

 Always replace
 Screw length 43 mm 60 Nm plus additional 180 ° turn
 Screw length 22.5 mm 60 Nm plus additional 90 ° turn
4 - Clutch plate
 Clutch lining must make full contact with flywheel

 Marking "Getriebeseite" (if present) goes toward pressure plate and transmission
2:27:03 AM Page 42
 Spring pack (coil springs) toward pressure plate and transmission
 Centering. See Removing and installing clutch with SAC pressure plate
 Do not grease
 Clutch plate diameter. Refer to Code letters, mechanical unit assignment, transmission ratios,
capacitiesonward
Fig. 66: Identifying Clutch Components (SAC Pressure Plate)

 Resetting adjuster ring. Refer to SAC clutch pressure plate adjuster ring, resetting
 Removing and installing. See Removing and installing clutch with SAC pressure plate
 Check ends of diaphragm spring. See Checking ends of the diaphragm spring
2:27:03 AM Page 43
 Check spring connection and riveted fastenings
6 - Bolt, 25 Nm
 Tighten in small stages and in diagonal sequence
Removing and installing clutch with SAC pressure plate
Fig. 67: Removing And Installing Of Clutch With SAC Pressure Plate
NOTE:  The SAC pressure plate adjuster ring must be turned back prior to
installation when the clutch plate is replaced exclusively. Refer to SAC
clutch pressure plate adjuster ring, resetting onward.
 The clutch plate lining and the contact surface of the pressure plate must
make full contact with the flywheel before the securing bolts are inserted.
 Tighten securing bolts evenly and in diagonal sequence in small steps to
avoid damaging centering holes in pressure plate and centering pins on
flywheel.
 Installation position of clutch plate: spring pack (coil springs) or marking "Getriebeseite" toward pressure
plate and transmission.
 Loosen and tighten bolts gradually in several stages working diagonally. Tightening torque: 25 Nm.
 Re-position Retainer 10-201 when removing.
 Use mandrel 3176 to center clutch plate.
Checking ends of the diaphragm spring
2:27:03 AM Page 44

NOTE: When performing repairs always match up clutch pressure plate and clutch
plate by checking engine code.
SAC clutch pressure plate adjuster ring, resetting
"SAC" stands for self-adjusting clutch.
When installing a new clutch plate with a used SAC pressure plate, the pressure plate adjuster ring must
be turned back to the limit stop. If the pressure plate adjuster ring is not turned back, the SAC pressure
plate functions at a reduced pressure, resulting in increased wear of the clutch and in particular of the
clutch plate (clutch slips).
If the clutch plate is not replaced, the adjuster ring does not require resetting.
New SAC pressure plates are pre-set and consequently do not require resetting.
2:27:03 AM Page 45
 Insert 3 pressure plate securing bolts -A- in the fixing holes of the pressure plate at a 120 ° offset (1/3
turn) as indicated in the illustration.
 Screw 3 nuts -B- (M8) onto bolts -A-and tighten slightly.

 Position SAC pressure plate on the pressing tool in such a way that only the 3 bolt heads rest upon it.
 Center special tool 3062 on the center of the pressure plate.
2:27:03 AM Page 46
 Position two screwdrivers at the adjuster ring. Press against the pressure plate with the pressing tool until
the adjuster ring can just be moved.
 Turn the adjuster ring evenly using both screwdrivers in direction of arrow until it reaches the limit stop -
arrow A-.
 Hold the adjuster ring at the stop while reducing the pressure of the pressing tool so that the adjuster ring
remains in position.
2:27:03 AM Page 47
TRANSMISSION 6-speed manual transmission 01X, front-wheel drive
30 CLUTCH


Cabriolet
.
G052142A2 .
side -->
.
 Make sure that no brake fluid escapes into the footwell, the plenum
chamber or onto the transmission below. If this does happen, clean the
affected area thoroughly.
2:35:00 AM
2:35:05 Page 1
I - Pedal cluster - LHD vehicles, assembly overview --> Pedal cluster - LHD vehicles, assembly overview
II - Pedal cluster - RHD vehicles, assembly overview --> Pedal cluster - RHD vehicles, assembly overview
III - Hydraulics, assembly overview --> Hydraulic system, assembly overview
Pedal cluster - LHD vehicles, assembly overview
2:35:00 AM Page 2

 Removing and installing --> Master cylinder, removing and installing
3 - Retaining clip
4 - Hex socket head bolt -25 Nm-
5 - Brake pedal
2:35:00 AM Page 3
6 - Clutch pedal switch F 36
 Removing and installing --> Clutch pedal switch F36, removing and installing
 Only installed one time
 Replace
8 - Clutch pedal
9 - Retaining clip
10 - Retaining clip

 Black side points toward clutch pedal

14 - Clutch pedal starter interlock switch F194
 Only for USA

 Engine can only be started when clutch is fully depressed ( clutch pedal starter interlock switch activated).
 Replace
 Only install one time
Clutch pedal switch F36, removing and installing
2:35:00 AM Page 4
NOTE:  Clutch pedal switch F36 may only be installed once so as to ensure a firm
fit.
Removing

clutch pedal switch F36 should then rest against the clutch pedal.
 Release clutch pedal switch F36 - 2 - by turning 45° counter-clockwise and remove from guide.
Installing
2:35:00 AM Page 5
Installation is perform in reverse sequence. Note the following:
 Pull out operating rod - arrow - all the way before installing clutch pedal switch F36.

 Guide clutch pedal switch F36 through mounting hole, press against clutch pedal and attach by turning
45° clockwise.
 Plug in connector for clutch pedal switch F36.
Removing and installing clutch pedal starter interlock switch F194
NOTE:  To ensure a secure fit, the clutch pedal starter interlock switch F194 must
Removing

2:35:00 AM Page 6
 Disconnect electrical connector - 3 - on clutch pedal starter interlock switch.

 At the same time, release clutch pedal starter interlock switch - 2 - by turning it 45° in the direction
indicated - arrow - and pull it out of the guide.
Installing
2:35:00 AM Page 7
 When installing clutch pedal starter interlock switch, press clutch pedal - 1 - all the way down - arrow A
-. Hold clutch pedal in this position.
 Guide clutch pedal starter interlock switch - 2 - through opening in retainer, and at the same time push
operating rod against clutch pedal and secure switch by turning it 45° in the direction indicated - arrow B
-.
 Connect electrical connector - 3 - on clutch pedal starter interlock switch.
2:35:00 AM Page 8

 Assembly clamp T40025
Removing


 Move clutch pedal to rest position and remove over-center spring together with assembly clamp T40025
downward.
Installing
2:35:00 AM Page 9
 Black side of over-center spring points toward clutch pedal.
clamp.
Pedal cluster - RHD vehicles, assembly overview
Fig. 18: Pedal Cluster - RHD Vehicles, Assembly Overview

2:35:00 AM Page 10
2 - Washer
3 - Brake pedal
 For securing the bearing sleeve
6 - Clutch pedal switch F36

 Replace
7 - Bearing sleeve
 Check for freedom of movement in clutch pedal
8 - Clutch pedal
9 - Retaining clip
10 - Hex socket head bolt, 20 Nm

13 - Bolt -22 Nm-
 Self-locking
 Replace
14 - Lever
 Pin only fits in one position
2:35:00 AM Page 11
15 - Washer
16 - Mounting
 For over-center spring
18 - Bolt, 25 Nm

2:35:00 AM Page 12
2 - Supply hose
 For plug-in connections on master cylinder and slave cylinder

 Disconnecting from master cylinder and installing Fig. 32
 Disconnecting from clutch slave cylinder Disconnecting slave cylinder from hose/line assembly
4 - Grommet
6 - Clutch pedal
7 - Master cylinder

 Do not remove clip - arrow A - or seal - arrow B -.
 To remove line/hose assembly, pull out clip - arrow A - , but only as far as limit stop Fig. 32.
9 - Retaining clip
 Only replace when master cylinder has been removed

 Pry off to remove Prying retaining clip - A - off in direction of - arrow -
arrow - ).
10 - Transmission
11 - Slave cylinder
 Removing and installing --> Slave cylinder, removing and installing
 Bleed slave cylinder after working on hydraulic clutch mechanism --> Clutch hydraulic system,
bleeding
 Disconnecting hose/line assembly Disconnecting slave cylinder from hose/line assembly
2:35:00 AM Page 13
12 - Bleeder valve
 Follow correct procedure when bleeding --> Clutch hydraulic system, bleeding.
13 - Dust cap
14 - Clip
 To remove line pull out clip as far as limit stop Disconnecting slave cylinder from hose/line assembly
15 - Bracket


 Self-locking
 Replace
17 - Retaining clip
18 - Gasket
19 - Securing bolt
Prying retaining clip - A - off in direction of - arrow -
2:35:00 AM Page 14
Pressing master cylinder operating rod into retaining clip - A - (in direction of - arrow - ).

Disconnecting slave cylinder from hose/line assembly

Removing
 To remove hose/line assembly, use a screwdriver to pry off clip - A - as far as stop. Only then can
Installing

 Insert hose/line assembly - B - in slave cylinder and make sure that it engages audibly.
Notes on removing and installing master cylinder and slave cylinder
2:35:00 AM Page 15
 Before replacing the master cylinder or slave cylinder on the assumption that it is faulty, first perform a
function check.
 After installing the slave cylinder, carefully press the clutch pedal. If you feel an unusually strong
resistance when depressing the clutch pedal, you must not press it down further. The push rod of the slave
cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be
Function check for master cylinder and slave cylinder
Before you replace the clutch master or slave cylinder you must - in the case of the following malfunctions -
first carry out the appropriate checks.
 First check the over-center spring / clutch pedal switch for noise.
 replace relevant component.
After releasing clutch pedal it still remains depressed / does not return to its initial position.
 Check whether clutch pedal returns all the way to its initial position, thereby uncovering the ventilation
opening in the master cylinder.
of time.

 If you identify any leaks you must replace the leaking component.
 Bleed clutch system --> Clutch hydraulic system, bleeding.
High pedal force:

 Mechanically faulty pressure plate/clutch plate --> Clutch, servicing
Pedal forces:
2:35:00 AM Page 16
Conventional clutch: - Clutch lining when new: approx. 115 N- Clutch lining at wear limit: approx. 160 N
SAC clutch: - Approx. 140 N higher for complete service life of the clutch
 Air in hydraulic system: bleed clutch system --> Clutch hydraulic system, bleeding and check hydraulic
 Needle bearing in flywheel (centering bearing for input shaft) faulty, replace needle bearing -->
 13 ENGINE - CRANKSHAFT, CYLINDER BLOCK for AVK
.
 Foreign body in clutch system

 Wrong components used or components omitted when performing repair work (e.g. intermediate plate).

 Hose clamp 3094
2:35:00 AM Page 17

 Spark plug connector pliers V.A.G1922
Removing
Observe the notes on removing and installing master cylinder and slave cylinder --> Notes on removing and
installing master cylinder and slave cylinder.


Cabriolet
.

 With ignition switched off, disconnect battery Ground (GND) strap -->
2:35:00 AM Page 18

.

 Use screwdriver to pry off the two caps - 3 -.

 Remove nuts - 4 - and detach the two wiper arms - 2 -.
 Pull off clips - 1 - and detach cowl panel grille - 5 -.
Take the electronics box out of the plenum chamber as follows:
 Remove bolts - arrows - and take off cover.
2:35:01 AM Page 19


 Disconnect connectors - 2 - at console.

 Disconnect electrical wiring connection - 1 -.
2:35:01 AM Page 20



 Clamp supply hose - A - from brake fluid reservoir using hose clamp 3094. Disconnect hose from master
cylinder and plug hose.
2:35:01 AM Page 21
 Pry out retaining clip - C - using a screwdriver and pull out line/hose assembly - B - slightly.

 Remove brake fluid reservoir bolt - 1 - and disconnect connector for brake fluid level warning contact
downward.
NOTE:  Brake fluid reservoir must not be removed.


 Remove two TORX bolts - arrows -.
 The brake fluid reservoir must be moved slightly to the side in order to
unscrew the upper TORX bolt.
2:35:01 AM Page 22

.

 Disconnect steering column from steering gear - arrow A - --> 48 - STEERING .
2:35:01 AM Page 23
 Disconnect connectors from clutch pedal switch - 1 - , brake light switch - 2 - and accelerator pedal
module - 3 -.
 If installed, disconnect connector from clutch pedal starter interlock switch F194.
 Remove securing bolt for mounting bracket - arrow B - and remove entire pedal cluster.
1922
 Apply spark plug connector pliers V.A.G1922 in clutch pedal recesses, press on sides of retaining clip
and detach clutch pedal from master cylinder.
 Remove retaining clip - 1 - and remove clutch pedal - 2 -.
2:35:01 AM Page 24
 Remove bolts - 3 - and remove master cylinder - 4 -.
Installing
 Install master cylinder - 4 - and tighten bolts - 3 - to 20Nm.
Clutch Pedal
 Insert retaining clip - 1 - in clutch pedal.

2:35:01 AM Page 25
assembly into master cylinder from plenum chamber.

 Tighten bolts for brake servo - arrows - to 25 Nm.
2:35:01 AM Page 26


 Insert hose/line assembly - B - in master cylinder and make sure that it engages audibly.

 Tighten securing bolt - 1 - for brake fluid reservoir and connect connector at brake fluid level warning
contact.
2:35:01 AM Page 27
 Tighten hex socket head bolt - arrow B - for securing pedal cluster to instrument panel carrier to 25Nm.
 If installed, plug in connector for clutch pedal switch F194.
 Secure steering column to steering gear - arrow A - --> 48 - STEERING .

 Install over-center spring.
.
 Bleed clutch system --> Clutch hydraulic system, bleeding.
2:35:01 AM Page 28

 Insert electronics box and tighten nuts - arrows - to 4Nm.

 Route engine wiring harness and connect connector in console.
 Install engine control module-->
 28 - IGNITION/GLOW PLUG SYSTEM for AVK
 28 - IGNITION/GLOW PLUG SYSTEM for BPG
 97 WIRING

Clutch hydraulic system, bleeding
2:35:01 AM Page 29
 Brake filler bleeder unit VAS 5234
Brake fluid specification --> 47 - BRAKES - HYDRAULIC COMPONENTS .
Procedure
clutch mechanism.
 Before bleeding the clutch system, pull out clutch pedal and top off brake
fluid to "Max" marking on brake fluid reservoir.
 The clutch hydraulic system should be bled at the same intervals as the
brake system.
 Connect brake filler bleeder unit VAS 5234, but do not switch on.
 If installed, remove sound insulation beneath transmission.
2:35:01 AM Page 30

 If installed, remove heat shield - arrows - for drive axle (left-side).

NOTE:  Make sure bleeder hose is correctly installed during bleeding operation.

 If installed, screw heat shield for drive axle (left-side) onto transmission.
Tightening torques
Component Nm
2:35:01 AM Page 31


 Thrust disc VW 412
 Thrust tube VW 454
 Press tube 2040

 Locking fluid AMV 185 101 A1
2:35:01 AM Page 32


1 - Release bearing

plastic ring
2:35:01 AM Page 33
 Replace if running mark (groove) is too deep Checking release bearing with mechanically attached
plastic ring
 Retainer tabs on release bearing must engage in release lever
grease Z381351TE .
3 - Torx bolt, 35Nm
 3 (Qty.)
 Apply locking fluid AMV 185 101 A1 when installing
 Secure to clutch release lever
5 - Guide sleeve
 Installation position: Oil drain hole points downward.

 Before removing and installing, cover input shaft splines with a shrink-fit hose to protect oil seal.
6 - Oil seal
 For input shaft

7 - O-ring
 Always replace
8 - Convex washer
 Installation position: insert locating element between ribs of housing
10 - Ball head stud
 Lubricate with MoS2 grease.
11 - Transmission
12 - Slave cylinder
2:35:01 AM Page 34

 When installing push in until the securing bolt can be installed.
 Self-locking
 Replace
14 - Bracket

15 - Operating rod

Identification: inner side of plastic ring has three tabs - arrows -.
 Before installing the transmission, glue the loose plastic ring back onto the bearing ring with adhesive
AMV195KD101 .
2:35:01 AM Page 35
Three square tabs - arrows - of the plastic ring engage in recesses of bearing ring.

 The release bearing must be replaced if plastic ring - 1 - has come loose.
 The release bearing - 3 - must be replaced if groove - arrow2 - worn on the plastic ring - 1 - is deeper
than 0.8mm.
Pulling oil seal out of guide sleeve
Fig. 54: Pulling Oil Seal Out Of Guide Sleeve

A - Counter-support, e.g. Kukko 22/1
B - Internal puller 23.5...30 mm, e.g. Kukko 21/4
2:35:01 AM Page 36
Pressing oil seal into guide sleeve (press in onto stop)
Fig. 55: Pressing Oil Seal Into Guide Sleeve (Press In Onto Stop)
NOTE:  The open side of seal faces toward thrust tube VW 454.
Slave cylinder, removing and installing
Fig. 56: Identifying Torque Wrench V.A.G. 1331


 Lithium grease G052150A2
 Copper grease Z381351TE
2:35:01 AM Page 37
Fig. 57: Fasteners

Removing
 On vehicles installed with auxiliary heater, remove bolts - arrows - securing exhaust pipe of
auxiliary/heater to sound insulation.

 Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.
 If installed, loosen quick release fasteners - 3 - and remove rear sound insulation - B -.
2:35:01 AM Page 38
Fig. 59: Exhaust System Clamps

Vehicles with 6-cylinder engine:
 Disconnect exhaust system at clamp (left-side) - left arrow -.
 Remove front exhaust pipe (left-side) with catalytic converter --> 3.0 Liter 6-Cyl. 5V Engine Mechanical,
Engine Code(s): AVK - 26 EXHAUST SYSTEM, EMISSION CONTROLS .

 Remove heat shield - arrows - for drive axle (left-side).
Continued for all vehicles:
 Remove drive axle (left-side) - 1 - from flange shaft and move to front, making sure you do not damage
surface protection.
2:35:01 AM Page 39
Fig. 61: Selector Shaft Lever Nut

 Remove nut - arrow - and detach selector shaft lever from selector shaft.

 Remove bolt - arrow - and remove slave cylinder from rear.
2:35:01 AM Page 40

 To remove hose/line assembly, use a screwdriver to pry off clip - A - as far as stop. Only then can the
Installing
 If the slave cylinder is inserted at an angle, there is a danger that the
operating rod will be guided past the clutch release lever.
installed easily.

2:35:01 AM Page 41
 Push line - B - into slave cylinder until it engages audibly.
G052150A2 .
Z381351TE .

 Attach bracket for hose/line assembly - 3 - to slave cylinder - 4 -.
2:35:01 AM Page 42

tilting operating rod - arrow A - ) and insert in recess - arrow B - on clutch release lever - 3 -.
 Use new hex socket head bolt - 2 - to secure to transmission.


 If line/hose assembly was disconnected at slave cylinder, the clutch system has to be bled after installing
slave cylinder --> Clutch hydraulic system, bleeding.
2:35:01 AM Page 43
feel an unusually strong resistance when depressing the clutch pedal, you
must not press it down further. The push rod of the slave cylinder is likely
to have been guided past the clutch release lever. The slave cylinder
would then be destroyed once pedal force exceeds approx. 300 N.

 Install selector shaft lever and tighten nut - arrow -.

 Bolt drive axle (left-side) to flange shaft --> 40 - FRONT SUSPENSION
 Screw heat shield for drive axle (left-side) onto transmission.

 Install exhaust system and perform stress-free alignment --> 3.0 Liter 6-Cyl. 5V Engine Mechanical,
Tightening torques
Component Nm
Slave cylinder to transmission* See note 23
Selector shaft lever to transmission 23
* replace bolt
CLUTCH, SERVICING
Clutch, servicing
2:35:01 AM Page 44

 Counterhold tool 10 - 201

 Locking bar 3067
 Grease for clutch plate splines G 000 100

 Observe the notes on removing and installing master cylinder and slave
cylinder --> Notes on removing and installing master cylinder and slave
2:35:01 AM Page 45
cylinder.
 On vehicles with SAC pressure plate (self-adjusting clutch, LuK version)
an adjuster ring has to be reset when only the clutch plate is replaced -->
Adjuster ring in SAC clutch pressure plate, adjusting.
 To avoid damaging SAC pressure plate when removing and installing,
observe assembly instructions for SAC pressure plate --> Clutch with SAC
pressure plate, removing and installing.
 Check that SAC pressure plate is not warped Check SAC pressure plate
for warpage, cracks and burns
 If the vehicle is installed with a self-adjusting clutch (Sachs version), the
clutch plate and pressure plate can only be replaced together --> Self-
adjusting clutch (Sachs version), servicing.
 Replace clutch plate and pressure plate if riveted fastening is damaged or
loose.
 Select correct clutch plate and pressure plate according to engine code
 To avoid damaging dual-mass flywheel during removal please observe
instructions for removal Removing dual-mass flywheel
splines. Remove corrosion and apply only a very thin coating of grease for
clutch plate splines G000100 to the splines. Then move clutch plate
backward and forward on input shaft until hub moves freely on shaft. It is
important to remove excess grease.
 If the clutch has burned out, thoroughly clean the bell housing, flywheel
and parts of the engine facing the transmission in order to prevent odors.
Servicing conventional clutch --> Conventional clutch, servicing
Servicing self-adjusting clutch (Sachs version) --> Self-adjusting clutch (Sachs version), servicing
Servicing clutch with SAC pressure plate (LuK version) --> Clutch with SAC pressure plate (LuK version),
servicing
Conventional clutch, servicing
 Please refer to notes --> Clutch, servicing.

 The transmission has to be removed before working on the clutch --> Transmission, removing and
installing.
2:35:01 AM Page 46
Fig. 71: Conventional Clutch Remove/Install Components

1 - Flywheel/dual mass flywheel
 Make sure that dowel pins fit tightly

 Always replace
 Bolt length: 22.5 mm; 60 Nm plus an additional 90° 1 /4 turn
2:35:01 AM Page 47
 Bolt length: 43 mm; 60 Nm plus an additional 180° 1 /2 turn
3 - Clutch plate
 The marking "Getriebeseite" (if provided) faces pressure plate/transmission.
 Coil springs (damper assembly) point toward pressure plate and transmission
 Centralize Centralizing clutch plate and removing and installing pressure plate
 Clutch plate diameter --> Code letters, allocation, transmission ratios, capacities
4 - Pressure plate
 Removing and installing Centralizing clutch plate and removing and installing pressure plate
 Check wire ring Checking wire ring
5 - Bolt, 22 Nm
 Loosen and tighten gradually in several stages and in diagonal sequence
6 - Needle bearing

Centralizing clutch plate and removing and installing pressure plate
Fig. 72: Changing Over Flywheel Retainer 3067

2:35:01 AM Page 48
 Loosen and tighten bolts gradually in several stages and in diagonal sequence.
 To remove, reverse position of counter-hold tool 3067 or counter-hold tool 10 - 201.
Installation position of clutch plate: coil springs (damper assembly) or marking "Getriebeseite" point toward
pressure plate and transmission.
 Before tightening securing bolts, clutch lining and contact surface of pressure plate must make full
contact with flywheel.

NOTE:  When performing repairs, always select the correct clutch pressure plate
and clutch plate by checking engine code.

2:35:01 AM Page 49
 Check spring connections - arrows A - for damage and make sure riveted fastenings - arrows B - are
seated tightly.
Checking wire ring
Fig. 75: Identifying Wire Ring In Thrust Plate

 Check that wire ring in pressure plate - arrow - is not damaged. Replace pressure plate if wire ring is
broken.
Self-adjusting clutch (Sachs version), servicing
CAUTION: On this type of clutch the pressure plate and clutch plate can only be
replaced together.

installing.
 Identification Identification
2:35:01 AM Page 50
Fig. 76: Self-Adjusting Clutch Assembly Overview (Manufactured By Sachs)

1 - Bolt, 22 Nm
 Observe instructions for installation --> Self-adjusting clutch (Sachs version), removing and installing
2 - Pressure plate
 Self-adjusting
 Pressure plate and clutch plate can only be replaced together.
 Removing and installing --> Self-adjusting clutch (Sachs version), removing and installing
2:35:01 AM Page 51
3 - Clutch plate

 The marking "Getriebeseite" (transmission side), if provided, faces toward pressure plate/transmission.
 If installed, coil springs (damper assembly) face pressure plate and transmission
 Centralize Fig. 86
 Always replace

6 - Needle bearing

Identification
2:35:01 AM Page 52
Fig. 77: Pressure Plate With Impact (Position Sensor)

Pressure plate with stop mechanism (position sensor) - arrow -.

2:35:01 AM Page 53

seated tightly.
Checking wire ring

broken.
2:35:01 AM Page 54


 Rotate flywheel - A - so that bolts - B - are aligned centrally behind holes - arrows -.
 When removing bolts - B - , make sure the bolt heads do not contact flywheel - arrows - because this
would damage the flywheel when the bolts are turned further.
 Removing and installing dual-mass flywheel -->
for the appropriate engine code.
Self-adjusting clutch (Sachs version), removing and installing
Fig. 82: Identifying Flywheel Retainer 3067

2:35:01 AM Page 55
 Flywheel retainer 3067



 Attach flywheel retainer 3067 or counter-hold tool 10 - 201 before loosening bolts.
2:35:01 AM Page 56
Fig. 85: Identifying Stop & Pin

 Loosen all six bolts consecutively in clockwise direction and in steps of 90° (14 turn) until pressure plate
is released.
 Stop - 2 - (position sensor) with pin - 1 - should come free when bolts are loosened.
Installing
 Installation position of clutch plate: coil springs (damper assembly) or marking "Getriebeseite" point
toward pressure plate and transmission.

 To remove, reverse position of flywheel retainer 3067 or counter-hold tool 10 - 201.

2:35:01 AM Page 57

always adhere to the following procedure when installing pressure plate:

 Make sure that the stop mechanism (position sensor) - arrow - is free to move.
 Tighten all six bolts consecutively in clockwise direction and in steps of 90° (14 turn) until the housing
 The stop pin - arrow - should then lift away from pressure plate.

 Remove transmission before working on clutch --> Transmission, removing and installing.
2:35:01 AM Page 58


2 - Needle bearing
2:35:01 AM Page 59

 Always replace

4 - Clutch plate
 Marking "Getriebeseite" (if provided) faces pressure plate/transmission.
 Centralize
 Resetting adjuster ring --> Adjuster ring in SAC clutch pressure plate, adjusting
 Check that pressure plate is not warped Check SAC pressure plate for warpage, cracks and burns
6 - Bolt -22 Nm-
2:35:01 AM Page 60


seated tightly.
Check SAC pressure plate for warpage, cracks and burns
2:35:01 AM Page 61
A - Straightedge
B - Feeler gauge
 Pressure plate warpage up to 1.0 mm is allowed


 When removing bolts - B - , make sure bolt heads do not contact flywheel - arrows - because this would
damage flywheel when bolts are turned further.
2:35:02 AM Page 62

.
Fig. 93: Counterhold 10-201



2:35:02 AM Page 63
 Attach counter-hold tool 10 - 201 before loosening bolts.
To prevent the pressure plate from becoming warped during removal (causes clutch grab when driving off),
always adhere to the following procedure when unscrewing the pressure plate:
 Loosen all six bolts consecutively in clockwise direction and in steps of 90° (14 turn) until the pressure
plate is released.
Installing
NOTE:  Before re-installing the SAC pressure plate check that it is not warped
Check SAC pressure plate for warpage, cracks and burns.
pressure plate has to be reset before assembly --> Adjuster ring in SAC
clutch pressure plate, adjusting.
marking "Getriebeseite" point toward pressure plate and transmission.
Fig. 96: Using Centering Mandrel 3176 To Centralize Clutch Plate
2:35:02 AM Page 64

 Re-position counterhold tool 10 - 201 to tighten bolts.
To prevent the pressure plate from becoming warped during installation (causes clutch grab when driving off),

Adjuster ring in SAC clutch pressure plate, adjusting

 When installing a new clutch plate in conjunction with a used SAC
pressure plate, the adjuster ring in the pressure plate has to be reset by
turning it back as far as it will go. If you do not reset the adjuster ring in
the pressure plate, the SAC pressure plate will operate with reduced
clamping force, which will cause excessive wear, especially of the clutch
plate (clutch will then slip).
ring.
reset.

2:35:02 AM Page 65
 Thrust disc VW412

 Thrust pad 3062
Procedure
 Insert 3bolts for securing pressure plate - A - into mounting holes on pressure plate at 120° (13) intervals,
as illustrated.
 Screw 3 nuts - B - M8 onto bolts - A - and tighten nuts.
2:35:02 AM Page 66

 Place SAC pressure plate onto thrust disc so that only 3 bolt heads - arrows - make contact.
 Position thrust pad 3062 in center of pressure plate.
off.
2:35:02 AM Page 67
Fig. 101: Positioning Two Screwdrivers On Adjusting Ring Forks

 Apply two screwdrivers to forks on adjuster ring. Use thrust disc to apply pressure to pressure plate until
it is just possible to move adjuster ring.
 Using two screwdrivers, turn back adjuster ring evenly in direction of - arrows - until it reaches stop.
 Hold adjuster ring against stop and reduce pressure applied by thrust disc so that the adjuster ring is held
in this position.
2:35:02 AM Page 68
TRANSMISSION 6-speed manual transmission 02X, four-wheel drive
30 CLUTCH


Cabriolet
.
G052142A2 .
side -->
.
2:48:50 AM
2:48:55 Page 1
I - Pedal cluster (LHD vehicles), assembly overview --> Pedal cluster (LHD vehicles), assembly overview
II - Pedal cluster (RHD vehicles), assembly overview --> Pedal cluster (RHD vehicles), assembly overview
Pedal cluster (LHD vehicles), assembly overview
2:48:50 AM Page 2

3 - Retaining clip
5 - Brake pedal
2:48:50 AM Page 3
 Replace
8 - Clutch pedal
9 - Retaining clip
10 - Retaining clip


 USA models and vehicles with 3.2liter. FSI engine only

 Engine can only be started when clutch is fully depressed (switch activated).
 Removing and installing --> Clutch Pedal Starter Interlock Switch F194, removing and installing
 Replace
2:48:50 AM Page 4
NOTE:  Clutch pedal switch may only be installed once so as to ensure a secure
fit.
Removing

 The clutch pedal - 3 - is in the normal position (i.e. not pressed down). The operating rod - arrow - of
clutch pedal switch should then rest against clutch pedal.
 Release clutch pedal switch - 2 - by turning 45° counter-clockwise and remove from guide.
Installing
2:48:50 AM Page 5
Installation is in reverse order of removal. Note the following:

 Guide clutch pedal switch through mounting hole, press against clutch pedal and attach by turning 45°
clockwise.
 Connect connector for clutch pedal switch.
Removing

2:48:50 AM Page 6

 At the same time, release clutch pedal starter interlock switch F194 - 2 - by turning it 45° in the direction
Installing
2:48:50 AM Page 7
 When installing clutch pedal starter interlock switch F194, press clutch pedal - 1 - all the way down -
arrow A -. Hold clutch pedal in this position.
 Guide clutch pedal starter interlock switch F194 - 2 - through opening in retainer, and at the same time
arrow B -.
 Connect electrical connector - 3 - on clutch pedal starter interlock switch F194.
2:48:50 AM Page 8

Removing


downward.
Installing
2:48:50 AM Page 9

clamp.
Pedal cluster (RHD vehicles), assembly overview
2:48:50 AM Page 10

2 - Washer
3 - Brake pedal
2:48:50 AM Page 11

 Replace
7 - Bearing sleeve
8 - Clutch pedal
9 - Retaining clip

13 - Bolt, 22 Nm
 Self-locking
 Replace
14 - Lever
15 - Washer
16 - Mounting
2:48:50 AM Page 12
18 - Bolt, 25 Nm

2 - Supply hose
 For connections on master cylinder and slave cylinder
2:48:50 AM Page 13

 Disconnecting from slave cylinder Disconnecting slave cylinder from hose/line assembly
4 - Grommet
6 - Clutch pedal
7 - Master cylinder

9 - Retaining clip

arrow - ).
10 - Transmission
11 - Slave cylinder
 Removing and installing --> Slave cylinder, removing
bleeding
12 - Bleeder valve
13 - Dust cap
2:48:50 AM Page 14
14 - Clip
15 - Bracket


 Self-locking
 Replace
17 - Retaining clip
18 - Gasket
19 - Securing bolt

2:48:50 AM Page 15


Removing
Installing

 Insert hose/line assembly in slave cylinder and make sure that it engages audibly.
function check.
2:48:50 AM Page 16
 After installing the slave cylinder carefully press the clutch pedal. If an unusually strong point of pressure
is felt when depressing the clutch pedal, do not press it down further. The push rod of the slave cylinder is
likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once
pedal force exceeds approx. 300 N.
Function check for master and slave cylinder
Before replacing the master or slave cylinder - in the case of the following faults - first perform the appropriate
checks.
 Replace relevant component.
of time.

 Check master and slave cylinder as well as the line/hose assembly including connecting points for
High pedal force:

Pedal forces:
2:48:51 AM Page 17
 Needle bearing in flywheel (centering bearing for input shaft) faulty, replace needle bearing --> 13 -
ENGINE - CRANKSHAFT, CYLINDER BLOCK .

 Wrong components used or components forgotten when carrying out repair work (e.g. intermediate plate).

 Hose clamp 3094

 Pliers V.A.G1922
Removing
Observe the notes on removing and installing clutch master cylinder and slave cylinder --> Notes on removing
and installing master cylinder and slave cylinder.


Cabriolet
2:48:51 AM Page 18
 Remove rubber seal on plenum chamber in direction of - arrow -.


 Use screwdriver to pry off two caps - 3 -.

 Remove nuts - 4 - and take off two wiper arms - 2 -.
 Pull off clips - 1 - and remove cowl panel grille - 5 -.
2:48:51 AM Page 19
Take electronics box out of plenum chamber as follows:

2:48:51 AM Page 20
Fig. 32: Disconnecting Electrical Harness Connectors On Connector Station



2:48:51 AM Page 21


 Pry out retaining clip - C - using a screwdriver and pull line/hose assembly - B - out slightly.

2:48:51 AM Page 22
 Remove bolt for brake fluid reservoir - 1 - and disconnect connector for brake fluid level warning contact
downward.



.
2:48:51 AM Page 23


 Disconnect connectors from clutch pedal switch F36 - 1 - , brake light switch F - 2 - and accelerator pedal
module - 3 -.
 If installed, disconnect connector from clutch pedal switch for engine start F194.
1922
2:48:51 AM Page 24
 Position spark plug connector pliers V.A.G1922 in clutch pedal recesses, press on sides of retaining clip
and disconnect clutch pedal from master cylinder.

Installing
Installation is in reverse order of removal. Note the following:
2:48:51 AM Page 25
 Insert master cylinder - 4 - and tighten bolts - 3 - to 20Nm.
Clutch Pedal

 Insert entire pedal cluster and tighten bolt - 1 - by hand. Second technician must guide hose/line assembly
into master cylinder from plenum chamber.
2:48:51 AM Page 26



2:48:51 AM Page 27

contact.
 If installed, connect connector for Clutch Pedal Starter Interlock Switch F 194.
2:48:51 AM Page 28

.


 Route engine wiring harness and plug in connector in connector console.
 Install engine control unit --> 24 - MULTIPORT FUEL INJECTION (MFI) or 24 - FUEL
INJECTION SYSTEM .
 97 WIRING

2:48:51 AM Page 29
 Brake filler and bleeder unit VAS 5234
Procedure
clutch mechanism.
 The clutch system should be bled at the same intervals as the brake
system.
 Connect brake filler and bleeder unit VAS 5234, but do not switch on at this stage.
2:48:51 AM Page 30

 If installed, remove heat shield - arrows - for drive axles (left-side).


Tightening torques
Component Nm
2:48:51 AM Page 31
Fig. 53: Identifying Special Tools -- Clutch Release Mechanism, Servicing


 Tube 2040

2:48:51 AM Page 32


1 - Release bearing

plastic ring
2:48:51 AM Page 33
plastic ring
 3x
grease Z381351TE .
5 - Guide sleeve

6 - Seal
 For input shaft

7 - O-ring
 Always replace
8 - Convex washer
10 - Ball head stud
11 - Transmission
12 - Slave cylinder
2:48:51 AM Page 34
 Removing and installing --> Slave cylinder, removing

 Self-locking
 Replace
14 - Bracket

 Bolt to transmission with slave cylinder
15 - Operating rod

 Before installing the transmission, glue loose plastic ring back onto bearing with adhesive
AMV195KD101 .
2:48:51 AM Page 35
Three square tabs - arrows - of the plastic ring engage in recesses of the bearing ring.
 The release bearing must be replaced if the groove worn on the plastic ring is deeper than 0.8 mm.

than 0.8mm.

B - Internal puller 23.5 to 30 mm, e.g. Kukko 21/4
2:48:51 AM Page 36
Slave cylinder, removing
Observe the notes on removing and installing clutch master cylinder and slave cylinder --> Notes on removing
and installing master cylinder and slave cylinder.


2:48:51 AM Page 37
Fig. 60: Fasteners

Removing
 On vehicles equipped with auxiliary heater, remove bolts - arrows - securing exhaust pipe of auxiliary

2:48:51 AM Page 38

 Remove front exhaust pipe (left-side) with catalytic converter --> 26 - EXHAUST SYSTEM,
EMISSION CONTROLS .

surface protection.
2:48:51 AM Page 39


 Remove bolt - arrow - and take out slave cylinder from rear.
2:48:51 AM Page 40

Installing
Installation is in reverse sequence or removal. Note the following:
installed easily.

 To connect line to slave cylinder, press in retaining clip - A - as far as it will go.
2:48:51 AM Page 41
G052150A2 .
Z381351TE .

2:48:51 AM Page 42

 After installing the slave cylinder carefully press the clutch pedal. If you
pedal, you must not press it down further. The push rod of the slave
300 N.
2:48:51 AM Page 43


 If line-hose assembly was disconnected at slave cylinder, the clutch system has to be bled after installing



 Install exhaust system and perform stress-free alignment --> 26 - EXHAUST SYSTEM, EMISSION
CONTROLS .
Tightening torques
Component Nm
* Replace bolt
CLUTCH, SERVICING
Clutch, servicing
2:48:51 AM Page 44


 Counterhold tool 3067

2:48:51 AM Page 45
cylinder.
Adjuster ring in SAC clutch pressure plate, resetting.
 Check that SAC pressure plate is not distorted Check SAC pressure plate
for warpage, cracks and burns.
 If the vehicle is fitted with a self-adjusting clutch (Sachs version), the
 replace clutch plate and pressure plate if riveted fastening is damaged or
loose.
code
 To avoid damaging dual-mass flywheel during removal, please observe
backward and forward on the input shaft until hub moves freely on shaft. It
is important to remove excess grease.
servicing

 Remove transmission to work on clutch --> Transmission, removing and installing.
2:48:51 AM Page 46


 Always replace
2:48:51 AM Page 47
3 - Clutch plate
 Marking "Getriebeseite" (transmission side), if provided, faces pressure plate/transmission.
4 - Pressure plate
5 - Bolt -22 Nm-
6 - Needle bearing

2:48:51 AM Page 48

NOTE:  When performing repairs, always match the correct clutch pressure plate

seated tightly.
2:48:51 AM Page 49
NOTE:  replace pressure plate if spring connections are broken or badly bent, or if
riveted fastenings are loose.
Checking wire ring

broken.
replaced together.

 Remove transmission to work on clutch--> Transmission, removing and installing.
2:48:51 AM Page 50

1 - Bolt -22 Nm-
2 - Pressure plate
 Self-adjusting
2:48:51 AM Page 51
3 - Clutch plate

 The marking "Getriebeseite" (transmission side), if provided, faces pressure plate/transmission.
 Always replace

6 - Needle bearing
Identification
2:48:51 AM Page 52


2:48:51 AM Page 53

seated tightly.
Checking wire ring

 Check that wire ring in pressure plate - arrow - is not damaged. replace pressure plate if wire ring is
broken.
2:48:51 AM Page 54


 When removing bolts - B - , make sure the bolt heads do not contact the flywheel - arrows - because this
 Removing and installing dual-mass flywheel --> 13 - ENGINE - CRANKSHAFT, CYLINDER
BLOCK for the appropriate engine code.

 Counterhold tool 3067
2:48:51 AM Page 55



 Attach counter-hold tool 3067 or counter-hold tool 10 - 201 before loosening bolts.
2:48:51 AM Page 56
plate is released.
 Stop - 2 - with pin - 1 - should come loose when the bolts are loosened.
Installing


2:48:51 AM Page 57


 Make sure that the stop mechanism - arrow - is free to move.
 Tighten all 6 bolts evenly by hand until bolt heads make contact with pressure plate.
 The stop mechanism - arrow - should then lift away from the pressure plate.

 Remove transmission to work on clutch --> Transmission, removing and installing.
2:48:51 AM Page 58


2 - Needle bearing
2:48:52 AM Page 59
 Always replace

4 - Clutch plate
 Resetting adjuster ring --> Adjuster ring in SAC clutch pressure plate, resetting
6 - Bolt -22 Nm-

2:48:52 AM Page 60

seated tightly.
A - Straightedge
B - Feeler gauge
2:48:52 AM Page 61


 Removing and installing dual-mass flywheel --> 13 - ENGINE - CRANKSHAFT, CYLINDER
BLOCK for the appropriate engine code.

2:48:52 AM Page 62


Removing
is released.
Installing
2:48:52 AM Page 63
NOTE:  Before re-installing the SAC pressure plate, check that it is not warped
clutch pressure plate, resetting.



 Tighten all 6 bolts evenly by hand until bolt heads make contact with pressure plate.
 Tighten all six bolts consecutively in clockwise direction and in steps of 90° (14 turn) until housing
Adjuster ring in SAC clutch pressure plate, resetting

2:48:52 AM Page 64
ring.
reset.


 Thrust pad 3062
Procedure
2:48:52 AM Page 65
 Insert 3 bolts for securing pressure plate - A - into mounting holes on pressure plate located at 120° (13)
intervals, as shown in illustration.

 Place SAC pressure plate onto press tool so that only the 3 bolt heads - arrows - make contact.
off.
2:48:52 AM Page 66

 Apply two screwdrivers to forks on adjuster ring. Use press tool to apply pressure to pressure plate until it
is just possible to move adjuster ring.
 Hold adjuster ring against stop and reduce pressure applied by press tool so that adjuster ring is held in
this position.
2:48:52 AM Page 67
TRANSMISSION 5 Spd. Manual Transmission 012/01W Front Wheel Drive
30 CLUTCH
Fig. 7: Clutch Mechanism, Servicing - Pedal Cluster And Hydraulic System

II - Exploded view of hydraulic system. Refer to Hydraulic system, assembly overview
NOTE:  Note or obtain radio code on vehicles with coded radio.

 Disconnect battery ground strap with the ignition switched off.
2:16:03 AM
2:16:07 Page 1

052 142 A 2.
CAUTION: On vehicles equipped with Audi Telematics by OnStar ® , switch-off the

emergency (back-up) battery for the Telematic/Telephone Control Module
prior to disconnecting the vehicle battery. Switch-on the emergency (back-
up) battery after reconnecting the vehicle battery. Refer to
Cabriolet
 Remove cover below instrument panel, before working on foot pedal cluster
Refer to
 Make sure brake fluid does not escape into footwell or plenum chamber or onto transmission below. If
this does happen, clean the affected areas thoroughly.
 Protect the carpet from brake fluid using rags, when performing work in the footwell.
2:16:03 AM Page 2

 Removing and installing. Refer to Slave cylinder, removing and installing
2 - Fulcrum pin for clutch and brake pedal
3 - Fastener
5 - Brake pedal
 Mounting is maintenance-free, do not grease
2:16:03 AM Page 3
 Can only be installed one time
 For securing pivot pins for clutch and brake pedal
8 - Clutch pedal
9 - Fastener
10 - Retainer
 Removing and installing. Refer to Hydraulic system, assembly overview

 Black end points toward clutch pedal

 Allocation
Refer to Parts list
14 - Clutch Pedal Position (CPP) Switch -F194-
 Can only be installed one time
15 - Torx bolt - 25 Nm
2:16:04 AM Page 4

 T40025 Installation clamp
Removing
Refer to

 Tension over-center spring with clutch pedal and press on installation clamp T40025.
 Bring clutch pedal to rest position and take out over-center with spring and installation clamp T40025
from below.
Installing
2:16:04 AM Page 5
Installation position over-center spring:
 Black end over-center spring points toward clutch pedal.

 Insert over-center spring with installation clamp T40025, depress clutch pedal and pull out installation
clamp.
2:16:04 AM Page 6

2 - Supply hose
3 - Hose assembly
 For plug-in connections on master/slave cylinder

 Separating from master cylinder and installing. Refer to Slave cylinder, removing and installing
 Separating from slave cylinder. See Separating slave cylinder from hose and pipe assembly
4 - Grommet
2:16:04 AM Page 7
6 - Clutch pedal
7 - Master cylinder

 Clip (arrow A) and seal (arrow B) must not be removed
 To remove hose/pipe assembly, pull clip (arrow A) out up to stop. Refer to Fig. 27
9 - Retainer

 Removing. See Pulling off retainer
 Pressing on. See Pressing master cylinder operating rod into retainer
10 - Transmission
11 - Slave cylinder
 Removing and installing. Refer to Before installing, coat clutch slave cylinder with grease
 Separating from hose/pipe assembly. See Separating slave cylinder from hose and pipe assembly
 Brake fluid must not come into contact with transmission
12 - Bleeder valve
 Follow correct sequence when bleeding. Refer to Clutch system, bleeding
13 - Dust cap
14 - Clip
 To remove pipe, pull out clip up to stop. Refer to Separating slave cylinder from hose and line
assembly
15 - Bracket
 for hose and line assembly
2:16:04 AM Page 8
 Secured to transmission with slave cylinder

 Self-locking
 Always replace
17 - Retaining clip
18 - Seal
19 - Securing bolt
 for brake fluid reservoir
Pulling off retainer

Pressing master cylinder operating rod into retainer
2:16:04 AM Page 9

Separating slave cylinder from hose and pipe assembly

Removing
 Use a screwdriver to remove hose and line assembly, pull out clip -A- up to stop. Then the hose and pipe
assembly can be pulled out.
Installing
 Press in clip -A- up to stop

 Insert hose and pipe assembly into slave cylinder until it is heard to engage.
 Test by pulling on hose and pipe assembly.
2:16:04 AM Page 10

 3094 Hose clip

 VAG 1922 Pliers
Removing
 Remove rubber seal from plenum chamber in direction of arrow.

 Remove cover -1- over plenum chamber.

 Check whether an encoded radio is installed. If so, obtain anti-theft code.
CAUTION: On vehicles equipped with Audi Telematics by OnStar ® , switch-off the

emergency (back-up) battery for the Telematic/Telephone Control Module
prior to disconnecting the vehicle battery. Switch-on the emergency (back-
2:16:04 AM Page 11
up) battery after reconnecting the vehicle battery. Refer to
Cabriolet
 Disconnect battery ground strap with ignition switched off.

 Use screwdriver to pry off the two caps -3-.

 Remove nuts -4- and detach the two wiper arms -2-.

 Screw out bolts -arrows- and pull off sealing cover.
2:16:04 AM Page 12
 Carefully pry off retainer bar with screwdriver -arrow-.
 Release connector latches -arrows- and pull off connectors -1- and -2- on engine control module.

2:16:04 AM Page 13
 Pull off connector -2- from connector rail

 Disconnect wire -1-.

 Release catches -arrows- and pull auxiliary relay carrier in electronics box upward to remove.
 Pull engine wiring harness together with rubber grommet out of recess in electronics box.

NOTE:  Make sure that brake fluid does not escape into the plenum chamber or
thoroughly.
 Protect the carpet from brake fluid using rags when performing work in the
footwell.
2:16:04 AM Page 14

 Remove rubber grommet from bulkhead on the supply hose connecting line.
 Use a screwdriver to pry out retaining clip -C- and then pull out line -B- slightly.

 Remove bolt from brake fluid reservoir -1- and disconnect connector from fluid level below.
NOTE: Do not remove the brake fluid reservoir.
NOTE:  For ease of illustration, brake fluid reservoir is not shown.

 To remove the top Torx bolt, swivel brake fluid reservoir slightly to one
side.
2:16:04 AM Page 15


 Remove vacuum line from brake servo -1-.
Refer to

2:16:04 AM Page 16
 Disconnect steering column from steering gear -arrow A-.
 Disconnect connector on clutch pedal switch -1-, brake pedal switch -2- and on accelerator pedal module
-3-.
 Remove securing bolt from mounting bracket -arrow B- and complete pedal cluster.
 Removing over-center spring. Refer to Over-center spring, removing and installing.
NOTE:  Make sure a tight connection in the clutch pedal switch. Refer to Pedal
cluster, assembly overview Pos. 6 as well as the Clutch Pedal Position
(CPP) Switch -F194-. Refer to Pedal cluster, assembly overview Pos. 14 in
the pedal cluster, these switches may only be installed once.
2:16:04 AM Page 17
Fig. 31: pressing Retainer Together And Detaching Clutch Pedal From Master Cylinder Using VAG 1922
 When releasing clutch pedal make sure that it does not strike against retainer for clutch pedal switch -
arrow-. This could break the retainer.
 Insert pliers VAG 1922 into recess of clutch pedal, press retainer together -arrows- and detach clutch
 Remove retaining clip -1- and pull off clutch pedal -2-.
 Remove bolts -3- and detach master cylinder -4-.
Installing
2:16:04 AM Page 18
 Insert master cylinder and tighten screws -3- to 20 Nm.
Fig. 34: Locating Mounting Bolts

 Insert retainer -1- into clutch pedal.

 Press clutch pedal in direction of arrow to engage, make sure that retainer -1- is correctly locked in clutch
pedal.
 Install over-center spring. Refer to Over-center spring, removing and installing.
2:16:04 AM Page 19
 Insert complete pedal cluster and install bolt -1- hand-tight. The second mechanic must simultaneously
insert line into master cylinder from plenum chamber side.

 Tighten bolts for brake servo -arrows- to 25 Nm.
2:16:04 AM Page 20
 Press in retaining clip -C- up to stop.

 Insert line -B- into master cylinder until it is heard to engage.
 Insert rubber grommet -D- over supply hose connecting line -A- into bulkhead.
 Slide supply hose -A- for the brake fluid reservoir up to stop.

 Install bolt for brake fluid reservoir.
 Tighten hex socket-head bolt for securing pedal cluster on instrument panel support to 25 Nm.
 Plug in connectors.
 Secure steering column to steering gear -arrow A-.
 Installing driver's storage compartment:
Refer to

 Insert electronics box and tighten nuts -arrows- to 4 Nm.
2:16:04 AM Page 21
 Route engine wiring harness and connect connectors to connector point.

 Install engine control module and if applicable auxiliary relay carrier with auxiliary fuse carrier.
Refer to 97 WIRING
 Press on sealing cover hand-tight and tighten screws in diagonal sequence to 4 Nm.
NOTE:  On re-connecting battery, remember to check and re-activate vehicle

equipment (radio, clock, convenience electronics, etc.).
Refer to
 Brake filling and bleeding unit VAS 5234
 Brake fluid specification
NOTE:  Open bleed valve before switching on bleeding appliance.

 Performing work on the hydraulic clutch mechanism the clutch system
must be bled.
2:16:04 AM Page 22
 Pull out clutch pedal and fill brake fluid reservoir with brake fluid up to
"max." mark before bleeding.
 Connect brake filling and bleeding unit VAS 5234, but do not turn on at this time.

 Connect bleed hose to pressure hose of collector bottle.
 Switch on bleeding appliance and allow about 100 cm3 of brake fluid to flow out.
NOTE: Make sure bleed hose is correctly installed during bleeding operation.
 Tighten bleed valve to 4.5 Nm.

 Depress clutch pedal several times after bleeding process.
2:16:04 AM Page 23
Fig. 41: Clutch Release Mechanism, Overview

1 - Slave cylinder
 Separating from hose and line assembly. See Separating slave cylinder from hose and line assembly
 Installing. See Before installing, coat clutch slave cylinder with grease and . Installing clutch slave
cylinder
 When installing, press in slave cylinder far enough so that securing bolt can be installed easily.

 Bleeding clutch system. Refer to Clutch system, bleeding
2:16:04 AM Page 24

 Self-locking
 Always replace
3 - Bracket
 For hose and line assembly

 Secured to transmission with slave cylinder
4 - Push rod
5 - Dished washer
 Smaller diameter (convex side) to guide sleeve
6 - Input shaft oil seal
 Available with guide sleeve -Item 11- Clutch release mechanism, servicing as replacement part
7 - Torx socket head bolt
 Self-locking
 Always replace
 Black; only for aluminum transmission
 Allocation
 On aluminum transmission tighten to 35 Nm
8 - Release bearing
 With or without plastic ring depending on design. See Servicing release bearing with plastic ring
 Adhering detached plastic ring. See Servicing release bearing with plastic ring
 Do not wash out bearing, only wipe
 Allow retaining lugs on release bearing to engage in release lever
 Coat contact surface of clutch slave cylinder push rod with copper grease, e.g. Z 381 351 TE before
installing
2:16:04 AM Page 25
11 - Guide sleeve
 Available with oil seal -Item 6- Clutch release mechanism, servicing as replacement part
 Installation position: Oil drain hole points downward
 Cover input shaft splines with a shrink-fit hose to protect oil seal -Item 6- Clutch release mechanism,
servicing before removing and installing
12 - O-ring
 Always replace
14 - Ball stud
 Lubricate with MoS2-grease

 On aluminum transmissions tighten to 25 Nm
Separating slave cylinder from hose and line assembly

Removing
 Use a screwdriver to remove hose and line assembly, pry out clip -A- up to stop. Then pulled out the hose
and line assembly.
Installing
 Press in clip -A- up to stop
2:16:04 AM Page 26
 Insert hose and line assembly into slave cylinder until it is heard to engage.
 Test by pulling on hose and line assembly.
Before installing, coat clutch slave cylinder with grease
TE.
 Lubricate area -a- on boot with lithium grease G 052 150 A2 before fitting slave cylinder into

2:16:04 AM Page 27
 Fasten bracket for hose line assembly -3- onto slave cylinder -4- and bolt together slave cylinder to
transmission.
 Insert the clutch slave cylinder into the mounting hole of the transmission housing, keep it in line with the
direction of operation of the push rod.
NOTE:  There is a danger that the push rod will be guided past the clutch release
lever if the clutch slave cylinder -4- is inserted off-line.
 Press in the clutch slave cylinder far enough so that the securing bolt can
be fitted easily.
 Replace securing bolt - 2-.

On release bearings with plastic ring it is possible that the plastic ring detaches from the release bearing
during removal of transmission or release bearing; this is not a reason for replacing release bearing.
 Adhere plastic ring back onto bearing ring with adhesive AMV 195 KD1 01 before installing
transmission.
Three right-angled lugs -arrows- on plastic ring engage in the recesses of bearing ring.
NOTE: The release bearing must be replaced if the plastic ring lies deeper than 0.5 mm
on the contact surface.
CLUTCH, SERVICING
Clutch, servicing
2:16:04 AM Page 28

 3067 Flywheel retainer


instructions.
code:
2:16:04 AM Page 29
apply only a very thin coating of grease G 000 100 to the splines. Then move clutch plate on input shaft
 Pressure plates are protected against corrosion and are greased. Only the contact surface may be cleaned,
otherwise the service life of the clutch will be reduced.
 If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the
transmission to reduce the smell of burnt linings.

A - Colored marking on dual mass flywheel
 If components are marked, white marking -A- on dual mass flywheel must coincide with white marking -
2:16:04 AM Page 30
B- on pressure plate.
B - Colored marking on pressure plate
 If components are marked, white marking -A- on dual mass flywheel must coincide with white marking -
B- on pressure plate.
 Make sure that centering pins are a tight fit

 Removing and installing. Refer to 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
 Always replace
 Vehicles without dual mass flywheel 60 Nm + turn 90 ° further
 Vehicles with dual mass flywheel
 Bolt length 22 mm 60 Nm + turn 90 ° further

 Bolt length 42 mm 60 Nm + turn 180 ° further
3 - Clutch plate

 Do not grease
 Clutch plate diameter. Refer to Code letters, application, ratios, capacitiesonward
 Centering. See Centering clutch plate and removing and installing pressure plate
 Lightly grease splines
4 - Pressure plate
 Removing and installing. See Centering clutch plate and removing and installing pressure plate
 Check ends of diaphragm spring. See Checking ends of diaphragm spring
 Checking spring connection and riveted fastenings. See Checking spring connection and riveted
fastenings
 If components are marked, assemble with white marking on flywheel -A- aligning with white marking on
pressure plate -B-.
2:16:04 AM Page 31
5 - Bolt, 25 Nm
 Loosen and tighten gradually over several stages in diagonal sequence
6 - Needle bearing
Centering clutch plate and removing and installing pressure plate
 Loosen and tighten bolts gradually over several stages in diagonal sequence - 25 Nm.
 Reverse position of counterhold 3067 when removing.
 Installation position of clutch plate: Spring pack (coil springs) or marking "Getriebeseite" toward pressure
 Do not insert mounting bolts until clutch lining and contact surface of pressure plate must make full

 If components are marked, assemble with white marking on dual-mass flywheel -A- aligning with white
marking on pressure plate -B-.
2:16:04 AM Page 32

Checking spring connection and riveted fastenings

 Check spring connection between pressure plate and cover for cracks and make sure rivet fastenings are
seated tightly.
 Replace clutches with damaged springs or loose riveted fastenings -arrows-.
2:16:04 AM Page 33
TRANSMISSION
6-speed manual transmission 0A3, All wheel drive
00 TECHNICAL DATA
The 6-speed manual transmission 0A3 (All-wheel drive) is installed on the AudiA42001 --> in conjunction with
the 4.2ltr. V8 gasoline engine.
Fig. 1: Transmission Identification

Location on transmission
 Code letters and serial number - arrow1 -

 Manual transmission 0A3 - arrow2 -
Fig. 2: Locating Code Letters And Transmission Serial Number

2:52:56 AM
2:53:07 Page 1
Code letters and transmission serial number - arrow1 -
Example: FVD 0314

I I
Code letters Transmission serial number
stickers.
Fig. 3: Transmission Code Letters On The Vehicle Data Stickers

Manual transmission 0A3 - arrow2 -
Code letters, assignment of mechanical units, transmission ratios, capacities
Manual transmission 6-speed 0A3, All wheel drive

Code letters FVD FVD
to 12.03 02.04
Allocation Model Audi A4 2001 --> Audi A4 Cabriolet 2003-->
Engine 4.2 ltr. - 253 kW S4 4.2 ltr. - 253 kW
Ratio Final drive 35 : 9 = 3.889 35 : 9 = 3.889
Z2 : Z1 = i 1st gear 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 41 : 20 = 2.050 41 : 20 = 2.050
3rd gear 38 : 26 = 1.462 38 : 26 = 1.462
4th gear 34 : 30 = 1.133 34 : 30 = 1.133
5th gear 34 : 37 = 0.919 34 : 37 = 0.919
6th gear 35 : 45 = 0.778 35 : 45 = 0.778
Reverse gear 30 : 09 = 3.333 30 : 09 = 3.333
2:52:56 AM Page 2
Capacity 3.2 liters

Specification Gear oil G 052 911 A SAE 75 W 90 (synthetic oil)
Clutch operation Hydraulic
Clutch plate 240 mm 240 mm
Drive shaft flange 88 mm 88 mm
Overall ratio iov. in top gear 3.025 3.025
Allocation of rear final driveCode letters EXZ EXZ
Final drive 01R is assigned with manual transmission 0A3 (All wheel drive).
NOTE:  For identification of rear final drive refer to --> 00 GENERAL, TECHNICAL
DATA
 For repairs on the driveshaft or the rear final drive refer to --> 39 FINAL
DRIVE, DIFFERENTIAL .

Code letters and date of manufacture - arrow1 -
Final drive 01R - arrow2 -
2:52:56 AM Page 3

Final drive 01R - arrow2 -
Fig. 6: Rear Final Drive Identification

Code letters and date of manufacture of final drive - arrow1 -
Example: EXZ 26 11 02
I I I I
I I I I
Code letters Day Month Year of manufacture (2002)
Transmission layout
Identification
NOTE:  - Arrows - point in direction of travel.
2:52:56 AM Page 4
Fig. 7: Transmission Layout

1 - Engine
2 - Clutch
3 - Manual transmission
4 - Input shaft (main shaft)
5 - Differential (front)
6 - Front pinion shaft (output shaft)
7 - Hollow shaft
2:52:56 AM Page 5
9 - Driveshaft
10 - Rear pinion shaft
11 - Differential (rear)
Ratio

I - 1st gear
2:52:57 AM Page 6
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A1 - Front final drive
A2 - Rear final drive
Calculating ratio "i"
Transmission ratio
Transmission ratio = No. of teeth on driven gear : No. of teeth on drive gear
Ratios Formula
iG = Gear ratio ZG2 : ZG1
iA = Axle ratio ZA2 : ZA1
iov = Overall ratio iG x iA
Example:
6th gear Final drive
Drive gear ZG1 = 45 ZA1 = 9
Driven gear ZG2 = 35 ZA2 = 35
Calculations:
iG = 35 : 45 = 0.778
iA = 35 : 9 = 3.889
iov = 0.778 x 3.889 = 3.025
Proper tools and the maximum possible care and cleanliness are essential for satisfactory transmission repairs.
The usual basic safety precautions also naturally apply when carrying out repair work.
2:52:57 AM Page 7
repeated at numerous places in the article - are summarized under the designation "Components". They apply to
the work described in this article.
Components
Transmission
 Select the correct bolts and other components according to transmission code letters --> Code letters,
assignment of mechanical units, transmission ratios, capacities.
 When installing a new transmission, check the oil level and fill up with oil if necessary --> Transmission
gear oil, checking level.
 Capacities and specifications --> Code letters, assignment of mechanical units, transmission ratios,
capacities
 When installing a new rear final drive, check the oil level in the rear final drive and top off if necessary.
Capacities and specifications --> 39 FINAL DRIVE, DIFFERENTIAL .
 Thoroughly clean all joints and surrounding areas before dismantling.

 When installing transmission ensure dowel sleeves are correctly seated.
Sealants
 Thoroughly clean joint surfaces on transmission housing etc. before applying sealing paste.
 Apply sealing paste AMV18800102 evenly and not too thick.
 Breather holes must remain free of sealing paste.

2:52:57 AM Page 8

 Before installing oil seals, lightly oil the outer circumference of the seal and fill the space between the
sealing lips - arrow - about half full with grease G052128A1 .
 Lightly oil O-rings before installing to prevent them being trapped and damaged when assembling.
 After replacing seals and gaskets, check and, if necessary, top off oil level in transmission -->
Transmission gear oil, checking level.
Locking elements

 Always replace circlips which have been damaged or over-stretched.
 Retaining rings/circlips must be properly seated in the base of the groove.
Fig. 10: Identifying Locking Elements

 Replace spring pins. Position: the slit - A - should be in line with the line of force - arrow -.
Nuts, bolts
 Loosen the nuts and bolts in reverse sequence to the specified tightening sequence.
2:52:57 AM Page 9
 Loosen and tighten particularly sensitive parts in diagonal sequence and in stages, taking care to keep
them straight.

 Clean the threads of bolts which are secured by a locking compound with a wire brush. Then apply
locking fluid AMV185101A1 to bolt threads before installing.
 Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a
tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being removed.
Shims
 Use a micrometer to measure the shims at several points. Tolerance variations make it possible to obtain
the exact shim thickness required.
 Check for burrs and damage.
 Do not install shims which are damaged or not in perfect condition.
Bearings
 Install needle bearings so the lettering (side with thicker metal) faces towards the installing tool.
 Grease needle bearing for transmission input shaft in rear of flywheel.
 Lubricate all bearings in transmission housing with gear oil before installing.
Clutch mechanism
 When removing transmission, remove clutch slave cylinder without disconnecting lines.
 Do not depress the clutch pedal after removing the clutch slave cylinder if the hydraulic line is still
connected. Otherwise the piston will be pressed out of the clutch slave cylinder. As a result the clutch
slave cylinder will be destroyed.
 If the clutch pedal does not return to its initial position after releasing it, you must bleed the clutch system
(further measures --> Clutch master cylinder and slave cylinder, notes on removing and installing).
 Note assembly instructions for SAC pressure plate --> Clutch with SAC pressure plate, removing and
installing
 On vehicles with SAC pressure plate an adjuster ring has to be reset when only the clutch plate is
replaced --> Resetting adjuster ring in SAC clutch pressure plate.
30 CLUTCH
2:52:57 AM Page 10


Cabriolet
.
battery. -->

Cabriolet
G052142A2 .
side -->
.
 Make sure brake fluid does not leak into footwell, plenum chamber or onto
transmission below. If it does, area affected must be thoroughly cleaned.
 When working in footwell, use cloths to protect floor covering against
brake fluid spillage.
2:52:57 AM Page 11
I - Pedal cluster - exploded view --> Pedal cluster, assembly overview
II - Pedal cluster (RHD vehicles) - exploded view
Not applicable for North American market
III - Hydraulics - exploded view --> Hydraulic system, assembly overview
2:52:57 AM Page 12

3 - Retaining clip
5 - Brake pedal
2:52:57 AM Page 13
6 - Clutch Pedal Switch F36
 Removing and installing --> Clutch Pedal Switch F36, removing and installing
 Replace
8 - Clutch pedal
9 - Retaining clip
10 - Retaining clip
 Black side points towards clutch pedal

 Only for USA vehicles

 Engine can only be started when clutch is fully depressed (Clutch Pedal Starter Interlock Switch F194
activated).
 Replace
 Do not re-install
Clutch Pedal Switch F36, removing and installing
2:52:57 AM Page 14
NOTE:  Clutch Pedal Switch F36 may only be installed once so as to ensure a firm
fit.
Removing

Clutch Pedal Switch F36 should then rest against the clutch pedal.
 Release Clutch Pedal Switch F36 - 2 - by turning 45° counterclockwise and take out of guide.
Installing
2:52:57 AM Page 15
Installation is performed in reverse of removal; note the following:
 Pull out operating rod - arrow - all the way before installing Clutch Pedal Switch F36.

 Guide Clutch Pedal Switch F36 through mounting hole, press against clutch pedal and attach by turning
45° clockwise.
 Connect connector for Clutch Pedal Switch F36.
NOTE:  To ensure a secure fit, the Clutch Pedal Starter Interlock Switch F194 must
Removing

2:52:57 AM Page 16
 Disconnect electrical connector - 3 - on clutch pedal switch for engine start.

 At the same time, release Clutch Pedal Starter Interlock Switch F194 - 2 - by turning it 45° in the
direction indicated - arrow - and pull it out of the guide.
Installing
2:52:57 AM Page 17
 When installing Clutch Pedal Starter Interlock Switch F194, press clutch pedal - 1 - all the way down -
arrowA -. Hold clutch pedal in this position.
 Guide Clutch Pedal Starter Interlock Switch F194 - 2 - through opening in retainer, and at the same time
arrowB -.
 Attach electrical connector - 3 - on clutch pedal switch for engine start.
2:52:57 AM Page 18

Removing


.
 Move clutch pedal to rest position and take out over-center spring together with assembly clamp T40025
downwards.
Installing
2:52:57 AM Page 19

 Installation position of over-center spring: black side of over-center spring faces clutch pedal.
clamp.
2:52:57 AM Page 20

2 - Supply hose
 For plug-in connections on clutch master cylinder and slave cylinder

 Disconnecting from clutch master cylinder and installing --> Clutch master cylinder, removing and
installing
 Disconnecting from clutch slave cylinder Disconnecting clutch slave cylinder from hose/line assembly
2:52:57 AM Page 21
4 - Grommet
6 - Clutch pedal
 Do not remove clip - arrowA - or seal - arrowB -.
 To remove line/hose assembly, pull out clip - arrowA - , but only as far as limit stop Clutch master
cylinder, removing and installing.
9 - Retaining clip
 Only replace when clutch master cylinder has been removed

 Pry off to remove Removing retaining clip - A - in direction of - arrow -
arrow -).
10 - Transmission
 Removing and installing --> Clutch slave cylinder on vehicles with 4.2 Liter V8 engine (S4),
 Bleed clutch slave cylinder after working on hydraulic clutch mechanism --> Hydraulic clutch system,
bleeding
 Disconnecting hose/line assembly Disconnecting clutch slave cylinder from hose/line assembly
12 - Bleeder valve
13 - Dust cap
14 - Clip
2:52:57 AM Page 22
 To remove line pull out clip as far as limit stop Disconnecting clutch slave cylinder from hose/line
assembly
15 - Bracket


 Self-locking
 Replace
17 - Retaining clip
18 - Seal
19 - Securing bolt
Removing retaining clip - A - in direction of - arrow -

Pressing master cylinder operating rod into retaining clip - A - (in direction of - arrow -).
2:52:57 AM Page 23

Disconnecting clutch slave cylinder from hose/line assembly

Removing
 To remove hose/line assembly, use a screwdriver to pry off clip - A - as far as the stop. Only then can the
Installing

 Push hose/line assembly into clutch slave cylinder until it engages audibly.
Clutch master cylinder and slave cylinder, notes on removing and installing
 Before replacing the clutch master cylinder or slave cylinder on the assumption that it is defective you
must first perform a function check.
2:52:57 AM Page 24
 After installing the slave cylinder, carefully press the clutch pedal. If you feel an unusually strong point of
resistance when depressing the clutch pedal, you must not press it down further. The operating rod of the
slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be
Clutch master cylinder and slave cylinder, function check
Before replacing the master and/or slave cylinder, perform the appropriate checks in the case of the following
errors:
 First check the over-center spring/clutch pedal switch for noise.

 Replace faulty component.
After releasing clutch pedal it still remains depressed/does not return to its initial position.
of time.

 Bleed clutch system --> Hydraulic clutch system, bleeding.
High pedal force:

Pedal forces:
Conventional clutch:
2:52:57 AM Page 25
 - Clutch lining when new: approx. 115 N

 - Clutch lining at wear limit: approx. 160 N
SAC clutch:
 - approx. 140 N higher for complete service life of the clutch
 Air in hydraulic system: bleed clutch system --> Hydraulic clutch system, bleeding and check hydraulic
 Needle bearing in flywheel (centering bearing for input shaft) defective, replace needle bearing -->
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for BHF
.
 Foreign material in clutch system

 Wrong components used or components forgotten when performing repair work (e.g. intermediate plate).
Clutch master cylinder, removing and installing

2:52:57 AM Page 26

 Pliers V.A.G 1922
Removing


Cabriolet
.
battery -->

Cabriolet
2:52:57 AM Page 27

 With the ignition switched off, disconnect battery ground (GND) strap -->

 Pry off the two caps - 3 -.

 Remove nuts - 4 - and remove the two wiper arms - 2 -.
 Remove clips - 1 - and disconnect cowl panel grille - 5 -.
2:52:57 AM Page 28
 Unscrew bolts - arrows - and take off the cover.


 Disconnect connectors - 2 - at connector console.

 Remove electrical wiring connection - 1 -.
2:52:57 AM Page 29


2:52:57 AM Page 30

 Pinch off supply hose - A - from brake fluid reservoir using hose clamp 3094. Disconnect hose from
clutch master cylinder and plug hose.
 Lever out retaining clip - C - using a screwdriver and then pull out line/hose assembly - B - slightly.

 Remove bolt for brake fluid reservoir - 1 - and disconnect connector for Brake fluid level warning contact
downwards.
NOTE:  The brake fluid reservoir does not have to be removed.
2:52:57 AM Page 31


 Remove the two TORX bolts - arrows -.
 Brake fluid reservoir must be moved slightly to the side in order to
unscrew upper Torx bolt.

.

2:52:57 AM Page 32
 Disconnect steering column from steering box - arrowA - --> 48 - STEERING .

 Disconnect connectors at clutch pedal switch - 1 - , brake pedal switch - 2 - and at accelerator pedal
module - 3 -.
 If installed, disconnect connector from Clutch Pedal Starter Interlock Switch F194.
 Remove securing bolt for mounting bracket - arrowB - and remove entire pedal cluster.
1922
2:52:57 AM Page 33
 Insert pliers V.A.G 1922 in recesses on clutch pedal, press on sides of retaining clip and Disconnect
clutch pedal from master cylinder.
 Disconnect retaining clip - 1 - and remove clutch pedal - 2 -.

 Remove bolts - 3 - and remove clutch master cylinder - 4 -.
Installing
 Install clutch master cylinder - 4 - and tighten bolts - 3 - to 20Nm.
2:52:57 AM Page 34
Clutch Pedal
 Install retaining clip - 1 - in clutch pedal.

assembly into clutch master cylinder from plenum chamber.
2:52:57 AM Page 35

 Tighten bolts for brake servo - arrows - to 25Nm.


 Insert hose/line assembly - B - in clutch master cylinder and make sure that it engages audibly.
2:52:57 AM Page 36

 Screw in securing bolt - 1 - for brake fluid reservoir and Connect connector at brake fluid level warning
contact.
 Tighten hexagon socket head bolt - arrowB - for securing pedal cluster to instrument panel carrier to
25Nm.
 If installed, attach connector for Clutch Pedal Starter Interlock Switch F194.
 Secure steering column to steering box - arrowA - --> 48 - STEERING .
2:52:57 AM Page 37
 Install over-center spring Installing.

.
 Bleed clutch system --> Hydraulic clutch system, bleeding.

 Install electronics box and tighten nuts -arrows- to 4Nm.

 Route engine wiring harness and Connect connector in connector console.
 Install engine control module --> 24 MULTIPORT FUEL INJECTION (MFI) .
 97 WIRING

NOTE:  Upon re-connecting the battery, remember to check and activate the
vehicle equipment (radio, clock, convenience electrics etc.).
Hydraulic clutch system, bleeding
2:52:57 AM Page 38
 Brake filling and bleeding equipment VAS 5234 or brake filling and bleeding equipment V.A.G 1869
 Brake fluid specification --> 47 - BRAKES - HYDRAULIC COMPONENTS .
Procedure
clutch mechanism.
 Before bleeding the clutch system, pull back the clutch pedal to the
normal position and top off brake fluid to "Max" marking on brake fluid
reservoir.
 Connect brake charge and bleed equipment V.A.G1869 or VAS 5234, but do not switch on at this stage.
2:52:57 AM Page 39
 If installed, remove rear part of noise insulation - 2 to 3 -.

 If installed, remove noise insulation cover - arrows - in wheel housing (left-side).

 Remove heat shield - arrows - for driveshaft (left-side).
2:52:57 AM Page 40

NOTE:  Ensure bleeder hose is correctly installed during bleeding operation.

Tightening torque
Component Nm
2:52:57 AM Page 41



2:52:57 AM Page 42

 Removing and installing on vehicles with 8-cylinder engine --> Clutch slave cylinder on vehicles with
4.2 Liter V8 engine (S4), removing and installing
 When installing, push in until the securing bolt can be installed.
2:52:57 AM Page 43

 Self-locking
 Replace
3 - Bracket

4 - Operating rod
5 - O-ring
 Always replace Replacing O-ring

6 - Oil seal
 For input shaft

 Removing Removing input shaft oil seal
 Installing Installing input shaft oil seal
7 - Guide sleeve
 Removing Removing and installing guide sleeve
 Removing Clutch release lever, removing and installing

grease Z381351TE .
9 - Release bearing

plastic ring
2:52:57 AM Page 44
 Replace if groove worn on plastic ring is too deep Checking release bearing with mechanically
attached plastic ring
 Retainer lugs on release bearing must engage in release lever
10 - Bolt, 24 Nm
 Self-locking
 Replace
11 - Leaf spring
12 - Bolt, 24 Nm
 2x
 Self-locking
 Replace
13 - Retaining piece
15 - Transmission
Clutch release lever, removing and installing
Fig. 57: Clutch Release Lever Remove/Install Components

2:52:57 AM Page 45
Removing

 Disengage retaining tabs of release bearing at release lever.
Installing
 Before installing clutch release lever, apply a thin coat of copper grease Z381351TE to contact surface
for operating rod of clutch slave cylinder.
 Install clutch release lever - 3 - with release bearing onto guide sleeve.
 Install leaf spring - 2 - and tighten new bolt - 1 - to 24Nm.

Identification: inner side of plastic ring has three lugs - arrows -.
 Before installing the transmission, glue the loose plastic ring back onto the bearing with adhesive
AMV195KD101 .
The three square lugs - arrows - on the plastic ring engage in the recesses of the bearing ring.
2:52:57 AM Page 46

than 0.8mm.
Removing and installing guide sleeve
Fig. 60: Guide Sleeve Remove/Install Components

Removing
 Unscrew bolts - arrows - and remove retaining piece - 1 -.

Installing
 Replace O-ring in transmission housing Replacing O-ring.

 Install a thin insulating hose tightly over splines of input shaft.
2:52:57 AM Page 47
 Pack space between sealing lip and dust lip with sealing grease G 052 128 A1 .
 Lightly oil outer circumference of guide sleeve.
 Push guide sleeve - 2 - over input shaft and into transmission housing.
 Remove insulating hose.
 Secure retaining piece - 1 - with new bolts - arrows -.
Replacing O-ring

 Remove O-ring - arrow - using a small screwdriver.

 Lubricate new O-ring with gear oil before installing.
Removing input shaft oil seal
Fig. 62: Removing Input Shaft Oil Seal

A - Counter support, e.g. - Kukko 22/1 -
B - Internal puller 30 to 37 mm, e.g. - Kukko 21/5 -
2:52:57 AM Page 48
Installing input shaft oil seal
Fig. 63: Installing Input Shaft Oil Seal

 Lightly lubricate outer circumference of seal with gear oil.

 Press in oil seal for input shaft as far as it will go.
 The open side of seal faces towards press tool VW 454.
Clutch slave cylinder on vehicles with 4.2 Liter V8 engine (S4), removing and installing
Observe the notes on removing and installing clutch master cylinder and slave cylinder --> Clutch master
cylinder and slave cylinder, notes on removing and installing.

2:52:58 AM Page 49

Removing

2:52:58 AM Page 50
Wood
 Remove universal mounting V.A.G 1359/2 from engine and transmission jack V.A.G 1383 A and place a
rear cross member and body reaches dimension - x -.
2:52:58 AM Page 51


 Unbolt drive shaft - 1 - from flange shaft and move clear to the front.

 Remove bolt - arrow - and take out clutch slave cylinder from the rear.
2:52:58 AM Page 52

 To remove hose/line assembly, use a screwdriver to Pry off clip - A - as far as the stop. Only then can the
Installing
 If the clutch slave cylinder is inserted at an angle, there is a danger that
the operating rod will be guided past the clutch release lever.
 To facilitate assembly, engage 6th gear before fitting slave cylinder.
installed easily.

2:52:58 AM Page 53
 Push line - B - into clutch slave cylinder until it engages audibly.
G052150A2 .
Z381351TE .

 Engage bracket for hose/line assembly - 3 - at slave cylinder - 4 -.
2:52:58 AM Page 54

 Use new hexagon socket head bolt - 2 - to secure to transmission.


 If the line-hose assembly was disconnected at the slave cylinder, the clutch system has to be bled after
installing slave cylinder --> Hydraulic clutch system, bleeding.
2:52:58 AM Page 55
300 N.


 Install tunnel cross member --> 40 - FRONT SUSPENSION
Tightening torques
Component Nm
* Replace bolt
CLUTCH, SERVICING
Clutch, servicing

 Before replacing the clutch plate and pressure plate Fault-finding No.9 -
Defects on the clutch and clutch mechanism.
 Observe the notes on removing and installing clutch master cylinder and
slave cylinder --> Clutch master cylinder and slave cylinder, notes on
 On vehicles with SAC pressure plate (self-adjusting clutch) an adjuster
ring has to be reset when only the clutch plate is replaced--> Resetting
adjuster ring in SAC clutch pressure plate.
 To avoid damaging SAC pressure plate when removing and installing, observe assembly instructions for
SAC pressure plate --> Clutch with SAC pressure plate, removing and installing.
 Check that SAC pressure plate is not distorted Check SAC pressure plate for distortion, cracks and
burns.
 Replace clutch plate and pressure plate if riveted fastening is damaged or loose.
 Select the correct clutch plate and pressure plate according to engine code
2:52:58 AM Page 56
 To avoid damaging dual-mass flywheel during removal, please observe instructions for removal
Removing dual-mass flywheel.
apply only a very thin coating of grease for clutch plate splines G000100 to the splines. Then move
clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to
remove excess grease.
 Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned,
otherwise the service life of the clutch will be considerably reduced.
 Please refer to notes --> Clutch, servicing.
2:52:58 AM Page 57

 The transmission has to be removed before working on the clutch --> Transmission, removing and
installing.
2:52:58 AM Page 58


2 - Needle bearing
2:52:58 AM Page 59
 Replace
 Bolt length: 22.5 mm; 60 Nm + 90° further
 Bolt length: 43 mm; 60 Nm + 180° further
4 - Clutch plate
 The marking "Transmission end" (transmission side), if provided, faces towards pressure
plate/transmission.
 Coil springs (damper assembly) point towards pressure plate and transmission
 Clutch plate diameter --> Code letters, assignment of mechanical units, transmission ratios,
capacities
 Resetting adjuster ring --> Resetting adjuster ring in SAC clutch pressure plate
 Check that pressure plate is not distorted Check SAC pressure plate for distortion, cracks and burns
6 - Bolt, 22 Nm

2:52:58 AM Page 60

 Check spring connections - arrowsA - for damage and make sure riveted fastenings - arrowsB - are
seated tightly.
Check SAC pressure plate for distortion, cracks and burns
A - Straightedge
2:52:58 AM Page 61
B - Feeler gauge
 Pressure plate distortion up to 1.0 mm is allowed


 When unscrewing bolts - B - , make sure the bolt heads do not contact the flywheel - arrows - because
this would damage the flywheel when the bolts are turned further.
Removing and installing dual-mass flywheel --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
2:52:58 AM Page 62

 Counterhold tool 10-201

 Centring mandrel 3176

Removing
 Attach counter-hold tool 10-201 before loosening bolts.
 Loosen all 6 bolts consecutively in clockwise direction and in steps of 90° (1 /4 turn) until the pressure
plate is released.
2:52:58 AM Page 63
Installing
NOTE:  Before you re-install the SAC pressure plate check that it is not distorted
Check SAC pressure plate for distortion, cracks and burns.
pressure plate has to be reset before assembly --> Resetting adjuster ring
in SAC clutch pressure plate.
marking "transmission side" point towards pressure plate and
transmission.
Fig. 86: Identifying 3176 And Counterhold Tool 10-201 On Clutch Plate

 Re-position counterhold tool 10-201 to tighten bolts.

 Tighten all six bolts consecutively in clockwise direction and in steps of 90° (1 /4 turn) until the housing
Resetting adjuster ring in SAC clutch pressure plate

 When fitting a new clutch plate in conjunction with a used SAC pressure
plate, the adjuster ring in the pressure plate has to be reset by turning it
back as far as it will go. If you do not reset the adjuster ring in the
2:52:58 AM Page 64
pressure plate, the SAC pressure plate will operate with reduced clamping
force, which will cause excessive wear, especially of the clutch plate
(clutch will then slip).
ring.
reset.


 Thrust pad 3062
2:52:58 AM Page 65
Procedure
 Insert 3 securing bolts for pressure plate - A - into the mounting holes on the pressure plate at 120° (1 /3
turn) intervals, as shown in the illustration.
 Screw 3 nuts - B - M8 onto bolts - A - and tighten nuts lightly.

 Place the SAC pressure plate onto the press tool so that only the 3 bolt heads - arrows - make contact.
 Position thrust pad 3062 in the center of the pressure plate.
off.
2:52:58 AM Page 66
 Apply two screwdrivers to the forks on the adjuster ring. Use the press tool to apply pressure to the
pressure plate until it is just possible to move the adjuster ring.
 Using the two screwdrivers, turn back the adjuster ring evenly in direction of - arrows - until it reaches
the stop - arrowA -.
 Hold the adjuster ring against the stop and reduce the pressure applied by the press tool so that the
adjuster ring is held in this position.
SHIFT MECHANISM, SERVICING
Installation position of shift mechanism
2:52:58 AM Page 67
- Arrow A - gear selection movement
- Arrow B - gate selection movement
Fig. 92: Installation Position Of Selector Mechanism

1 - Shift rod
2 - Push rod (front)
3 - Connecting rod
4 - Shift lever
Shift mechanism, assembly overview
2:52:58 AM Page 68
NOTE:  Lubricate all bearings and moving surfaces with polycarbamide grease
G052142A2 .
Part I
Fig. 93: Shift Mechanism Remove/Install Components -- Part 1

1 - Ball
2 - Rubber ring
3 - Ball guide
4 - Rubber ring
2:52:58 AM Page 69
5 - Washer
6 - Circlip
 Take out before removing ball
7 - Spring
8 - Spacer sleeve
9 - Washer
10 - Circlip
 - Arrow - marked on noise insulation points in direction of travel
12 - Gear lever knob
 With cover
 Removing and installing --> Gear shift knob with boot, removing and installing
13 - Nut, 10 Nm
14 - Gear lever bearing
16 - Gear lever
 Bend points towards rear
17 - Bolt
18 - Nut, 10 Nm
20 - Joint for gear lever/selector rod
21 - Nut, 10 Nm
 Self-locking
 Replace
2:52:58 AM Page 70
22 - Bush

1 - Ball socket
2 - Washer
3 - Ball socket
4 - Bellows
6 - Nut, 23 Nm
2:52:58 AM Page 71
7 - Bolt, 23 Nm
8 - Connecting rod
9 - Retaining clip
10 - Bolt, 40 Nm
11 - Push rod
 With bearing bush, bolt and washers
13 - Washer
15 - Clamping ring for bellows
16 - Bellows
 Pull carefully over selector rods when removing

 Align with markings on selector rod and push rod when installing
18 - Clamp
19 - Selector rod
21 - Nut, 10 Nm
22 - Ball stud
Gear shift knob with boot, removing and installing
2:52:58 AM Page 72
Fig. 95: Identifying Hose Clamp Pliers V.A.G 1275

 Hose clip pliers V.A.G 1275
NOTE:  The gear lever knob is removed together with the gear lever boot and the
cover for the center console.
Fig. 96: Lifting Cover For Center Console Upward

Removing
 Open ashtray.
 Unclip cover for center console and lift it off - arrows -.
2:52:58 AM Page 73
Fig. 97: Locating Clip And Pulling Off Gear Lever Knob Together With Boot
Gear shift knob with clip:
 Pull boot up and over gear lever knob.

 Open clip - arrow - and pull off gear lever knob together with boot.
Fig. 98: Releasing Connector Piece

Gear shift knob with locking mechanism:
 Release connecting piece - 1 - in direction of - arrow - and pull gear lever knob off upwards together
with gear lever boot.
Installing
2:52:58 AM Page 74
Perform installation in reverse sequence of removal.
Shifter mechanism, removing and installing

Removing
 Remove gear lever knob together with boot --> Gear shift knob with boot, removing and installing.
Vehicles with large radio slot
 Remove operating and display unit for air conditioner --> 87 AIR CONDITIONING .
Fig. 100: Lifting Cover And Pulling Out And Removing Bolts And Pulling Ashtray From Center Console
Vehicles with small radio slot
2:52:58 AM Page 75
 First lift trim panel - 1 - in direction of - arrow A - , then pull it out in direction of - arrow B -.
All models:
 Unscrew bolts - arrowsC - and then pull ashtray - 2 - out of center console.
 Disconnect electrical connector for ashtray light.
 Remove foam wedges from center console.
 Lift out the noise insulation.
Fig. 101: Locating Noise Insulation For Shift Lever Housing Bolts
 Unscrew noise insulation for gear lever housing - arrows -.
Fig. 102: Shift Lever Housing Nuts

2:52:58 AM Page 76
Fig. 103: Fasteners

 On vehicles installed with auxiliary heater remove screws - arrows - securing exhaust pipe of

 Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front noise insulation - A -.
 If installed, loosen quick release fasteners - 3 - and remove rear noise insulation - B -.
2:52:58 AM Page 77

NOTE:  The flexible exhaust pipe connection (de-coupling element) in the front
exhaust pipe must not be bent more than 10 ° - otherwise it can be
damaged.
 Disconnect exhaust system at clamp(s) - arrows -.

exhaust system.
Fig. 106: Identifying Driveshaft Shield

 Unbolt heat shield for driveshaft - arrows -.
Fig. 107: Heatshield Bolts

2:52:58 AM Page 78
 Unscrew bolts at transmission/driveshaft flange.

 Push driveshaft - 2 - together towards rear final drive. The constant velocity joints can be moved axially.
Fig. 108: Driveshaft Tied Up To One Side Onto Heat Shield

 Tie driveshaft - 1 - up to one side onto heat shield - arrow -.
Wood
 Remove universal mounting V.A.G1359/2 from engine and transmission jack V.A.G 1383 A and place a
 Support rear cross member with engine and transmission jack V.A.G 1383 A.
2:52:58 AM Page 79
rear cross member and body reaches dimension "x".

 If installed, unbolt heat shield for drive shaft (right-side) - arrow -.
2:52:58 AM Page 80

 If installed, unbolt heat shield for drive shaft (left-side) - 1 -.
Fig. 113: Identifying Selector Mechanism Fasteners

 Unscrew nut - 1 - and pull selector shaft lever - 2 - off transmission selector shaft.
Fig. 114: Identifying Push Rod And Connecting Rod For Selector Rod
2:52:58 AM Page 81
 Unscrew connecting rod - 2 - for selector rod.

 Disconnect push rod - 1 - ; to do so, unscrew hexagon socket head bolt.
 Remove selector mechanism from right side of vehicle.
Installing
NOTE:  Always replace seals, gaskets and self-locking nuts.
 Install tunnel cross member --> 40 - FRONT SUSPENSION .

 Bolt driveshaft onto transmission --> 39 FINAL DRIVE, DIFFERENTIAL .
CONTROLS .
 If installed, install rear noise insulation.
 Adjust selector mechanism --> Shift mechanism, adjusting.

 Install operating and display unit for air conditioner --> 87 AIR CONDITIONING .
Tightening torques
Component Nm
Connecting rod to transmission 23
Shift lever to selector shaft 23
Push rod to transmission 40
Noise insulation to selector mechanism 10
Shift mechanism, adjusting
The following are prerequisites for correct gear lever alignment:
NOTE:  Shift linkage must be in proper condition and undamaged.

 Shift mechanism must move freely.
 Transmission, clutch and clutch mechanism must be in proper condition.
 Transmission in neutral.
Procedure
2:52:58 AM Page 82
Continued for all vehicles
 Remove bolts - arrowsC - and then pull ashtray - 2 - out of center console.
 Remove noise insulation for gear lever housing - arrows -.
2:52:58 AM Page 83
Fig. 117: Shift Mechanism Measurement And Bolts

 Measure distance - a - between the two studs in the selector mechanism.
 Specification: distance - a - = 85 mm
NOTE:  Measure from center of one stud to center of the other.
 If distance measured is not correct, adjust dimension - a - as follows:

 Loosen bolt - arrow - for push rod.
 Rear push rod (in selector mechanism) should move freely in both directions on slide.
 Set to distance - a - by moving rear push rod (in selector mechanism).

 Tighten bolt for push rod - arrow - to 23 Nm.
Fig. 118: Selector Rod Bolt

 Loosen bolt for selector rod - arrow -.
2:52:58 AM Page 84
 Connection between selector rod and selector mechanism should move freely.
Fig. 119: Centering Bottom Of Shift Lever Centered In Ball Housing

Align the gear lever as follows:
 Center the bottom of the gear lever in the center of the ball guide.
 Distance between ball guide and bottom of gear lever - arrows - must be the same at all points.
Fig. 120: Gear Lever Alignment Pointing Slightly To Right

 Align gear lever so that it points slightly (1.5°) to the right (as seen in direction of travel).
 Hold gear lever in this position.
2:52:58 AM Page 85

 Tighten bolt for selector rod - arrow - to 23Nm.
NOTE:  The gear lever must remain in the same position while the bolt is being
tightened.
Checking gear lever setting
 The gear lever should rest in the 3rd/4th gear gate when the transmission is in neutral.
 Press clutch pedal.

 Select all gears several times.
 Check operation of reverse gear lock.
 It should only be possible to engage reverse gear after pressing the gear lever down to overcome the
reverse gear lock.
 The gear lever should return by itself from the reverse gear gate to the 3rd/4th gear gate.
If the gear lever sticks or balks repeatedly when engaging a gear, perform the adjustment procedure again.
 Install trim parts and gear lever knob --> Gear shift knob with boot, removing and installing.
Removing transmission on vehicles with 4.2 Liter V8 engine (S4)--> Removing transmission on vehicles with
4.2 Liter V8 engine (S4)
Installing transmission on vehicles with 4.2 Liter V8 engine (S4) --> Installing transmission on vehicles with
2:52:58 AM Page 86
Removing transmission on vehicles with 4.2 Liter V8 engine (S4)
Fig. 122: Identifying Special Tools - Removing Transmission On Vehicles With 4.2 Liter V8 Engine (S4)
 Support bracket 10 - 222 A

 Shackle 10 - 222 A/12
 Lifting tackle 2024 A

2:52:58 AM Page 87
Fig. 123: Locating Pins 3393

 Locating pins 3393

 Engine and transmission jack V.A.G 1383 A
Removing
NOTE:  All cable ties which are released or cut open during removal must be

2:52:58 AM Page 88
Cabriolet
.
 With the ignition switched off, disconnect battery ground (GND) strap.

 Pull off rear engine cover - arrows -.

 Pull off front engine cover - arrows -.
2:52:58 AM Page 89

Fig. 128: Coolant Expansion Tank, Bolts And Coolant Hose

 Clamp off coolant hose - 1 - with hose clamp 3094 and disconnect hose at coolant expansion tank.
 Unbolt coolant expansion tank - 2 - - arrows -.
 Disconnect electrical wire leading to Engine Coolant Level (ECL) Warning Switch F66 at expansion tank
 If necessary, close off the connection with a suitable plug.
2:52:59 AM Page 90

 Disconnect retainer at bulkhead.
 Disconnect heat insulation sleeve at wiring harness and move wiring harness clear.
 Move oxygen sensor probe wires clear (downwards).

2:52:59 AM Page 91


2:52:59 AM Page 92
Fig. 133: Securing Shackle 10-222 A/12 To Right Rear Engine Lifting Eyelet
 Fix a shackle 10 - 222 A/12 to engine lifting eye (rear right).
Fig. 134: Support Bracket 10 - 222 A Set Up On Wing Mounting Flanges

 Set up support bracket 10 - 222 A on wing mounting flanges.
Fig. 135: Support Hooks And Locking Pins On Lifting Tackle Secured With Retainers And Pin In Lifting
Tackle Center Hole
 Remove eye of lifting tackle 2024 A.

 Re-insert pin - 1 - in center hole of lifting tackle and secure with split pin.
 Hook pin on lifting tackle 2024 A onto spindle of support bracket 10 - 222 A.
 Hook lifting tackle 2024 A into lifting eye at front of engine and into shackle 10 - 222 A/12 at rear.
CAUTION: Support hooks and locking pins on lifting tackle must be secured with
2:52:59 AM Page 93
retainers - arrows - in illustration.
 Take up weight of engine on spindle of support bracket, but do not lift.
Fig. 136: Fasteners

 Unbolt both front wheels.


2:52:59 AM Page 94

 Unbolt bracket for noise insulation - arrows -.

 Unbolt bracket for wiring harness at engine support (right-side) - arrows -.
Fig. 140: Threaded Connections And Positioning Sleeves On Lower Engine Mounts
2:52:59 AM Page 95
 Unscrew nuts - 1 - at bottom of engine mountings (left and right).
 If installed, unclip operating rod for vehicle level sender from lower transverse link - arrow -.

 Before slackening subframe mountings, use locating pins 3393 to check whether holes - 1...3 - are
aligned.
CAUTION: If this is not the case, wheel alignment has to be performed after installing
the subframe.
2:52:59 AM Page 96
Fig. 143: Removing Front Bolts From Left And Right Subframe
 First remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
 Lower subframe at the front.
Fig. 144: Removing/Installing Bottom Engine/Transmission Connecting Bolts

 Unscrew lower engine/transmission securing bolts - arrows -.
2:52:59 AM Page 97
 Temporarily secure subframe again. Temporary tightening torque:
1. approx. 100 Nm
2. approx. 70 Nm
3. approx. 70 Nm
CAUTION: Do not replace bolts yet or tighten to their final torque. This will be done
when installing the transmission.

exhaust pipe must not be bent more than 10° - otherwise it can be
damaged.
Wood
2:52:59 AM Page 98
 Slowly lower rear cross member with engine and transmission jack V.A.G 1383 A.
NOTE:  Do not lower the transmission too far: the distance between the rear cross
member and the body (dimension - x -) must not be more than 60mm.
Otherwise, the driveshaft joint and the flexible joint in the front exhaust
pipe could be damaged. If necessary, tighten spindle of support bracket 10
- 222 A so that dimension - x - is not exceeded.
2:52:59 AM Page 99

 Remove heat shields - arrow - for drive shafts (left and right).
 Unbolt drive shafts from transmission flanges.
NOTE:  Make sure you do not damage surface coating on drive shafts.

Fig. 151: Freeing Up Oxygen Sensor Wires At Areas Indicated By On Transmission

 Disconnect oxygen sensor probe wiring on transmission at the points marked with - arrows -.
NOTE:  In the illustration the engine/transmission assembly has been removed.
2:52:59 AM Page 100

 Unscrew bolt - arrow - at bracket for front exhaust pipe (left-side).
Fig. 153: Removing/Installing Nuts For Left Front Exhaust Pipe/Exhaust Manifold
 Unscrew nuts - 1 to 3 - connecting front exhaust pipe (left-side) to exhaust manifold.
 Disconnect front exhaust pipe from exhaust manifold (left-side).

2:52:59 AM Page 101

 Unscrew bolt - arrow - at bracket for front exhaust pipe (right-side).
 Unscrew nuts - 1 to 3 - connecting front exhaust pipe (right-side) with exhaust manifold.
2:52:59 AM Page 102



 Slide driveshaft together towards rear final drive. The constant velocity joints can be moved axially.
 Allow driveshaft to rest on rear section of exhaust system.
Fig. 157: Tunnel Cross Member Nuts

 Unscrew two nuts - arrows - and Disconnect tunnel cross member.
2:52:59 AM Page 103


 Unscrew nut - 1 - and pull transmission selector lever - 2 - off transmission selector shaft.
Fig. 159: Disconnecting Harness Connector For Back-Up Light Switch At Right Of Transmission
 Disconnect connector - arrow - for reversing light switch on right side of transmission and move wiring
clear.
Fig. 160: Starter And Mounting Bolts
2:52:59 AM Page 104

 Unbolt starter - 1 - - arrows - and pull it away from bell housing.

 Remove remaining engine/transmission bolts. Leave 2 bolts screwed in hand-tight.
Fig. 161: Bracket For Front Exhaust Pipe (Left-Side) On Transmission

 Unbolt bracket for front exhaust pipe (left-side) on transmission - arrows -.
Fig. 162: Hole In Supporting Elements Of Transmission Support 3282

 Drill a hole of 10.2mm - arrow - in supporting element of transmission support 3282.
2:52:59 AM Page 105

Fig. 163: Transmission Support 3282 With Adjustment Plate 3282/38 For Removing Manual
Transmission 03A (All Wheel Drive) And Place On Engine And Transmission Jack V.A.G 1383 A.
 Set up transmission support 3282 with adjustment plate 3282/38 for removing manual transmission 03A
(All wheel drive) and place on engine and transmission jack V.A.G 1383 A.
NOTE:  The positions of the support elements - arrows - are shown on the
adjustment plate in schematic form (the arrow points in direction of travel).
 The adjustment plate can only be installed in one position.
Fig. 164: Adjustment Plate Aligned Parallel To Transmission And Support Elements Secured To Left
Side Of Transmission
 Align adjustment plate parallel to transmission and secure support elements - arrows - to left side of
transmission.
2:52:59 AM Page 106

Fig. 165: Adjustment Plate Aligned Parallel To Transmission And Support Elements Secured To Right
 Align adjustment plate parallel to transmission and secure support elements - arrows - to right side of
transmission.
 Remove 2 last engine/transmission bolts.
 Press transmission off dowel sleeves and lower carefully with engine and transmission jack V.A.G 1383
A just far enough to gain access to the clutch slave cylinder.
NOTE:  When lowering transmission, ensure hydraulic line to clutch slave cylinder
is not damaged.

 Remove clutch slave cylinder - arrow - and secure with wire; do not open hydraulic system.
CAUTION: Do not depress clutch pedal after removing slave cylinder. The slave
 Lower transmission completely.
2:52:59 AM Page 107


drive shafts.
Fig. 167: Identifying Transmission Mounting Is Transferred To New Transmission

 If you will be installing a new transmission instead of the one removed, the transmission mounting has to
be transferred to the new transmission - arrows -.
Installing transmission --> Installing transmission on vehicles with 4.2 Liter V8 engine (S4).
Installing transmission on vehicles with 4.2 Liter V8 engine (S4)
equipment)
 Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and
apply only a very thin coating of grease for clutch plate splines G000100 to the splines. Do not grease
guide sleeve.
 It should be possible to push the clutch plate back and forth slightly on the input shaft.
2:52:59 AM Page 108


 Check clutch release bearing for wear and replace if necessary.

 If plastic ring - arrows - has come loose, service release bearing as required Checking and servicing
release bearing with glued plastic ring.
NOTE:  The release bearing must be replaced if the groove worn on the plastic
ring is deeper than 0.8mm.
 Lightly lubricate contact surface for operating rod at clutch release lever with copper grease, e.g. Z 381
351 TE.
 Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate
self-locking bolts.
 Check that dowel sleeves for centralizing engine/transmission are in the cylinder block, install if
necessary.
 Place intermediate plate on dowel sleeves at engine flange.
 Before installing transmission, tie electrical wiring off to one side so that it cannot be trapped between the
engine and the transmission.
2:52:59 AM Page 109


 Lightly lubricate surface where operating rod and clutch release lever make contact - arrowB - using
copper grease Z381351TE.
 Raise transmission far enough to be able to install clutch slave cylinder with bracket for hose/line
assembly.
300 N.
2:52:59 AM Page 110


 Secure clutch slave cylinder with new bolt - arrow -.

 Insert transmission, making sure there is sufficient clearance to drive shafts.

 Install starter - arrows - and tighten top left and right engine/transmission connecting bolts.
NOTE:  The bottom bolts are installed at a later stage.
2:52:59 AM Page 111


 Bolt bracket for front exhaust pipe (left-side) to transmission - arrows -.

 Install transmission selector lever - 2 - and tighten nut - 1 -.
Fig. 174: Disconnecting/Connecting Harness Connector For Back-Up Light Switch At Right Of
Transmission
2:52:59 AM Page 112

 Connect connector - arrow - for reversing light switch on right side of transmission.

 Bolt tunnel cross member onto transmission mounting - arrows -.

 It is important to clean the threaded holes for driveshaft bolts to remove any remaining locking fluid. The
threads can be cleaned with a thread tap.

 Bolt on heat shield for driveshaft - arrows -.
2:52:59 AM Page 113

 Bolt front exhaust pipe (right-side) to bracket - arrow -.
Fig. 178: Removing/Installing Nuts For Right Front Exhaust Pipe/Exhaust Manifold
 Tighten nuts - 1to3 - at front exhaust pipe/exhaust manifold connection evenly and progressively (hold
catalytic converter in a horizontal position).
NOTE:  Shown in illustration with engine removed.
2:52:59 AM Page 114

damaged.
 Bolt front exhaust pipe (left-side) to bracket - arrow -.
 Tighten nuts - 1 to 3 - at front exhaust pipe/exhaust manifold connection evenly and progressively (hold
2:52:59 AM Page 115


 Attach oxygen sensor probe wiring to transmission at the points marked with - arrows -.
 Install push rod - 1 - ; to do so, tighten hexagon socket head bolt.

 Secure connecting rod - 2 - for selector rod.
 Bolt drive shafts to flange shafts --> 40 - FRONT SUSPENSION .
2:52:59 AM Page 116


 Install heat shields - arrow - for drive shafts (left and right).
Wood
 Remove transmission support 3282 from engine and transmission jack V.A.G 1383 A and place a wooden
block - arrow - on the lifting column in its place.
 Push rear cross member upwards with engine and transmission jack V.A.G 1383 A.
 Replace bolts - 1 to 4 -.
 Bolt on tunnel cross member hand-tight.
2:52:59 AM Page 117


 Install clamps - arrows - for exhaust system.

CONTROLS .
2:52:59 AM Page 118


 Tighten three bottom engine/transmission securing bolts - arrows -.
 Replace front subframe bolts - 1...3 - on both sides of the vehicle.
Before tightening subframe, it must be aligned with body using locating pins 3393.
2:52:59 AM Page 119

Fig. 189: Identifying Hole, Sub-Frame Hole And Aluminum Console Hole Align On Both Sides
 Hole - 1 - , hole - 2 - in subframe and hole - 3 - in aluminum bracket must be in alignment on both sides.
NOTE:  If this is not the case, wheel alignment will have to performed at a later
stage.
 Secure subframe and tunnel cross member --> 40 - FRONT SUSPENSION .
 Tighten nuts - 1 - for engine mountings.
The remaining installation steps are performed in the reverse sequence; note the following points:
 Check selector mechanism setting and adjust if necessary --> Shift mechanism, adjusting.
 Check gear oil level in transmission --> Transmission gear oil, checking level.
.
 Perform wheel alignment if required --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .
 Wheel alignment is not necessary if subframe was located in relation to body using locating pins 3393
prior to dismantling and assembly of subframe (before tightening bolts).
 Wheel alignment must, however, be performed if the subframe was not located in relation to the body
using locating pins 3393 or if it was not possible to fully insert the two locating pins into the holes.

2:52:59 AM Page 120



Item Bolt Nm
1, 2 M12x120 65
3 M12x110 65
4, 5 M12x105 65
6 M12x130 65
7 M12x170 65
8, 9, 10 M10x60 45
- A - = Dowel sleeves for aligning
Tightening torques
Component Nm
Selector shaft lever to transmission 23* See note
Connecting rod for selector rod to transmission 23
Transmission mounting to transmission 23
Transmission mounting to tunnel cross member 23
Heat shields above drive shafts to transmission 23
2:52:59 AM Page 121


Engine mounting to engine support 23
* Replace bolt
Fig. 192: Lifting Aid T40013

 Lifting aid T40013
Fig. 193: Identifying Shop Crane VAS 6100

 Workshop hoist VAS 6100
2:52:59 AM Page 122

Fig. 194: Lifting Transmission With Workshop Hoist VAS 6100 And Lifting Aid T40013
Procedure
 Insert lifting aid T40013 in lifting eye on transmission and secure.

 Engage hook of workshop hoist VAS 6100 in 4th notch - arrow - on lifting aid.
 Lift transmission with workshop hoist VAS 6100 and lifting aid T40013.
TRANSMISSION GEAR OIL, CHECKING LEVEL
Transmission gear oil, checking level
Fig. 195: Locating Oil Filler Plug

Procedure
NOTE:  The vehicle must be horizontal when checking gear oil level.
 To check gear oil level, unscrew oil filler plug - arrow -.
Check oil level with a suitable tool (such as a length of wire bent to shape).
2:52:59 AM Page 123

 Specification: Oil level 2mm +-1mm below lower edge of oil filler hole.
 Top off with gear oil if necessary. Specification --> Code letters, assignment of mechanical units,
transmission ratios, capacities.
 Screw in oil filler plug.
Tightening torque
Component Nm
Oil filler plug 40
TRANSMISSION MOUNTING, REMOVING AND INSTALLING
Transmission mounting, removing and installing

2:52:59 AM Page 124

Removing

 Disconnect exhaust system at clamp - arrows -.
Fig. 199: Transmission Raised Using Punch Of VAG 1383 A So That A Piece Of Wood Can Be Placed In
Between
 Use engine and transmission jack V.A.G 1383 A to lift transmission up slightly. Insert a wooden block - 1
- between transmission and transmission jack.
2:52:59 AM Page 125

Fig. 200: Tunnel Cross Member Bolts

 First remove bolts - 3 - and then bolts - 2 - at tunnel cross member.

 Lower transmission slightly.
 Unscrew the two nuts - 1 - and push tunnel cross member backwards slightly.

 Unscrew transmission mounting - arrows -.
Installing
2:52:59 AM Page 126


 Install transmission mounting on transmission. Tighten bolts - arrows - to torque setting Torque
settings.

 Bolt tunnel cross member onto transmission mounting - 1 -.

 Lift transmission far enough to be able to screw in the bolts - 2 -.
 First tighten bolts - 2 - and then bolts - 3 - --> 40 - FRONT SUSPENSION .
 Install noise insulation below transmission.
Torque settings
Component Nm
Tunnel cross member to transmission mounting 23
Clamp for exhaust pipe 40
2:53:00 AM Page 127

MOUNTING TRANSMISSION ON ASSEMBLY STAND
Mounting transmission on assembly stand
Fig. 204: Identifying Special Tools - Mounting Transmission On Assembly Stand


 Engine/transmission support VW 540
2:53:00 AM Page 128

Procedure

 Engage hook of workshop hoist VAS6100 in 4th notch - arrow - on lifting aid T40013.
 Lift transmission with workshop hoist VAS6100 and lifting aid T40013.
Fig. 206: Securing Engine And Transmission Support VW 540 To Transmission And Fitting Into
Support Clamp VW313
 Secure engine and transmission support VW 540 to transmission and fit into support clamp VW313.
TRANSMISSION COVER AND TORSEN DIFFERENTIAL, REMOVING AND INSTALLING
Transmission cover and Torsen differential, assembly overview
2:53:00 AM Page 129

Fig. 207: Transmission Cover And Torsen Differential, Assembly Overview

1 - Transmission cover
 With or without vibration damper, depending on design

 Removing and installing (transmission removed) --> Transmission cover (transmission removed),
 Removing and installing (transmission installed) --> Transmission cover (transmission installed),
 Dismantling and assembling --> Transmission cover, dismantling and assembling
2 - Bolt, 24 Nm
 6x
2:53:00 AM Page 130

3 - Dished spring
 Installation position: larger diameter (concave side) faces shim
4 - Shim
5 - Spring
6 - O-ring
 Always replace
 Lubricate with gear oil before installing.
 Can only be serviced by manufacturer
 Removing and installing --> Transmission, removing and installing

 Mounting on assembly stand --> Mounting transmission on assembly stand
Transmission cover (transmission removed), removing and installing

 Drip tray V.A.G1306
2:53:00 AM Page 131

Fig. 209: Identifying Transmission Cover Bolts

Removing
 Mount transmission on assembly stand --> Mounting transmission on assembly stand

 Place drip tray V.A.G1306 under transmission.
 Drain off gear oil.
 Unscrew bolts - arrows - and pull off transmission cover.
Installing
 Replace O-ring on transmission housing.

 Install transmission cover and tighten bolts - arrows -.
 Fill up with gear oil and check gear oil level --> Transmission gear oil, checking level.
Tightening torque
Component Nm
Transmission cover to transmission 24
Transmission cover (transmission installed), removing and installing
2:53:00 AM Page 132



Removing
damaged.

exhaust system.
2:53:00 AM Page 133



2:53:00 AM Page 134




 Unscrew bolts - arrows - and take off transmission cover.
Installing
NOTE:  Always replace O-rings, gaskets and self-locking nuts.

 Install exhaust system and perform stress-free alignment -->
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for BHF
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for BPG
Tightening torques
Component Nm
2:53:00 AM Page 135

TRANSMISSION COVER, DISMANTLING AND ASSEMBLING
Transmission cover, dismantling and assembling
Fig. 216: Identifying Special Tools - Transmission Cover, Dismantling And Assembling (1 Of 2)

 Press tool VW 408 A
2:53:00 AM Page 136

 Punch 2005
 Drift sleeve 30 - 100
 Shim 016 311 391 A
2:53:00 AM Page 137

Fig. 218: Exploded View Of Transmission Cover

1 - Flange shaft
 Pressing out Pressing out flange shaft (transmission cover with vibration damper) or Pressing out
flange shaft (transmission cover without vibration damper)
 Pressing in Pressing in flange shaft
2 - Bolt, 20 Nm + 90°
 For vibration damper

 3x
 Self-locking
 Replace
2:53:00 AM Page 138

3 - Vibration damper
 Not installed on all versions
4 - Oil seal
 Levering out Levering off the oil seal.

 Preparing for installation Preparing oil seal for installation
 Driving in Drive in seal onto stop.
 Removing and installing --> Transmission cover and Torsen differential, removing and installing
6 - Ball bearing
 For flange shaft

 Pressing out Pressing out ball bearing for flange shaft
 Pressing in Pressing in ball bearing for flange shaft
7 - Circlip
Pressing out flange shaft (transmission cover with vibration damper)
Fig. 219: Pressing Out Flange Shaft (Transmission Cover With Vibration Damper)
 Remove circlip before pressing out flange shaft.

 Set up transmission cover in such a way that flange shaft does not make contact with press plate - arrows
- when it is pressed out.
Pressing out flange shaft (transmission cover without vibration damper)
2:53:00 AM Page 139

Fig. 220: Pressing Out Flange Shaft (Transmission Cover Without Vibration Damper)
Pressing in flange shaft
Fig. 221: Pressing In Flange Shaft

 Secure vibration damper before pressing in flange shaft.

 Fit circlip.
Levering off the oil seal.
2:53:00 AM Page 140

Fig. 222: Levering Off The Oil Seal.

Preparing oil seal for installation
Fig. 223: Preparing Seal For Installation

A - Shim 016 311 391 A (1.4 mm)
B - Oil seal
 Place shim and oil seal on tool, as shown in illustration.
 Installation position: open side of seal towards bearing housing
Drive in seal onto stop.
2:53:00 AM Page 141

Fig. 224: Preparing Oil Seal For Installation

 Remove shim.
Pressing out ball bearing for flange shaft
Fig. 225: Pressing Out Ball Bearing For Flange Shaft

Pressing in ball bearing for flange shaft
2:53:00 AM Page 142

Fig. 226: Pressing In Ball Bearing For Flange Shaft

SELECTOR SHAFT WITH SELECTOR CYLINDER, SERVICING
Selector shaft with selector cylinder, removing and installing
Fig. 227: Slide Hammer-Multi-Purpose Tool Set VW 771

 Multi-purpose tool VW 771/1

 Puller T40050
2:53:00 AM Page 143

Fig. 229: Removing Bolts And Selector Shaft Cover

Removing
 Remove bolts - arrows - and remove selector shaft cover - B -.
Fig. 230: Pulling Out Both Selector Shaft Locking Bushes Using Multi-Purpose Tool VW 771/1 And
Puller T40050
 Pull out both selector shaft locking bushes (- item A - in Fig. 229) using multi-purpose tool VW 771/1
and puller T40050.
 Make sure that no gear has been engaged.
2:53:00 AM Page 144

Fig. 231: Pushing Selector Shaft Into Transmission & Removing Pin
 Push selector shaft - A - into transmission as far as it will go, simultaneously removing pin - B -.
 Pull out selector shaft.
Installing
Fig. 232: Installing Seal And Selector Shaft With Assembly Sleeve
 Push assembly sleeve 01E 311 120 - A - onto selector shaft - B -.

 Install complete selector shaft.
 Installation position: Chamfer of selector shaft points downwards.
2:53:00 AM Page 145

 Push selector shaft - A - into transmission as far as it will go, simultaneously inserting pin - B -.
 Installation position of pin - B - : lug on pin points in direction of transmission housing.

 Fit cover - B - and tighten bolts - arrows -.
2:53:00 AM Page 146

Fig. 235: Driving In Selector Shaft Locking Bushes Onto Stop

 Drive in selector shaft locking bushes onto stop.
Tightening torque
Component Nm
Selector shaft cover to transmission 24
Fig. 236: Identifying Tube VW 423

 Tube VW 423
Fig. 237: Identifying Extractor Hook T20143

 Puller hook T20143/1
2:53:00 AM Page 147

Removing

 Selector shaft installed
 Carefully pry out oil seal using puller hook T20143/1, taking care not to damage shaft.
 Selector shaft removed
Fig. 239: Prying Out Seal With Screwdriver

 Carefully pry out oil seal with a screwdriver.
Installing
2:53:00 AM Page 148

 To avoid damaging oil seal - C - , oil seal and selector shaft must only be installed using assembly sleeve
01E 311 120 , - item A -.
Fig. 241: Driving In Selector Shaft Seal

 Using tube VW 423, drive in oil seal to a depth of 1.1mm+-0.2mm.
REVERSING LIGHT SWITCH, REMOVING
Reversing light switch, removing
2:53:00 AM Page 149



2:53:00 AM Page 150

 Disconnect connector - arrow - for reversing light switch on right side of transmission.
 Unscrew reversing light switch - arrow - from selector shaft cover.
Reversing light switch, installing
 Screw reversing light switch - arrow - into selector shaft cover (tightening torque: 20 Nm).

 Install rear noise insulation - B -.
35 GEARS, SHAFTS
INPUT SHAFT, DISMANTLING AND ASSEMBLING
At present there is no provision for disassembling.
2:53:00 AM Page 151

39 FINAL DRIVE, DIFFERENTIAL

FINAL DRIVE, SERVICING
Fig. 247: Identifying Special Tools - Left Flange Shaft Oil Seal, Replacing
 Drift VW 295
 Drift 2062
 Puller T10037
 Drip tray V.A.G 1306 or drip tray for workshop hoist VAS 6208
2:53:00 AM Page 152



Removing
 Transmission is installed
 Please observe general repair instructions --> General repair instructions.

 Remove front left wheel.


 Disconnect drive shaft - 1 - from flange shaft and tie up as far as possible to the front, taking care not to
damage surface coating.
Drip tray V.A.G 1306 or drip tray for workshop hoist VAS 6208
2:53:00 AM Page 153

Fig. 250: Removing Flange Shaft (Left-Side)

 Remove flange shaft (left-side); to do so, secure puller T10037 to cover for final drive - arrow -.
Fig. 251: Prying Out Flange Shaft Oil Seal

 Lever out flange shaft oil seal.
Installing
2:53:00 AM Page 154

Fig. 252: Identifying Flange Shaft Clamped In Vise And Using New Circlip To Press Old Circlip Out Of
Groove In Flange Shaft
 Always replace circlip for flange shaft.

 Clamp flange shaft in vice, using jaw protectors. Use new circlip - A - to press old circlip out of groove in
flange shaft.
 Lightly oil outer circumference of new oil seal.
Fig. 253: Driving In New Flange Shaft Oil Seal Using Driver 2062
 Drive new oil seal for flange shaft in to a depth of 5.65 ± 0.15 mm below outer surface of cover, making
sure you keep seal straight.
 Drive flange shaft in with drift VW 295.
2:53:00 AM Page 155

 Fit drive shaft heat shield.
 Bolt drive shaft to flange shaft --> 40 - FRONT SUSPENSION .

 Fill up oil in transmission and check oil level --> Transmission gear oil, checking level.
Tightening torque
Component Nm
Heat shields for drive shafts to transmission 23
Right flange shaft oil seal, replacing
Fig. 254: Identifying Special Tools - Right Flange Shaft Oil Seal, Replacing
2:53:00 AM Page 156

 Drift VW 295
 Drift 2062
 Puller T10037

Removing

 Loosen bolt for right-side drive shaft/wheel hub.

 Remove front right wheel.

2:53:00 AM Page 157


 Remove heat shield - arrows - for drive shaft (right-side).

 Remove drive shaft (right-side) --> 40 - FRONT SUSPENSION .
Fig. 257: Removing Flange Shaft (Right-Side)

 Remove flange shaft (right-side); to do so, secure puller T10037 to transmission housing - arrow -.
2:53:00 AM Page 158


Installing

flange shaft.
2:53:00 AM Page 159

Fig. 260: Driving New Oil Seal For Flange Shaft In Below Outer Surface Of Housing
 Drive new oil seal for flange shaft in to a depth of 5.65 ± 0.15 mm below outer surface of housing,
making sure you keep seal straight.

Tightening torque
Component Nm
2:53:00 AM Page 160

Installation position of shift mechanism
Fig. 92: Installation Position Of Selector Mechanism

1 - Shift rod
2 - Push rod (front)
2:55:07 AM
2:55:12 Page 1
3 - Connecting rod
4 - Shift lever
Shift mechanism, assembly overview
G052142A2 .
Part I

1 - Ball
2:55:07 AM Page 2
2 - Rubber ring
3 - Ball guide
4 - Rubber ring
5 - Washer
6 - Circlip
7 - Spring
8 - Spacer sleeve
9 - Washer
10 - Circlip
 - Arrow - marked on noise insulation points in direction of travel
 With cover
 Removing and installing --> Gear shift knob with boot, removing and installing
13 - Nut, 10 Nm
16 - Gear lever
17 - Bolt
18 - Nut, 10 Nm
2:55:07 AM Page 3
21 - Nut, 10 Nm
 Self-locking
 Replace
22 - Bush

1 - Ball socket
2 - Washer
3 - Ball socket
2:55:07 AM Page 4
4 - Bellows
6 - Nut, 23 Nm
7 - Bolt, 23 Nm
8 - Connecting rod
9 - Retaining clip
10 - Bolt, 40 Nm
11 - Push rod
 With bearing bush, bolt and washers
13 - Washer
15 - Clamping ring for bellows
16 - Bellows
 Pull carefully over selector rods when removing

 Align with markings on selector rod and push rod when installing
18 - Clamp
19 - Selector rod
21 - Nut, 10 Nm
22 - Ball stud
Gear shift knob with boot, removing and installing
2:55:07 AM Page 5


Removing
 Open ashtray.
2:55:08 AM Page 6
Gear shift knob with clip:


Gear shift knob with locking mechanism:
 Release connecting piece - 1 - in direction of - arrow - and pull gear lever knob off upwards together
Installing
2:55:08 AM Page 7
Shifter mechanism, removing and installing

Removing
2:55:08 AM Page 8
All models:
 Unscrew bolts - arrowsC - and then pull ashtray - 2 - out of center console.
 Unscrew noise insulation for gear lever housing - arrows -.

2:55:08 AM Page 9
Fig. 103: Fasteners


 Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front noise insulation - A -.
2:55:08 AM Page 10

exhaust pipe must not be bent more than 10 ° - otherwise it can be
damaged.
 Disconnect exhaust system at clamp(s) - arrows -.

exhaust system.


2:55:08 AM Page 11

Fig. 108: Driveshaft Tied Up To One Side Onto Heat Shield

 Tie driveshaft - 1 - up to one side onto heat shield - arrow -.
Wood
 Support rear cross member with engine and transmission jack V.A.G 1383 A.
2:55:08 AM Page 12
rear cross member and body reaches dimension "x".

 If installed, unbolt heat shield for drive shaft (right-side) - arrow -.
2:55:08 AM Page 13

 If installed, unbolt heat shield for drive shaft (left-side) - 1 -.

 Unscrew nut - 1 - and pull selector shaft lever - 2 - off transmission selector shaft.
2:55:08 AM Page 14

 Remove selector mechanism from right side of vehicle.
Installing

CONTROLS .
 If installed, install rear noise insulation.
 Adjust selector mechanism --> Shift mechanism, adjusting.

Tightening torques
Component Nm
Shift lever to selector shaft 23
Noise insulation to selector mechanism 10
The following are prerequisites for correct gear lever alignment:
NOTE:  Shift linkage must be in proper condition and undamaged.

 Shift mechanism must move freely.
Procedure
2:55:08 AM Page 15
Continued for all vehicles
 Remove bolts - arrowsC - and then pull ashtray - 2 - out of center console.
 Remove noise insulation for gear lever housing - arrows -.
2:55:08 AM Page 16

 Measure distance - a - between the two studs in the selector mechanism.
 Specification: distance - a - = 85 mm



2:55:08 AM Page 17

Align the gear lever as follows:
 Center the bottom of the gear lever in the center of the ball guide.
 Distance between ball guide and bottom of gear lever - arrows - must be the same at all points.

 Align gear lever so that it points slightly (1.5°) to the right (as seen in direction of travel).
2:55:08 AM Page 18

 Tighten bolt for selector rod - arrow - to 23Nm.
tightened.
 The gear lever should rest in the 3rd/4th gear gate when the transmission is in neutral.

 It should only be possible to engage reverse gear after pressing the gear lever down to overcome the
reverse gear lock.
 The gear lever should return by itself from the reverse gear gate to the 3rd/4th gear gate.
If the gear lever sticks or balks repeatedly when engaging a gear, perform the adjustment procedure again.
 Install trim parts and gear lever knob --> Gear shift knob with boot, removing and installing.
Removing transmission on vehicles with 4.2 Liter V8 engine (S4)--> Removing transmission on vehicles with
Installing transmission on vehicles with 4.2 Liter V8 engine (S4) --> Installing transmission on vehicles with
2:55:08 AM Page 19
Removing transmission on vehicles with 4.2 Liter V8 engine (S4)
Fig. 122: Identifying Special Tools - Removing Transmission On Vehicles With 4.2 Liter V8 Engine (S4)
 Support bracket 10 - 222 A

 Shackle 10 - 222 A/12
 Lifting tackle 2024 A

2:55:08 AM Page 20
Fig. 123: Locating Pins 3393

 Locating pins 3393

Removing

2:55:08 AM Page 21
Cabriolet
.
 With the ignition switched off, disconnect battery ground (GND) strap.


2:55:08 AM Page 22

Fig. 128: Coolant Expansion Tank, Bolts And Coolant Hose

 Clamp off coolant hose - 1 - with hose clamp 3094 and disconnect hose at coolant expansion tank.
 Unbolt coolant expansion tank - 2 - - arrows -.
 Disconnect electrical wire leading to Engine Coolant Level (ECL) Warning Switch F66 at expansion tank
 If necessary, close off the connection with a suitable plug.
2:55:08 AM Page 23

 Disconnect retainer at bulkhead.
 Disconnect heat insulation sleeve at wiring harness and move wiring harness clear.

2:55:08 AM Page 24


2:55:08 AM Page 25
Fig. 133: Securing Shackle 10-222 A/12 To Right Rear Engine Lifting Eyelet
 Fix a shackle 10 - 222 A/12 to engine lifting eye (rear right).
Fig. 134: Support Bracket 10 - 222 A Set Up On Wing Mounting Flanges

 Set up support bracket 10 - 222 A on wing mounting flanges.
Fig. 135: Support Hooks And Locking Pins On Lifting Tackle Secured With Retainers And Pin In Lifting
Tackle Center Hole
 Remove eye of lifting tackle 2024 A.

 Re-insert pin - 1 - in center hole of lifting tackle and secure with split pin.
 Hook pin on lifting tackle 2024 A onto spindle of support bracket 10 - 222 A.
 Hook lifting tackle 2024 A into lifting eye at front of engine and into shackle 10 - 222 A/12 at rear.
2:55:08 AM Page 26
 Take up weight of engine on spindle of support bracket, but do not lift.
Fig. 136: Fasteners

 Unbolt both front wheels.


2:55:08 AM Page 27

 Unbolt bracket for noise insulation - arrows -.

 Unbolt bracket for wiring harness at engine support (right-side) - arrows -.
2:55:08 AM Page 28
 Unscrew nuts - 1 - at bottom of engine mountings (left and right).
 If installed, unclip operating rod for vehicle level sender from lower transverse link - arrow -.

 Before slackening subframe mountings, use locating pins 3393 to check whether holes - 1...3 - are
aligned.
CAUTION: If this is not the case, wheel alignment has to be performed after installing
the subframe.
2:55:08 AM Page 29

 Unscrew lower engine/transmission securing bolts - arrows -.
2:55:08 AM Page 30
 Temporarily secure subframe again. Temporary tightening torque:
1. approx. 100 Nm
2. approx. 70 Nm
3. approx. 70 Nm

damaged.
Wood
2:55:08 AM Page 31
 Slowly lower rear cross member with engine and transmission jack V.A.G 1383 A.
NOTE:  Do not lower the transmission too far: the distance between the rear cross
member and the body (dimension - x -) must not be more than 60mm.
Otherwise, the driveshaft joint and the flexible joint in the front exhaust
pipe could be damaged. If necessary, tighten spindle of support bracket 10
- 222 A so that dimension - x - is not exceeded.
2:55:08 AM Page 32

 Remove heat shields - arrow - for drive shafts (left and right).
 Unbolt drive shafts from transmission flanges.
NOTE:  Make sure you do not damage surface coating on drive shafts.


 Disconnect oxygen sensor probe wiring on transmission at the points marked with - arrows -.
2:55:08 AM Page 33
 Unscrew bolt - arrow - at bracket for front exhaust pipe (left-side).
 Unscrew nuts - 1 to 3 - connecting front exhaust pipe (left-side) to exhaust manifold.
 Disconnect front exhaust pipe from exhaust manifold (left-side).

2:55:08 AM Page 34
 Unscrew bolt - arrow - at bracket for front exhaust pipe (right-side).
 Unscrew nuts - 1 to 3 - connecting front exhaust pipe (right-side) with exhaust manifold.
2:55:08 AM Page 35


 Slide driveshaft together towards rear final drive. The constant velocity joints can be moved axially.
 Allow driveshaft to rest on rear section of exhaust system.

 Unscrew two nuts - arrows - and Disconnect tunnel cross member.
2:55:08 AM Page 36

 Unscrew nut - 1 - and pull transmission selector lever - 2 - off transmission selector shaft.
 Disconnect connector - arrow - for reversing light switch on right side of transmission and move wiring
clear.
2:55:08 AM Page 37
 Unbolt starter - 1 - - arrows - and pull it away from bell housing.

 Remove remaining engine/transmission bolts. Leave 2 bolts screwed in hand-tight.

 Unbolt bracket for front exhaust pipe (left-side) on transmission - arrows -.

 Drill a hole of 10.2mm - arrow - in supporting element of transmission support 3282.
2:55:08 AM Page 38
Fig. 163: Transmission Support 3282 With Adjustment Plate 3282/38 For Removing Manual
Transmission 03A (All Wheel Drive) And Place On Engine And Transmission Jack V.A.G 1383 A.
 Set up transmission support 3282 with adjustment plate 3282/38 for removing manual transmission 03A
(All wheel drive) and place on engine and transmission jack V.A.G 1383 A.
NOTE:  The positions of the support elements - arrows - are shown on the
adjustment plate in schematic form (the arrow points in direction of travel).
 The adjustment plate can only be installed in one position.
Fig. 164: Adjustment Plate Aligned Parallel To Transmission And Support Elements Secured To Left
 Align adjustment plate parallel to transmission and secure support elements - arrows - to left side of
transmission.
2:55:08 AM Page 39
Fig. 165: Adjustment Plate Aligned Parallel To Transmission And Support Elements Secured To Right
 Align adjustment plate parallel to transmission and secure support elements - arrows - to right side of
transmission.
 Remove 2 last engine/transmission bolts.
 Press transmission off dowel sleeves and lower carefully with engine and transmission jack V.A.G 1383
A just far enough to gain access to the clutch slave cylinder.
NOTE:  When lowering transmission, ensure hydraulic line to clutch slave cylinder
is not damaged.

 Remove clutch slave cylinder - arrow - and secure with wire; do not open hydraulic system.
2:55:08 AM Page 40

drive shafts.

Installing transmission --> Installing transmission on vehicles with 4.2 Liter V8 engine (S4).
Installing transmission on vehicles with 4.2 Liter V8 engine (S4)
equipment)
apply only a very thin coating of grease for clutch plate splines G000100 to the splines. Do not grease
guide sleeve.
 It should be possible to push the clutch plate back and forth slightly on the input shaft.
2:55:08 AM Page 41


 Lightly lubricate contact surface for operating rod at clutch release lever with copper grease, e.g. Z 381
351 TE.
 Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate
self-locking bolts.
 Check that dowel sleeves for centralizing engine/transmission are in the cylinder block, install if
necessary.
 Before installing transmission, tie electrical wiring off to one side so that it cannot be trapped between the
engine and the transmission.
2:55:08 AM Page 42

 Lightly lubricate surface where operating rod and clutch release lever make contact - arrowB - using
 Raise transmission far enough to be able to install clutch slave cylinder with bracket for hose/line
assembly.
300 N.
2:55:08 AM Page 43

 Secure clutch slave cylinder with new bolt - arrow -.

 Insert transmission, making sure there is sufficient clearance to drive shafts.

 Install starter - arrows - and tighten top left and right engine/transmission connecting bolts.
NOTE:  The bottom bolts are installed at a later stage.
2:55:08 AM Page 44

 Bolt bracket for front exhaust pipe (left-side) to transmission - arrows -.

 Install transmission selector lever - 2 - and tighten nut - 1 -.
Fig. 174: Disconnecting/Connecting Harness Connector For Back-Up Light Switch At Right Of
Transmission
2:55:08 AM Page 45


 It is important to clean the threaded holes for driveshaft bolts to remove any remaining locking fluid. The
threads can be cleaned with a thread tap.

 Bolt on heat shield for driveshaft - arrows -.
2:55:08 AM Page 46
 Bolt front exhaust pipe (right-side) to bracket - arrow -.
Fig. 178: Removing/Installing Nuts For Right Front Exhaust Pipe/Exhaust Manifold
 Tighten nuts - 1to3 - at front exhaust pipe/exhaust manifold connection evenly and progressively (hold
2:55:08 AM Page 47
damaged.
 Bolt front exhaust pipe (left-side) to bracket - arrow -.
 Tighten nuts - 1 to 3 - at front exhaust pipe/exhaust manifold connection evenly and progressively (hold
2:55:08 AM Page 48

 Attach oxygen sensor probe wiring to transmission at the points marked with - arrows -.
 Install push rod - 1 - ; to do so, tighten hexagon socket head bolt.

 Bolt drive shafts to flange shafts --> 40 - FRONT SUSPENSION .
2:55:09 AM Page 49

 Install heat shields - arrow - for drive shafts (left and right).
Wood
 Remove transmission support 3282 from engine and transmission jack V.A.G 1383 A and place a wooden
block - arrow - on the lifting column in its place.
 Push rear cross member upwards with engine and transmission jack V.A.G 1383 A.
 Replace bolts - 1 to 4 -.
 Bolt on tunnel cross member hand-tight.
2:55:09 AM Page 50

 Install clamps - arrows - for exhaust system.

CONTROLS .
2:55:09 AM Page 51

 Tighten three bottom engine/transmission securing bolts - arrows -.
 Replace front subframe bolts - 1...3 - on both sides of the vehicle.
Before tightening subframe, it must be aligned with body using locating pins 3393.
2:55:09 AM Page 52
 Hole - 1 - , hole - 2 - in subframe and hole - 3 - in aluminum bracket must be in alignment on both sides.
NOTE:  If this is not the case, wheel alignment will have to performed at a later
stage.
 Tighten nuts - 1 - for engine mountings.
The remaining installation steps are performed in the reverse sequence; note the following points:
 Check selector mechanism setting and adjust if necessary --> Shift mechanism, adjusting.
 Check gear oil level in transmission --> Transmission gear oil, checking level.
.
 Perform wheel alignment if required --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .
 Wheel alignment is not necessary if subframe was located in relation to body using locating pins 3393
prior to dismantling and assembly of subframe (before tightening bolts).
 Wheel alignment must, however, be performed if the subframe was not located in relation to the body
using locating pins 3393 or if it was not possible to fully insert the two locating pins into the holes.

2:55:09 AM Page 53


Item Bolt Nm
1, 2 M12x120 65
3 M12x110 65
4, 5 M12x105 65
6 M12x130 65
7 M12x170 65
8, 9, 10 M10x60 45
- A - = Dowel sleeves for aligning
Tightening torques
Component Nm
Selector shaft lever to transmission 23* See note
Transmission mounting to tunnel cross member 23
Heat shields above drive shafts to transmission 23
2:55:09 AM Page 54

* Replace bolt
Fig. 192: Lifting Aid T40013


2:55:09 AM Page 55
Procedure

 Engage hook of workshop hoist VAS 6100 in 4th notch - arrow - on lifting aid.
 Lift transmission with workshop hoist VAS 6100 and lifting aid T40013.
TRANSMISSION GEAR OIL, CHECKING LEVEL
Transmission gear oil, checking level

Procedure
 To check gear oil level, unscrew oil filler plug - arrow -.
Check oil level with a suitable tool (such as a length of wire bent to shape).
2:55:09 AM Page 56
 Specification: Oil level 2mm +-1mm below lower edge of oil filler hole.
 Top off with gear oil if necessary. Specification --> Code letters, assignment of mechanical units,
 Screw in oil filler plug.
Tightening torque
Component Nm
Oil filler plug 40

2:55:09 AM Page 57
Removing

 Disconnect exhaust system at clamp - arrows -.
Between
 Use engine and transmission jack V.A.G 1383 A to lift transmission up slightly. Insert a wooden block - 1
- between transmission and transmission jack.
2:55:09 AM Page 58

 First remove bolts - 3 - and then bolts - 2 - at tunnel cross member.

 Unscrew the two nuts - 1 - and push tunnel cross member backwards slightly.

 Unscrew transmission mounting - arrows -.
Installing
2:55:09 AM Page 59

 Install transmission mounting on transmission. Tighten bolts - arrows - to torque setting Torque
settings.

 Bolt tunnel cross member onto transmission mounting - 1 -.

 Lift transmission far enough to be able to screw in the bolts - 2 -.
 First tighten bolts - 2 - and then bolts - 3 - --> 40 - FRONT SUSPENSION .
 Install noise insulation below transmission.
Torque settings
Component Nm
2:55:09 AM Page 60
MOUNTING TRANSMISSION ON ASSEMBLY STAND
Mounting transmission on assembly stand
Fig. 204: Identifying Special Tools - Mounting Transmission On Assembly Stand


 Engine/transmission support VW 540
2:55:09 AM Page 61
Procedure

 Engage hook of workshop hoist VAS6100 in 4th notch - arrow - on lifting aid T40013.
 Lift transmission with workshop hoist VAS6100 and lifting aid T40013.
Fig. 206: Securing Engine And Transmission Support VW 540 To Transmission And Fitting Into
Support Clamp VW313
 Secure engine and transmission support VW 540 to transmission and fit into support clamp VW313.
TRANSMISSION COVER AND TORSEN DIFFERENTIAL, REMOVING AND INSTALLING
Transmission cover and Torsen differential, assembly overview
2:55:09 AM Page 62

 With or without vibration damper, depending on design

 Removing and installing (transmission removed) --> Transmission cover (transmission removed),
 Removing and installing (transmission installed) --> Transmission cover (transmission installed),
 Dismantling and assembling --> Transmission cover, dismantling and assembling
2 - Bolt, 24 Nm
 6x
2:55:09 AM Page 63
3 - Dished spring
 Installation position: larger diameter (concave side) faces shim
4 - Shim
5 - Spring
6 - O-ring
 Always replace
 Can only be serviced by manufacturer
 Removing and installing --> Transmission, removing and installing

 Mounting on assembly stand --> Mounting transmission on assembly stand
Transmission cover (transmission removed), removing and installing

2:55:09 AM Page 64

Removing
 Mount transmission on assembly stand --> Mounting transmission on assembly stand

 Unscrew bolts - arrows - and pull off transmission cover.
Installing
 Replace O-ring on transmission housing.

Tightening torque
Component Nm
Transmission cover (transmission installed), removing and installing
2:55:09 AM Page 65


Removing
damaged.

exhaust system.
2:55:09 AM Page 66


2:55:09 AM Page 67



 Unscrew bolts - arrows - and take off transmission cover.
Installing
NOTE:  Always replace O-rings, gaskets and self-locking nuts.

 26 - EXHAUST SYSTEM, EMISSION CONTROLS for BHF
Tightening torques
Component Nm
2:55:09 AM Page 68
TRANSMISSION COVER, DISMANTLING AND ASSEMBLING
Transmission cover, dismantling and assembling

2:55:09 AM Page 69
 Punch 2005
 Shim 016 311 391 A
2:55:09 AM Page 70

1 - Flange shaft
 Pressing out Pressing out flange shaft (transmission cover with vibration damper) or Pressing out
flange shaft (transmission cover without vibration damper)
2 - Bolt, 20 Nm + 90°
 For vibration damper

 3x
 Self-locking
 Replace
2:55:09 AM Page 71
 Not installed on all versions
4 - Oil seal
 Levering out Levering off the oil seal.

 Preparing for installation Preparing oil seal for installation
 Driving in Drive in seal onto stop.
 Removing and installing --> Transmission cover and Torsen differential, removing and installing
6 - Ball bearing

7 - Circlip
Pressing out flange shaft (transmission cover with vibration damper)
Fig. 219: Pressing Out Flange Shaft (Transmission Cover With Vibration Damper)

 Set up transmission cover in such a way that flange shaft does not make contact with press plate - arrows
- when it is pressed out.
Pressing out flange shaft (transmission cover without vibration damper)
2:55:09 AM Page 72
Fig. 220: Pressing Out Flange Shaft (Transmission Cover Without Vibration Damper)

 Secure vibration damper before pressing in flange shaft.

 Fit circlip.
Levering off the oil seal.
2:55:09 AM Page 73
Fig. 222: Levering Off The Oil Seal.

Preparing oil seal for installation

A - Shim 016 311 391 A (1.4 mm)
B - Oil seal
 Place shim and oil seal on tool, as shown in illustration.
 Installation position: open side of seal towards bearing housing
Drive in seal onto stop.
2:55:09 AM Page 74
Fig. 224: Preparing Oil Seal For Installation

 Remove shim.

2:55:09 AM Page 75

SELECTOR SHAFT WITH SELECTOR CYLINDER, SERVICING
Selector shaft with selector cylinder, removing and installing

 Multi-purpose tool VW 771/1

 Puller T40050
2:55:09 AM Page 76

Removing
Fig. 230: Pulling Out Both Selector Shaft Locking Bushes Using Multi-Purpose Tool VW 771/1 And
Puller T40050
 Pull out both selector shaft locking bushes (- item A - in Fig. 229) using multi-purpose tool VW 771/1
and puller T40050.
2:55:09 AM Page 77
 Push selector shaft - A - into transmission as far as it will go, simultaneously removing pin - B -.
Installing

 Installation position: Chamfer of selector shaft points downwards.
2:55:09 AM Page 78
 Push selector shaft - A - into transmission as far as it will go, simultaneously inserting pin - B -.
 Installation position of pin - B - : lug on pin points in direction of transmission housing.

 Fit cover - B - and tighten bolts - arrows -.
2:55:09 AM Page 79

 Drive in selector shaft locking bushes onto stop.
Tightening torque
Component Nm
Selector shaft cover to transmission 24

 Tube VW 423

 Puller hook T20143/1
2:55:09 AM Page 80
Removing

 Selector shaft installed
 Carefully pry out oil seal using puller hook T20143/1, taking care not to damage shaft.
 Selector shaft removed
Fig. 239: Prying Out Seal With Screwdriver

 Carefully pry out oil seal with a screwdriver.
Installing
2:55:09 AM Page 81
01E 311 120 , - item A -.

 Using tube VW 423, drive in oil seal to a depth of 1.1mm+-0.2mm.
REVERSING LIGHT SWITCH, REMOVING
Reversing light switch, removing
2:55:09 AM Page 82


2:55:09 AM Page 83
 Disconnect connector - arrow - for reversing light switch on right side of transmission.
 Unscrew reversing light switch - arrow - from selector shaft cover.
Reversing light switch, installing
 Screw reversing light switch - arrow - into selector shaft cover (tightening torque: 20 Nm).

 Install rear noise insulation - B -.
2:55:09 AM Page 84
35 GEARS, SHAFTS
INPUT SHAFT, DISMANTLING AND ASSEMBLING
At present there is no provision for disassembling.
2:56:31 AM
2:56:33 Page 1
TRANSMISSION 6 Spd. Manual Transmission 0A3 All Wheel Drive, Internal Component Servicing
TRANSMISSION
6 Spd. Manual Transmission 0A3 All Wheel Drive, Internal Component Servicing
00 - TECHNICAL DATA
NOTE:  You can find information about code letters, aggregate allocation, gear
ratios and capacities in --> 00 TECHNICAL DATA .
Fig. 1: Locating Code Letters, Serial Number And Possible Transmission Part Number
 Code letters, serial number and possible transmission part number - arrow 1 -
 Manual transmission 0A3 - arrow 2 -
Fig. 2: Locating Code Letters And Transmission Serial Number

2:57:53 AM
2:58:02 Page 1
Transmission code letters and serial number - arrow 1 -
Example: FVD 0314

I I
Code Transmission serial number
Fig. 3: Transmission Code Letters On Vehicle Data Stickers (Manual Transmission 0A3)
Manual transmission 0A3 - arrow 2 -
Fig. 4: Identification As Of Serial Number 2097

Identification as of serial number 2097
 Manual transmission 0A3 - arrow 1 - with transmission part number (e.g. 0A3 300 040 F) on the final
drive cover.
 Transmission serial number and code letters - arrow 2 -
GENERAL REPAIR NOTES
2:57:53 AM Page 2
To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of
good and proper tools is essential. The usual basic safety precautions also, naturally apply when carrying out
vehicle repairs.
at various points in the article, are summarized here under the topic "Components" --> Components. They
apply to this article.
For a complete list of special tools used in the article see AESIS; Library; Special Tools.
Components
Transmission
 You can find information about code letters, aggregate allocation, gear ratios and capacities in --> 00
TECHNICAL DATA .
 Allocate bolts and other components according to transmission code via .
 When exchanging or repairing a manual transmission, check oil level and top off if necessary --> 34
CONTROLS, HOUSING .
 Determine capacities and specifications using the respective code letters --> 00 TECHNICAL DATA .
Sealant
 Thoroughly clean housing joint surfaces before applying sealing compounds.

 Apply sealing paste AMV 188 001 02 evenly and not too thick.
 Do not allow sealing compound to enter ventilation openings.
 Always replace O-rings, gaskets and seals.

2:57:53 AM Page 3

 Before installing radial shaft seals, lightly oil outer circumference and fill space between sealing lips -
arrow - halfway with sealing grease G 052 128 A1 .
 When pressing in new gaskets, make sure sealing lip does not run on the same point as the sealing lip of
the old seal (use insertion depth tolerances).
 Lightly oil O-rings before installing; this prevents the rings from being crushed when inserting.
 The procedure for removing and installing shaft seals in an installed transmission is described in --> 34
CONTROLS, HOUSING and -->
.
 After replacing seals and sealing rings, check transmission fluid level and top off if necessary --> 34
CONTROLS, HOUSING .
Locking elements

 Always replace circlips which have been damaged or overtensioned.
 Circlips must be properly seated in base of the groove.
2:57:53 AM Page 4

 Replace spring pins. Installation position: Slit - A - should be in line with the line of force - arrow -.
Bolts and nuts
 Loosen bolts and nuts in reverse of tightening sequence.

 Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.
 Tightening torques stated apply to unoiled bolts and nuts.

 Clean threads of bolts that were applied with locking fluid using a wire brush. Apply locking fluid AMV
185 101 A1 before reinstalling.
 Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be
cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
Adjustment shims
 Use a micrometer to measure the shims at several points. Varying tolerances make it possible to measure
the required shim thickness exactly.
 Inspect for burrs and signs of damage.
 Do not install shims which are damaged or not in perfect condition.
Bearings
2:57:53 AM Page 5
 Set needle bearings, ball sleeves and roller sleeves with the inscribed side (greater thickness) facing
toward drift.
 Install new tapered roller bearing as supplied and do not use additional oil.
 Install various bearings (removed tapered roller bearings) into transmission, lubricated with gear oil.
 Heat inner races of taper roller bearings to approx. 100°C before installing. Press on to the stop when
installing, so there is no axial clearance.
 Warm inner race for needle and roller bearings to 130°C max.
 Do not interchange inner and outer bearing races with those from other bearings of the same size,
bearings are paired.
 Taper roller bearings installed on a shaft must be replaced as a set and use same make of bearings.
 If gear set is replaced, then always replace double angular contact ball bearing on drive pinion with it.
Synchronizer rings
 Do not interchange. When reusing synchronizer rings, always install to the same gear.
 Check for wear and replace if necessary.
Fig. 7: Checking Synchronizer Rings

 Check coated friction surfaces - arrows 2 - from intermediate ring - B - for damage (flat areas,
disintegrating areas or carbon layer).
 Check inner friction surface - arrow 1 - of synchronizer ring - A - and outer friction surface - arrow 4 -
of inner race - C - for grooves and scoring.
 On inner race - C - with coated friction surfaces - arrow 3 - , check coating for damage (disintegrating
2:57:53 AM Page 6
carbon layer).
 Coat with gear oil before installing.
Gears and synchronizer hub
 Before pressing on, clean and heat to max. 100°C on a heater.

 When installing, press onto stop so there is no axial play.
 Temperature can be check using temperature tester V.A.G 1558 , ignition tester V.A.G 1767 or diesel
tester V.A.G 1743.
 Observe installation position.
Selector gears
 After installing, check 1st through 6th gear for minimal amount of axial clearance of at least 0.10 mm and
for ease of movement.
34 - CONTROLS, HOUSING
Overview
2:57:53 AM Page 7
Fig. 8: Transmission, Disassembling And Assembling Overview

1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - 6th gear
7 - Reverse gear
2:57:53 AM Page 8
9 - Hollow shaft
10 - Double angular contact ball bearing
11 - Drive pinion (output shaft)
12 - Differential
13 - Input shaft
 For input shaft
15 - Transmission housing
17 - Torsen housing
18 - Flange shaft
Assembly overview
Assembly sequence --> Assembly sequence
2:57:53 AM Page 9
Fig. 9: Transmission Assembly Overview

I - Transmission cover and selector shaft, removing and installing --> Transmission cover and selector shaft,
 First, second and reverse gear with selector rod, removing and installing --> First, second and reverse
gears, removing and installing - assembly overview
 Input shaft, hollow shaft, drive pinion and selector rods, removing and installing --> Input shaft, hollow
shaft, drive pinion and selector rods, removing and installing - assembly overview
II - Torsen housing and torsen differential, removing and installing --> Torsen housing and torsen
differential, removing and installing - assembly overview
Torsen housing and torsen differential, removing and installing - assembly overview
2:57:53 AM Page 10
NOTE:  Removal can also be carried out with transmission installed --> 34
CONTROLS, HOUSING .

1 - Torsen housing
 With or without vibration dampener, depending on version

 Removing Torsen housing, removing
 Installing Torsen housing, installing
 Disassembling and assembling --> Torsen housing, disassembling and assembling
2 - Bolt -24 Nm
2:57:53 AM Page 11
 Qty. 6
3 - Plate spring
 Installation position: The inner diameter camber faces toward flange shaft in torsen housing Plate spring
and shim, inserting in torsen housing
4 - Adjustment shim
 Determine thickness
5 - Spring
 Place on flange shaft in torsen housing
6 - O-ring
 Always replace
 Insert in surrounding groove in transmission cover
 Service by manufacturer only

 Torsen differential bearing, servicing --> Torsen differential bearing, servicing
8 - Transmission
 Secure at assembly bracket --> Assembly sequence
Torsen housing, removing

2:57:53 AM Page 12
 Place oil receptacle underneath transmission.

 Drain gear oil.
 Remove screws - arrows - and remove torsen housing.
Plate spring and shim, inserting in torsen housing
Fig. 12: Identifying Plate Spring, Torsen Housing, Determined Shim, Shim & Spring
 Place plate spring - B - in torsen housing - A -.
 Plate spring installation location: The inner diameter camber faces toward flange shaft in torsen housing.
NOTE:  Redetermine thickness of shim - C -.
 Place shim - C - on plate spring - B -.

 Place spring - D - on flange shaft in torsen housing.
Torsen housing, installing

2:57:53 AM Page 13
 Coat new O-ring with transmission fluid and insert in surrounding groove in transmission cover.
 Place torsen housing on transmission cover.
 Tighten bolt - arrow - to 24 Nm.
 Top off transmission fluid and check transmission fluid level in manual transmission --> 34
CONTROLS, HOUSING .
Transmission cover and selector shaft, removing and installing
NOTE:  First, second and reverse gears, removing and installing --> First, second
and reverse gears, removing and installing - assembly overview.
 Input shaft, drive pinion, hollow shaft and selector rods, removing and
installing --> Input shaft, hollow shaft, drive pinion and selector rods,
removing and installing - assembly overview.
 Do not interchange securing bushings for selector shaft and selector rods.
Identify before removing.
2:57:53 AM Page 14
Fig. 14: Transmission Cover And Selector Shaft, Removing And Installing Overview
1 - Circlip
 Note thickness
 Determine thickness Determine thickness of circlip and shim(s) as follows:
2 - Washer
 Note thickness
 Determine thickness Determine thickness of circlip and shim(s) as follows:
3 - Tapered roller bearing inner race
 Can be installed and removed by hand
2:57:53 AM Page 15
5 - Spacer ring
6 - Twelve-point nut, 75 Nm
7 - O-ring
 Always replace
 Insert in surrounding groove in transmission cover
8 - Bolt, 27 Nm
 Qty. 2
 Self-locking
 Replace
9 - Bolt, 24 Nm
 Qty. 13
 Servicing --> Transmission cover, servicing
11 - Alignment pin
 Qty. 2
 Place in transmission cover
12 - Oil drain bore screw, 40 Nm
 Differential, removing and installing --> Differential, removing and installing

 Transmission housing, servicing --> Transmission housing, servicing
14 - Oil filler hole screw, 40 Nm
15 - Bolt, 24 Nm
 Qty. 2
2:57:53 AM Page 16
 Insert with locking fluid AMV 185 101 A1
16 - Securing plate
17 - Guide sleeve
 With seal
18 - O-ring
 Always replace
 Insert in transmission housing surrounding groove
19 - Circlip
 Insert in input shaft surrounding groove
20 - Securing bushing
 For selector shaft

 Qty. 2
 Do not interchange securing bushings for selector shaft and selector rods
 Change: with edged collar for ball sleeve Selector shaft securing bushings changed
21 - Selector shaft with selector cylinder
 Removing and installing --> Assembly sequence
22 - O-ring
 For selector shaft cover

 Always replace
 Insert in selector shaft cover surrounding groove
23 - Bolt -24 Nm
 Qty. 3
24 - Selector shaft cover
2:57:53 AM Page 17
 With Back-Up Light Switch F4

 Back-Up Light Switch F4 , removing and installing --> 34 CONTROLS, HOUSING
 Back-Up Light Switch F4 tightening torque - 20 Nm
25 - Dowel pin
 For selector shaft retainer

 Insert in transmission housing bore
NOTE:  There are dowel pins with and without pins, when replacing, allocate via .
 Installation location of dowel pin with pins: Insert pin side in transmission
housing.
 For 5th/6th gear selector rod
 For 3rd/4th gear selector rod
 For 1st/2nd gear selector rod
 For reverse gear selector rod
30 - Screw, 24 Nm
Selector shaft securing bushings changed
2:57:53 AM Page 18
Fig. 15: Identifying Selector Shaft Versions

A - Previous selector shaft securing bushings without edged ball sleeve collar - arrow 1 -. This securing
bushing must always be replaced, except for when version - B - is already installed.
B - New securing bushing for selector shaft with edged ball sleeve collar - arrow 2 - , can be reinstalled.
NOTE:  On transmission with version - A - selector shaft securing bushings

installed, these must always be replaced with version - B -.
 If version - B - is installed, this can be reused.
 Selector shaft securing bushings can also be replaced with transmission
installed --> 34 CONTROLS, HOUSING .
First, second and reverse gears, removing and installing - assembly overview
NOTE:  Items 8 and 11 to 18 were changed in the version with selector rod for
1st/2nd gear with spring-loaded shift fork --> 1st/2nd gear selector rod with
spring-loaded shift fork .
 After installing, the selector gears must have an axial clearance of at least
0.10 mm.
2:57:53 AM Page 19
Fig. 16: First, Second And Reverse Gears, Removing And Installing - Assembly Overview
1 - Clutch hub
2 - Needle bearing
 For reverse gear selector gear
3 - Reverse gear inner race
 Installed location Installation location of synchronizer rings for 1st and 2nd gear as well as reverse
gear
 Replace if grooved or scored
2:57:53 AM Page 20
4 - Reverse gear intermediate ring
gear
 Checking for wear Synchronizer rings for 1st, 2nd and reverse gears, checking for wear
5 - Synchronizer ring for reverse gear
gear
6 - Gear wheel for reverse gear
 With reverse gear locking collar

 Assemble locking collar and reverse gear selector gear Assemble locking collar and reverse gear
selector gear
7 - Thrust washer
 For 1st gear and reverse gear selector gears
8 - Drive gear for 1st gear
9 - Needle bearing
 For 1st gear
10 - Inner race/needle bearing
 For 1st gear selector gear
11 - Inner race for 1st gear
gear
12 - Intermediate ring for 1st gear
gear
2:57:53 AM Page 21
13 - Synchronizer ring for 1st gear
gear
14 - Locking collar/synchronizer hub for 1st and 2nd gear
 Note locking collar installation location 1st and 2nd gear locking collar installation location
 Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 1st and
2nd gear
15 - Synchronizer ring for 2nd gear
gear
16 - Intermediate ring for 2nd gear
gear
17 - Inner race for 2nd gear
gear
18 - Selector gear for 2nd gear
19 - Needle bearing
 For 2nd gear
 Input shaft, hollow shaft and drive pinion, removing and installing --> Input shaft, hollow shaft, drive
pinion and selector rods, removing and installing - assembly overview
21 - Bearing bracket
2:57:53 AM Page 22
 Supports input shaft and hollow shaft in transmission cover
22 - Reverse shaft mount
23 - Reverse shaft
 With support/reverse shaft

 Assembly of support/reverse shaft and reverse shaft Assembly of support/reverse shaft and reverse
shaft
24 - Needle bearing
 For reverse gear
25 - Reverse drive gear
 Installation position: Splines face toward reverse shaft mount
26 - Selector rod for 1st/2nd gear
 Installed location Installation location of selector rods in transmission

 Replace complete with selector fork for 1st/2nd gear with pins
 Change: with spring-loaded shift fork --> 1st/2nd gear selector rod with spring-loaded shift fork
27 - Reverse gear selector rod
 Installation location Installation location of selector rods in transmission

 Only complete with reverse gear selector fork with pins
Assembly of support/reverse shaft and reverse shaft
2:57:53 AM Page 23
Fig. 17: Assembly Of Support/Reverse Shaft And Reverse Shaft

 Insert O-ring - 1 - in surrounding groove - arrow A - in reverse shaft - 2 -.

 Coat O-ring with transmission fluid and then slide reverse shaft into side of support/reverse shaft - 3 -
with chamfer - arrow B -.
To do this, threaded hole - arrow C - and hole - arrow D - must line up.
1st/2nd gear selector rod with spring-loaded shift fork
Fig. 18: 1st/2nd Gear Selector Rod With Spring-Loaded Shift Fork
Input shaft, hollow shaft, drive pinion and selector rods, removing and installing - assembly overview
2:57:54 AM Page 24
Fig. 19: Input Shaft, Hollow Shaft, Drive Pinion And Selector Rods, Removing And Installing - Assembly
Overview
1 - Bolt -24 Nm
2 - Leaf spring
 Insert in hole in transmission housing
2:57:54 AM Page 25
 With release bearing
5 - Bolt, 24 Nm
 Qty. 2
6 - Securing plate
7 - Guide sleeve
 With seal
 Input shaft seal, removing Removing seal for input shaft
 Input shaft seal, installing Input shaft seal, installing
8 - O-ring
 Always replace
 Insert in transmission housing surrounding groove
9 - Circlip
 Insert in input shaft surrounding groove
10 - Selector rod for 5th/6th gear

 Replace only complete with selector fork for 5th/6th gear with pins
11 - Selector rod for 3rd/4th gear

 Replace only complete with selector fork for 3rd/4th gear with pins
 Change: with spring-loaded shift fork --> 3rd/4th gear selector rod with spring-loaded shift fork
12 - Input shaft
 Disassembling and assembling --> Input shaft, assembly overview
2:57:54 AM Page 26
 Clean threaded holes of locking compound, e.g. with a thread cutter

 Selector rod ball sleeves, pressing off and on Selector rod ball sleeves, pressing off and on
NOTE:  Outer roller bearing races on input shaft and hollow shaft cannot be
replaced individually.
 Roller bearing outer races must not have any radial clearance in bearing
bracket.
14 - Bolt, 30 Nm
 Qty. 6
 Clean threads and insert with locking compound AMV 185 101 A1
15 - Plate
 Installation position: sanded side faces toward transmission housing, fits only in one position
16 - Adjustment shim " S 4 "
 Adjustment overview --> Adjustment overview
17 - Pinion
 With double angular contact ball bearing and inner race/tapered roller bearing
 Disassembling and assembling --> Drive pinion and hollow shaft, assembly overview
18 - Needle bearing
 For pinion/hollow shaft
20 - Hollow shaft
 With gears for 5th and 6th gear pressed off

 Disassembling and assembling --> Drive pinion and hollow shaft, assembly overview
21 - Oil pan
 With differential and flange shafts
2:57:54 AM Page 27
Removing seal for input shaft
Fig. 20: Removing Seal For Input Shaft

 Carefully pry of sealing ring - arrow - with a screwdriver.
A - Jaw protectors
NOTE:  You can also remove the sealing ring with the puller hook T20143.
Input shaft seal, installing
Fig. 21: Input Shaft Seal, Installing


 Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
 Carefully press input shaft sealing ring on up to stop.
3rd/4th gear selector rod with spring-loaded shift fork - arrow -
2:57:54 AM Page 28
Fig. 22: 3rd/4th Gear Selector Rod With Spring-Loaded Shift Fork
Selector rod ball sleeves, pressing off and on
Fig. 23: Selector Rod Ball Sleeves, Pressing Off And On

 Support bearing bracket with tube split VW 422.
Place small dia. from the lock pin 2064 in ball sleeve.
 Press off previous ball sleeve.

 Press new ball sleeve onto dimension - a - approx. 4 mm.
NOTE:  Set ball sleeve in place with inscribed side (thicker wall) facing toward lock
pin 2064.
Installation location of selector rods in transmission
2:57:54 AM Page 29
Fig. 24: Installation Location Of Selector Rods In Transmission

1. Selector rod with reverse gear shifter fork

2. Selector rod with shift fork for 1st and 2nd gear
3. Selector rod with shift fork for 3rd and 4th gear
4. Selector rod with shift fork for 5th and 6th gear
Assembly sequence
Torsen housing, torsen differential, transmission cover, transmission-side shift mechanism, input shaft,
drive pinion and hollow shaft, removing and installing.
NOTE:  You do not need to remove the differential when removing the
components listed above.
 Removal is only necessary when adjustments have to be performed -->
Adjustment overview.
2:57:54 AM Page 30
Fig. 25: Identifying Special Tools - Torsen Housing, Torsen Differential, Transmission Cover,
Transmission-Side Shift Mechanism, Input Shaft, Drive Pinion And Hollow Shaft, Removing And
Installing (1 Of 2)

 Tube VW 415 A
 Tube VW 421
 Slide Hammer-Complete Set VW 771

 Driver 32 - 111
2:57:54 AM Page 31
Fig. 26: Identifying Special Tools - Torsen Housing, Torsen Differential, Transmission Cover,
Transmission-Side Shift Mechanism, Input Shaft, Drive Pinion And Hollow Shaft, Removing And
Installing (2 Of 2)
 Thrust piece 40 - 105

 Drive bushing 41 - 501
 Puller T40054
 - 1 - Two arm puller Kukko 20/10
 - 2 - Puller hooks, 250 mm long
2:57:54 AM Page 32
 Feeler gauge
 Sealing paste AMV 188 001 02

 Assembly sleeve 01E 311 120
 Thread locking compound AMV 185 101 A1
 Depth gauge, e.g. Digital Depth Gauge VAS 6087

 Oil receptacle

Transmission, disassembling

 Drain gear oil.
2:57:54 AM Page 33
Fig. 28: Securing Transmission To Assembly Stand With Bolts

 Secure transmission to assembly stand with bolts - arrows -.

 Tilt transmission on assembly stand to horizontal position.
Fig. 29: Identifying Bolt, Leaf Spring & Clutch Release Lever

Fig. 30: Identifying Bolts, Securing Plate, Guide Sleeve & Intermediate Piece
 Remove bolts - arrows - and remove securing plate - 1 -.

 Remove intermediate piece - 3 - from transmission housing.
2:57:54 AM Page 34

 Pry out O-ring - arrow - with a small screwdriver.
Fig. 32: Removing Input Shaft Circlip

 Circlip - arrow - in front of grooved ball bearing of input shaft must then be removed.
NOTE:  To disassemble transmission, you do not need to remove the input shaft
grooved ball bearing.
 A faulty input shaft grooved ball bearing can be released in a removed but
not disassembled transmission according to the procedure --> Input shaft
grooved ball bearing, replacing in uninstalled but not disassembled
transmission.
 Move shift shaft to neutral position.
2:57:54 AM Page 35
Fig. 33: Removing Both Securing Bushings For Selector Shaft

 Remove both securing bushings - A - for selector shaft.
NOTE:  Identify these securing bushings so that they are not interchanged with
the securing bushings for the selector rods.
 The securing bushings were changed shortly after series production
Selector shaft securing bushings changed.
Fig. 34: Identifying Selector Shaft & Dowel Pin

 Slide selector shaft - A - into transmission up to stop and pull out dowel pin - B -.
2:57:54 AM Page 36

 Remove bolts - arrows - and remove torsen housing.

 Remove torsen differential from drive pinion/hollow shaft.
Fig. 36: Removing Circlip, Shim(s), Inner Race, Outer Race & Spacer Ring
 Remove circlip - 1 - and shim(s) - 2 - from drive pinion
NOTE:  Note the thickness of the circlip and shim(s).
 Remove inner race - 3 - and outer race - 4 -. These components are push fit and can be installed by hand.
 Remove spacer ring - 5 - from twelve-point nut on hollow shaft.
2:57:54 AM Page 37
Fig. 37: Securing Hollow Shaft By Moving Selector Rods

 Secure hollow shaft by moving selector rods - 1 - to - 4 - in direction of - arrow -.
Fig. 38: Loosening Twelve-Point Nut On Hollow Shaft With Socket And Key T40097
 Loosen twelve-point nut on hollow shaft with socket and key T40097.
A - Torque wrench.
 Shift selector rods into neutral position.

 Turn transmission in assembly bracket so transmission cover faces up.
2:57:54 AM Page 38
Fig. 39: Identifying Bolts For Securing Bearing Bracket, Bolt For Securing Reverse Shaft, Connection
Screws & O-Ring
 Remove bolts - arrow 1 - (for securing bearing bracket), bolt - arrow 2 - (for securing reverse shaft) and
connection screws - A - for transmission cover on transmission housing.
NOTE:  Always replace the O-ring - C -.
Fig. 40: Identifying Reverse Gear, Clutch Hub & Magnet
2:57:54 AM Page 39
 Remove reverse gear - 1 - and reverse shaft.

 Remove clutch hub - 2 - with synchronizer ring for reverse gear by hand.
Remove magnet - 3 - from transmission housing.
Fig. 41: Removing Securing Bushings For Selector Rods

 Remove securing bushings - 1 - to - 4 - for selector rods.
Fig. 42: Removing Locking Collar With Shifter Fork And Reverse Gear Selector Gear
 Remove locking collar - A - with shifter fork - B - and reverse gear selector gear - C -.
2:57:54 AM Page 40
 Remove thrust washer and selector gears for reverse gear and 1st gear.
 Remove 1st gear selector gear with needle bearing and synchronizer rings.
Fig. 43: Removing 2nd Gear Selector Gear Together With Inner Race For 1st Gear Selector Gear And
Shifter Fork For 1st/2nd Gear From Hollow Shaft
 Remove 2nd gear selector gear - C - together with inner race for 1st gear selector gear - D - and shifter
fork for 1st/2nd gear - B - from hollow shaft.
A - Two arm puller , e.g. Kukko 20/10 with puller hook 250 mm
2:57:54 AM Page 41
Fig. 44: Removing/Installing Bearing Bracket With Reverse Shaft Mount & Oil Pan
 Remove bearing bracket - A - with reverse shaft mount - B -.

 Remove oil pan - C - from transmission housing.
Fig. 45: Guiding Hollow Shaft Together With Input Shaft And Selector Rods Upward Over Drive Pinion
 Then guide hollow shaft - 1 - together with input shaft - 2 - and selector rods - 3 - and - 4 - upward over
2:57:54 AM Page 42
the drive pinion - arrow -.
Fig. 46: Identifying Bolts & Retainer Plate

 Remove bolts - arrows - and retainer plate - A - with shim lying below " S 4 ".
Fig. 47: Removing Drive Pinion From Bore In Transmission Housing

 Carefully remove drive pinion - 1 - from bore in transmission housing - 2 -.
Double angular contact ball bearing outer races - 3 - and - 4 - must not be pulled apart, otherwise the double
angular contact ball bearing seal - 6 - can be damaged by the drive pinion face - 5 -. In this case, double angular
contact ball bearing must be replaced.
Transmission, assembling
2:57:54 AM Page 43
If transmission housing, gear set or hollow shaft was replaced, you must first redetermine the thickness of the
shim " S 6 " --> Shim " S 6 " for positioning 2nd gear selector gear, redetermining. It is located on the
hollow shaft and is responsible for position 2nd gear selector gear.
If gear set is replaced, then always replace double angular contact ball bearing on drive pinion with it.
To check double angular contact ball bearing for wear (running noise), differential must be removed.
When turning the installed drive pinion, the bearing must not catch and must run smoothly.
NOTE:  All threaded bores in which self-locking bolts are threaded must be
carefully cleaned of remaining locking fluid using a tap.
 Clean threads on hollow shaft for twelve-point nut.
 Lubricate all needle bearings and synchronizer rings with transmission
fluid before inserting.
 Housing joint surfaces must be cleaned.
 Checking synchronizer rings for wear --> Drive pinion and hollow shaft,
assembly overview.
 Place shim " S 3 " in transmission housing.

 Coat outer races - 3 - and - 4 - with transmission fluid.

 Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission
housing - 2 - and press onto upper outer race - 3 - at the same time.
2:57:54 AM Page 44
NOTE:  Warm transmission housing beforehand with a hot air gun in bearing seat
area, if necessary.
Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can
be damaged by the pinion face - 5 -.
If the double angular contact ball bearing seal is damaged, the bearing must be replaced.

 Insert shim " S 4 " and retainer plate - A - , only fits in one position.
 Clean threads of previous screws - arrows - with a wire brush. Then insert screws with locking compound
AMV 185 101 A1 and tighten in diagonal sequence to 30 Nm.
 Place hollow shaft needle bearing on drive pinion.
2:57:54 AM Page 45
Fig. 50: Guiding Hollow Shaft Together With Input Shaft And Selector Rods Upward Over Drive Pinion
 Insert hollow shaft - 1 - together with input shaft - 2 - and selector rods - 3 - and - 4 - in transmission
housing and at the same time, guide hollow shaft over drive pinion - arrow -.
Fig. 51: Placing Oil Pan With Ridge In Notch In Transmission Housing
 Place oil pan - 1 - with ridge - arrow A - in notch - arrow B - in transmission housing.
2:57:54 AM Page 46
Fig. 52: Removing/Installing Bearing Bracket With Reverse Shaft Mount & Oil Pan
 Guide bearing bracket - A - over input shaft and hollow shaft and place on oil pan - C -.
Reverse shaft mount - B - must be installed on bearing bracket.
Synchronizer rings for 1st, 2nd and reverse gears, checking for wear
Fig. 53: Checking Synchronizer Ring For Wear

 Check inner race on outer friction surface arrow for scoring or signs of wear, replace if necessary.
 Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
 Place inner race, intermediate ring and synchronizer ring on selector gear taper or clutch hub taper and
screw in.
NOTE:  Screw in means: Turn synchronizer ring approx. one turn while pressing
on the ring at the same time.
 Then measure gap - a - with a feeler gauge.
Gap dimension - a - Wear limit

1st and 2nd gear 0.7 mm
Reverse gear 0.7 mm
NOTE:  Replace inner race, intermediate ring and synchronizer ring for the
respective gear together.
Differentiation of reverse gear synchronization rings - A - and 1st/2nd gear - B -
2:57:54 AM Page 47
Fig. 54: Differentiation Of Reverse Gear Synchronization Rings And 1st/2nd Gear
1. Synchronizer ring for reverse gear: tabs arrow 1 have a smooth surface.
2. Reverse gear intermediate ring: friction surfaces arrow 2 are coated with centered linings (brass colored).
3. Reverse gear inner race: has no inner friction surface arrow 3.
4. Synchronizer ring for 1st and 2nd gear: tabs have 2 ridges each arrow 4.
5. Intermediate ring for 1st and 2nd gear: friction surfaces arrow 5 are coated with carbon (black).
6. Inner race for 1st and 2nd gear: inner race arrow 6 is coated with carbon (black).
Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
Fig. 55: Installation Position Of Synchronizer Rings For 1st And 2nd Gear
NOTE:
2:57:54 AM Page 48
 If the components are not to be replaced, make sure they are reallocated
to their original gear.
 Do not interchange reverse gear synchronizer rings with 1st and 2nd gear
synchronizer rings --> Differentiation of reverse gear synchronization
rings and 1st/2nd gear
 Place inner race - 2 - on selector gear - 1 - or clutch hub.

 Install intermediate ring - 3 -. Tab - B - must be inserted into recess - A -.
 Insert synchronizer ring - 4 -. Guide tabs - C - through recess - arrow -.
 Place 2nd gear selector gear together with needle bearing and synchronizer rings on hollow shaft.
 Then attach 1st and 2nd gear synchronizer hub.
1st and 2nd gear locking collar installation location
Fig. 56: 1st And 2nd Gear Locking Collar Installation Location
 Side with asymmetrical splines - arrow - must face toward 2nd gear.
Assembly of locking collar/synchronizer hub for 1st and 2nd gear
2:57:54 AM Page 49
Fig. 57: Assembly Of Locking Collar/Synchronizer Hub For 1st And 2nd Gear
 Place locking collar - A - (in installation location 1st and 2nd gear locking collar installation location)
together with shifter fork for 1st/2nd gear - C - over synchronizer hub - B -.
NOTE:  The locking collar only fits in one position over the synchronizer hub, the
splines - arrow 1 - and - arrow 2 - have different widths. Remove
synchronizer hub - B - from hollow shaft and rotate, if necessary.
 Then place thrust piece in synchronizer hub notches and push thrust piece in direction of - arrow 3 - into
locking collar notches. Locking collar must be held in middle position.
Fig. 58: Warming 1st Gear Selector Gear Inner Race/Needle Bearing & Attaching And Drive On To Stop
 Warm 1st gear selector gear inner race/needle bearing - 1 - to approx. 100°C, attach and drive on to stop.
Assemble locking collar and reverse gear selector gear
2:57:54 AM Page 50
Fig. 59: Assembling Locking Collar And Reverse Gear Selector Gear
1. Gear wheel for reverse gear

2. Locking collar
3. Thrust piece
 Slide locking collar over reverse gear selector gear.
 Pointed teeth - arrow A - in locking collar point opposite reverse gear selector gear drive splines - arrow
B -.
 Thrust piece notches - 3 - in reverse gear selector gear - arrow C - and locking collar - arrow D - must
align.
 Then place thrust piece in reverse gear selector gear notches and press thrust piece in locking collar
notches.
2:57:54 AM Page 51
Fig. 60: Placing 1st Gear Selector Gear With Needle Bearing And Synchronizer Rings On Inner
Race/Needle Bearing
 Then place 1st gear selector gear - C - with needle bearing and synchronizer rings on inner race/needle
bearing.
 Place thrust washer for 1st gear and reverse gear on hollow shaft.
 Attach reverse gear selector gear - A - (with locking collar mounted) together with reverse gear selector
rod - B -.
Fig. 61: Placing Reverse Shaft With Notch On Tab On Reverse Shaft Mount
 Place reverse shaft - 1 - with notch - arrow A - on tab - arrow B - on reverse shaft mount - 2 -.
2:57:54 AM Page 52
Fig. 62: Identifying Reverse Gear, Clutch Hub & Magnet

 Place reverse gear - 1 - with needle bearing in reverse shaft, when doing so, reverse gear splines must face
toward reverse gear selector gear.
 Place clutch hub - 2 - with needle bearing and synchronizer rings on hollow shaft.
 Place magnet - 3 - in transmission housing rib.
Fig. 63: Driving On Selector Rod Securing Bushings With Tube VW 421 To Stop
 Bring selector rods into neutral position - arrow -.

 Drive on selector rod securing bushings - 1 - to - 4 - with tube VW 421 to stop.
NOTE:  Do not interchange securing bushings for selector rods and selector shaft.
2:57:54 AM Page 53
 Check whether or not there are 2 alignment pins in transmission cover for centering transmission
cover/housing.
 Apply sealing paste AMV 188 001 02 evenly and not to thick on transmission housing joint surfaces at
transmission cover.
Fig. 64: Identifying Bolts For Securing Bearing Bracket, Bolt For Securing Reverse Shaft, Connection
Screws & O-Ring
 Place transmission cover - B - on transmission housing. Do not screw in screws - A - yet.

 Hand-tighten bolt - arrow 2 - in reverse shaft.
 Hand-tighten new bolts - arrow 1 - in bearing bracket.
 Then tighten the 13 bolts - A - to 24 Nm.
 Then tighten bolts - arrows 1 - to 27 Nm and bolt - arrow 2 - to 24 Nm.

 Coat new O-ring - C - with transmission fluid and insert in surrounding groove in transmission cover.
 Then rotate transmission horizontally in assembly bracket.
2:57:54 AM Page 54
Fig. 65: Securing Hollow Shaft By Moving Selector Rods

 Secure hollow shaft by moving selector rods - 1 - to - 4 - in direction of - arrow -.
Fig. 66: Loosening Twelve-Point Nut On Hollow Shaft With Socket And Key T40097
 Then tighten twelve-point nut hollow shaft to 75 Nm.
A - Torque wrench
 Then shift selector rods into neutral position.

 Turn transmission in assembly bracket with transmission cover upward.
2:57:54 AM Page 55
Fig. 67: Removing Circlip, Shim(S), Inner Race, Outer Race & Spacer Ring
 Place spacer ring - 5 - on hollow shaft twelve-point nut.

 Install inner race - 4 - and outer race - 3 -. These components are push fit and can be removed by hand.
If you have replaced the drive pinion (gear set), you must redetermine the thickness of the circlip - 1 -
and shim(s) - 2 - for tapered roller bearing on drive pinion --> Determine thickness of circlip and shim(s)
as follows:.
Determine thickness of circlip - 1 - and shim(s) - 2 - as follows:
Fig. 68: Determining Thickness Of Circlip And Shim(s)

 Measure a gap of 0.10 mm max. between the shim available as a replacement part and circlips, measured
between shim - 2 - and inner race/tapered ball bearing - 4 -.
2:57:54 AM Page 56
 Check gap with a feeler gauge - 3 -.
NOTE:  When measuring, the circlip - 1 - must be fully seated in groove and inner
race/tapered ball bearing - 4 - pushed in direction of - arrow -.
The following shims are available:
Shim thickness (mm)

* See note
0.7 1.1 1.5
0.8 1.2 1.6
0.9 1.3
1.0 1.4
*Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.
The following circlips are available:
Circlip thickness (mm)

1.70 1.80 1.90
1.75 1.85
 Install determined shim(s) and circlip.
Fig. 69: Sliding Torsen Differential On Hollow Shaft Splines

 Slide torsen differential on hollow shaft splines and press in direction of - arrow -.
 When doing so, measure distance - a - from flat surface of outer race/tapered ball bearing - 1 - to flat
surface of flange/transmission cover.
2:57:54 AM Page 57
Measuring range Adjustment shim

Measured value (mm) Thickness (mm)
109.88 to 110.00 1.65
109.91 to 110.15 1.45
110.16 to 110.45 1.20
110.41 to 110.70 0.95
110.66 to 110.95 0.70
110.91 to 111.20 0.45
NOTE:  Turn transmission horizontally in assembly bracket.
Fig. 70: Identifying Plate Spring, Torsen Housing, Determined Shim, Shim & Spring
 Place plate spring - B - in torsen housing - A -.
 Plate spring installation location: The inner diameter camber faces toward flange shaft in torsen housing.
 Place determined shim - C - on plate spring - B -.

 Place spring - D - on flange shaft in torsen housing.
 Then place torsen housing on transmission cover.
2:57:54 AM Page 58

 Tighten bolt - arrow - to 24 Nm.
NOTE:  To prevent damage to the seal - C - , the installation of the seal and
selector shaft must only be performed with the assembly sleeve 01E 311
120 - A -.
 Selector rods must be in neutral position.
 Installation position: Flattened part of selector shaft faces downward.
2:57:54 AM Page 59
Fig. 73: Identifying Selector Shaft & Dowel Pin

 Slide selector shaft - A - into transmission up to stop and insert dowel pin - B - at the same time.
NOTE:  On dowel pin version with pins, pin side must be inserted into hole in
Fig. 74: Removing/Installing Bolts And Selector Shaft Cover

 Install cover - B - with new O-ring.

 Clean screw threads - arrows - with a wire brush. Then insert screws with locking compound AMV 185
101 A1 and tighten to 24 Nm.
A - Selector shaft securing bushings
2:57:54 AM Page 60
Fig. 75: Identifying Selector Shaft Versions

NOTE:  Only install version - B - selector shaft securing bushings with edged
collar - arrow 2 -.
 On transmission with version - A - selector shaft securing bushings
installed, these must always be replaced with version - B -.
 If version - B - is installed, this can be reused.

 Drive in selector shaft securing bushings with tube VW 421 until stop.
2:57:54 AM Page 61
Fig. 77: Removing/Installing Input Shaft Circlip

 Circlip - arrow - in front of grooved ball bearing of input shaft must then be installed.

 Coat new O-ring - arrow - with transmission fluid before installing in surrounding groove in transmission
housing.
 Pull a thin insulating hose or heat-shrinkable hose over input shaft splines.
 Fill space between sealing lip and dust lip on sealing ring in guide sleeve halfway with grease G 052 128
A1 .
 Lightly lubricate outer circumference of guide sleeve.
2:57:54 AM Page 62
 Slide guide sleeve - 2 - over input shaft in transmission housing.

 Remove insulating hose or heat-shrinkable hose.
 Attach securing plate - 1 -.
 Clean bolt threads - arrows - with a wire brush. Then insert bolts with locking compound AMV 185 101
A1 and tighten to 24 Nm.
 Insert intermediate piece - 3 - in transmission housing.
 You must lightly coat contact surface of clutch slave cylinder plunger with copper paste before installing
clutch release lever - 3 -.
 Install clutch release lever with release bearing.
 Clean bolt threads - 1 - with a wire brush.
 Place leaf spring - 2 - on screws - 1 -.
 Then insert bolts - 1 - with locking compound AMV 185 101 A1 and tighten to 24 Nm.
 Shift through all gears.
2:57:54 AM Page 63
Input shaft grooved ball bearing, replacing in uninstalled but not disassembled transmission
Fig. 81: Driving Sleeve 32 - 109

Fig. 82: Tapered Roller Bearing Puller V.A.G 1582

 Taper roller bearing puller V.A.G 1582

 Attachment V.A.G 1582/12
2:57:55 AM Page 64

 Remove bolts - arrows - and securing plate - 1 -.

 Pull a thin insulating hose or heat-shrinkable hose over input shaft splines.
 Remove intermediate piece - 3 - from transmission housing.
2:57:55 AM Page 65

 Pry out O-ring - arrow - with a small screwdriver.

 Circlip - arrow - in front of grooved ball bearing of input shaft must then be removed.
Fig. 87: Removing Input Shaft Grooved Ball Bearing From Transmission Housing
2:57:55 AM Page 66
 Remove input shaft grooved ball bearing from transmission housing.

 Then slide new grooved ball bearing on input shaft.
Closed side of cage for balls points toward transmission housing.
Fig. 88: Driving Grooved Ball Bearing In Transmission Housing To Stop

 Drive grooved ball bearing in transmission housing to stop.

 Circlip - arrow - in front of grooved ball bearing of input shaft must then be installed.
2:57:55 AM Page 67

 Coat new O-ring - arrow - with transmission fluid before installing in surrounding groove in transmission
housing.
 Fill space between sealing lip and dust lip on sealing ring in guide sleeve halfway with grease G 052 128
A1 .
 Lightly lubricate outer circumference of guide sleeve.
 Slide guide sleeve - 2 - over input shaft in transmission housing.

 Remove insulating hose or heat-shrinkable hose.
 Attach securing plate - 1 -.
 Clean bolt threads - arrows - with a wire brush. Then insert screws with locking compound AMV 185 101
A1 and tighten to 24 Nm.
 Insert intermediate piece - 3 - in transmission housing.
2:57:55 AM Page 68
 You must lightly coat contact surface of clutch slave cylinder plunger with copper paste before installing
clutch release lever - 3 -.
 Install clutch release lever with release bearing.
 Clean bolt threads - 1 - with a wire brush.
 Place leaf spring - 2 - on bolts - 1 -.
 Then insert bolts - 1 - with locking compound AMV 185 101 A1 and tighten to 24 Nm.
TORSEN HOUSING, DISASSEMBLING AND ASSEMBLING
Torsen housing, disassembling and assembling
2:57:55 AM Page 69
Fig. 93: Identifying Special Tools - Torsen Housing, Disassembling And Assembling (1 Of 2)

 Punch VW 408 A
 Punch VW 412

2:57:55 AM Page 70
Fig. 94: Identifying Special Tools - Torsen Housing, Disassembling And Assembling (2 Of 2)
 Punch 2005
 Thrust plate 2050
 Seal driver-frt wheel bearing 30 - 100
 Pulling hook T20143

 Thrust plate T40106
 Adjustment shim 016 311 391 A
 Thread locking compound AMV 185 101 A1
2:57:55 AM Page 71

1 - Flange shaft
 Press off Press off flange shaft (torsen housing with vibration dampener) or Press off flange shaft
(torsen housing without vibration dampener)
 Change: as of serial number 42987 with groove --> As of serial number 42987 - Flange shaft with nut
and sealing ring with additional dust lip
2 - Screw - 20 Nm plus an additional 90°
 For vibration dampener
2:57:55 AM Page 72
 Qty. 3
 Self-locking
 Replace
3 - Vibration dampener
 Not present on all versions
4 - Seal
 Removing Pry off sealing ring

 Installing up to serial number 42986 Sealing ring - up to serial number 42986 - installing
 Change: as of serial number with additional dust lip Differentiation of sealing rings
 Installing as of serial number 42987 Sealing ring - as of serial number 42987 - with additional dust
lip, installing
5 - Torsen housing
 Removing and installing with transmission removed --> Torsen housing and torsen differential,
removing and installing - assembly overview
 Removing and installing with transmission installed --> 34 CONTROLS, HOUSING
6 - Ball bearing

7 - Circlip
Press off flange shaft (torsen housing with vibration dampener)
Fig. 96: Press Off Flange Shaft (Torsen Housing With Vibration Dampener)
2:57:55 AM Page 73

 Position torsen housing so that flange shaft does not come in contact with assembly plate when pressing
off - arrows -.
Press off flange shaft (torsen housing without vibration dampener)
Fig. 97: Press Off Flange Shaft (Torsen Housing Without Vibration Dampener)

 Before pressing in flange shaft, tighten damper.
NOTE:  If a sealing ring is installed with additional dust lip Differentiation of

sealing rings , a flange shaft must be installed with a groove --> As of
serial number 42987 - Flange shaft with nut and sealing ring with
2:57:55 AM Page 74
additional dust lip
 Install securing ring.
As of serial number 42987 - Flange shaft with nut - arrow A - and sealing ring with additional dust lip - arrow B -
Fig. 99: Identifying Flange Shaft With Nut And Sealing Ring With Additional Dust Lip
NOTE:  Sealing ring with additional dust lip - arrow B - must be installed in
connection with flange shaft with groove - arrow A -.
Pry off sealing ring
Fig. 100: Pry Off Sealing Ring

Differentiation of sealing rings
2:57:55 AM Page 75
Fig. 101: Differentiation Of Sealing Rings

A - Sealing ring - up to serial number 42986 - without additional dust lip - arrow 1 -.
B - Sealing ring - as of serial number 42987 - with additional dust lip - arrow 2 -.
Sealing ring - up to serial number 42986 - installing

A - Shim 016 311 391 A (1.4 mm thick)
B - Seal
 Set shim and seal onto tool as shown.
2:57:55 AM Page 76
 Installation position: Open side of sealing ring faces towards torsen housing.
 Lightly oil new sealing ring on outer circumference.
Fig. 103: Driving On New Flange Shaft Sealing Ring To Stop

 Drive on new flange shaft sealing ring to stop, when doing so, do not tilt.
 Remove tool and shim.
Sealing ring - as of serial number 42987 - with additional dust lip, installing
Fig. 104: Identifying Sealing Ring With Additional Dust Lip, Installing
 Installation position: Open side of sealing ring faces towards torsen housing.

 Drive on new flange shaft sealing ring to stop, when doing so, do not tilt.
2:57:55 AM Page 77


TRANSMISSION COVER, SERVICING
Transmission cover, servicing
2:57:55 AM Page 78
Fig. 107: Identifying Special Tools - Transmission Cover, Servicing (1 Of 2)


 Punch VW 408 A
 Punch VW 412

2:57:55 AM Page 79

 Thrust ring 2006 A

 Lock pin 2064
 Thrust pad 3062
 Alignment fixture 3253

 Depth gauge
2:57:55 AM Page 80
 Stud M10

2 - Alignment pin
 Qty. 2
 Place in transmission cover
 Drive in flush to rear side of housing joint surface
3 - Needle bearing
 For hollow shaft mounting in transmission cover
2:57:55 AM Page 81
 Pressing out Press needle bearing out of transmission cover

 Pressing in Press needle bearing into transmission cover
 Secure after installing with peen Secure needle bearing and roller housing in transmission cover with
peen
4 - Ball sleeve

 Pulling out Remove ball sleeve from transmission housing
 Pressing in Press ball sleeve into transmission cover
 Measure press-in depth Ball sleeve press-in depth in transmission cover
5 - Ball sleeve
 For selector rod for 1st and 2nd gear

 Pulling out Remove ball sleeve from transmission housing
 Pressing in Press ball sleeve into transmission cover
 Measure press-in depth Ball sleeve press-in depth in transmission cover
6 - Roller sleeve
 For input shaft mounting in transmission cover

 Always replace
 Pulling out Remove roller sleeve from transmission cover
 Pressing in Carefully press new roller sleeve into transmission cover to stop.
 Secure after installing with peen Secure needle bearing and roller housing in transmission cover with
peen
Press needle bearing out of transmission cover
Fig. 110: Press Needle Bearing Out Of Transmission Cover
2:57:55 AM Page 82
 Remove peening indentations, if present.
Press needle bearing into transmission cover
Fig. 111: Press Needle Bearing Into Transmission Cover

Install needle bearings with lettering on bearing (the side with thicker metal) facing towards thrust pad 3062.
 Press in needle bearing to a depth of 262 ± 0.5 mm, measured from housing joint surface to needle
bearing (similar to Ill. A34-10190 Ball sleeve press-in depth in transmission cover).
 Secure needle bearing after pressing into transmission cover with peen Secure needle bearing and roller
housing in transmission cover with peen.
Remove ball sleeve from transmission housing
Fig. 112: Remove Ball Sleeve From Transmission Housing

A - Support , e.g. Kukko 22/2
B - Internal puller 14.5 to 18.5 mm , e.g. Kukko 21/2
2:57:55 AM Page 83
C - Stud M10
NOTE:  You can also use adapter VW 771/44 in place of stud M10 and VW 771/15.
Press ball sleeve into transmission cover
Fig. 113: Press Ball Sleeve Into Transmission Cover

 Set ball sleeve in place with inscribed side (thicker wall) facing toward lock pin 2064. To do this, insert
smaller dia. of lock pin 2064 in ball sleeve.
 Support transmission cover under bearing mount with thrust ring 2006 A.
Ball sleeve press-in depth Ball sleeve press-in depth in transmission cover
Ball sleeve press-in depth in transmission cover
Fig. 114: Ball Sleeve Press-In Depth In Transmission Cover

 Press in ball sleeve for reverse gear selector rod - 1 - and 1st/2nd gear selector rod - 2 - to dimension - a -
= 250.5 ± 0.5 mm.
2:57:55 AM Page 84
Remove roller sleeve from transmission cover
Fig. 115: Remove Roller Sleeve From Transmission Cover

B - Internal puller 30 to 37 mm , e.g. Kukko 21/4
NOTE:  Always replace roller sleeve after removing.
Carefully press new roller sleeve into transmission cover to stop.
Fig. 116: Carefully Press New Roller Sleeve Into Transmission Cover To Stop.
2:57:55 AM Page 85
Support transmission cover under bearing mount with thrust ring 2006 A.
 Secure roller sleeve after pressing into transmission cover with peen Secure needle bearing and roller
housing in transmission cover with peen
Secure needle bearing and roller housing in transmission cover with peen
Fig. 117: Secure Needle Bearing And Roller Housing In Transmission Cover With Peen
 To peen, use blunt center punch with ball-shaped end (ball dia. 5 mm).
 Needle bearings - 1 - or roller sleeves - 2 - are secured with three peen marks each on the circumference
every 120°- arrow A - or - arrow B -.
Observe position and dia. of peening points:
 Dimension - b - = 3 mm
TRANSMISSION HOUSING, SERVICING
Transmission housing, servicing
2:57:55 AM Page 86
Fig. 118: Identifying Special Tools - Transmission Housing, Servicing (1 Of 2)

 Drift VW 295
 Adapter VW 295 A
 Tube VW 423

 Guide pin 10 - 15
2:57:55 AM Page 87


 Lock pin 2064
 Alignment fixture 3253
 Internal puller 3275

2:57:55 AM Page 88
 Depth gauge
Fig. 120: Straight-Edge T 40100

 Straight-edge T 40100
2:57:55 AM Page 89
Fig. 121: Exploded View Of Transmission housing

1 - Needle bearing
 For input shaft

 Always replace
 Pulling out Remove input shaft needle bearing from transmission housing
 Driving in Drive input shaft needle bearing into transmission housing
 Measure drive-in depth Measure needle bearing drive-in depth and secure needle bearing with
peening
 Secure after installing with peen Measure needle bearing drive-in depth and secure needle bearing
with peening
2:57:55 AM Page 90
2 - Ball sleeve

 Pulling out Remove selector shaft ball sleeve
 Driving in and securing Drive on selector shaft ball sleeve and secure with peening
3 - Cap
 For transmission breather
4 - Breather pipe
 Installation dimension Breather tube installation dimension
 If replacing: Redetermine 2nd gear selector gear position --> Shim " S 6 " for positioning 2nd gear
selector gear, redetermining , adjusting drive pinion and differential (gear set) --> Adjustment
overview
6 - Ball sleeve

 Pulling out Remove selector shaft ball sleeve
 Driving in Selector shaft ball sleeve, driving on
7 - Sealing ring for selector shaft
 Can be replaced with transmission installed --> 34 CONTROLS, HOUSING

 Always replace
 Removing with transmission removed Selector shaft sealing ring, removing from disassembled
transmission
 Removing with transmission installed Selector shaft sealing ring, removing from assembled
transmission
 Driving in Driving in selector shaft seal

 Only install with assembly sleeve 01E 311 120 with selector shaft installed
8 - Outer race/right tapered roller bearing
 For differential
 If replacing: Adjust differential (ring gear) --> Ring gear, adjusting
2:57:55 AM Page 91
 Note thickness
 For input shaft

 Removing off with transmission disassembled Input shaft grooved ball bearing, removing from
disassembled transmission
 Removing with transmission removed, not disassembled --> Input shaft grooved ball bearing,
replacing in uninstalled but not disassembled transmission
 Installing Drive input shaft grooved ball bearing in to stop
12 - Oil drain bore screw, 40 Nm
13 - Seal
 For right flange shaft

 Replace --> Flange shaft seals, replacing
14 - Magnet
 Clean
 Insert in housing rib
15 - Ball sleeve

 Pulling out --> Remove selector rod ball sleeve - C -
 Driving in Drive in selector rod ball sleeve
 Measure drive-in depth Drive-in depth for ball sleeves in transmission housing
16 - Ball sleeve

 Pulling out --> Remove selector rod ball sleeve
17 - Ball sleeve
2:57:55 AM Page 92
 For selector rod for 3rd and 4th gear

18 - Ball sleeve
 For selector rod for 5th and 6th gear

Remove input shaft needle bearing from transmission housing
Fig. 122: Removing Input Shaft Needle Bearing From Transmission Housing
Drive input shaft needle bearing into transmission housing
2:57:55 AM Page 93
Fig. 123: Drive Input Shaft Needle Bearing Into Transmission Housing
Install needle bearing with lettering on bearing (the side with thicker metal) facing towards sleeve 30 - 100.
Needle bearing drive-in depth Measure needle bearing drive-in depth and secure needle bearing with
peening
Measure needle bearing drive-in depth and secure needle bearing with peening
Fig. 124: Measure Needle Bearing Drive-In Depth And Secure Needle Bearing With Peening
 Drive-in dimension - a - = 88.0 ± 0.5 mm
 To peen, use blunt center punch with ball-shaped end (ball dia. 5 mm).
 Needle bearing is secured with three peening marks on circumference every 120°- arrows -.
2:57:55 AM Page 94
Remove selector shaft ball sleeve
Fig. 125: Remove Selector Shaft Ball Sleeve

A - Internal puller 14.5 to 18.5 mm , e.g. Kukko 21/2
Drive on selector shaft ball sleeve and secure with peening
Fig. 126: Drive On Selector Shaft Ball Sleeve And Secure With Peening
Set ball sleeve in place with inscribed side (thicker wall) facing toward guide pin 10 - 15.
 Drive in ball sleeve - 1 - to installation dimension - a - = 1.5 ± 0.5 mm below housing surface.
After driving on, secure ball sleeve with peening as follows:
 To peen, use blunt center punch with ball-shaped end.

 Secure ball sleeve with 3 peening marks - b - on circumference spaced every 120°.
Breather tube installation dimension
2:57:55 AM Page 95
Fig. 127: Breather Tube Installation Dimension

Dimension - a - = 16.8 mm
Selector shaft sealing ring, removing from disassembled transmission
Fig. 128: Selector Shaft Sealing Ring, Removing From Disassembled Transmission
 Carefully pry off sealing ring without damaging shaft.
Selector shaft sealing ring, removing from assembled transmission
2:57:55 AM Page 96
Fig. 129: Selector Shaft Sealing Ring, Removing From Assembled Transmission
 Carefully pry out seal using a screwdriver.
Remove selector shaft ball sleeve
Fig. 130: Remove Selector Shaft Ball Sleeve

Remove selector shaft sealing ring first Selector shaft sealing ring, removing from disassembled
transmission
Selector shaft ball sleeve, driving on
2:57:55 AM Page 97
Fig. 131: Selector Shaft Ball Sleeve, Driving On

 Drive-in depth: 8.5 ± 0.5 mm below housing surface.
Driving in selector shaft seal

 Drive sealing ring - arrow - in 1.0 ± 0.2 mm below housing surface, do not tilt when doing so.
Input shaft grooved ball bearing, removing from disassembled transmission
2:57:55 AM Page 98
Fig. 133: Input Shaft Grooved Ball Bearing, Removing From Disassembled Transmission
 Place adapter VW 295 A with small dia. in grooved ball bearing.

 Drive out grooved ball bearing.
Drive input shaft grooved ball bearing in to stop
Fig. 134: Input Shaft Grooved Ball Bearing, Removing From Disassembled Transmission
Closed side of cage for balls points toward transmission housing.
 Drive grooved ball bearing in transmission housing to stop.
Remove selector rod ball sleeve - C -
2:57:55 AM Page 99
Fig. 135: Remove Selector Rod Ball Sleeve

Drive in selector rod ball sleeve
Fig. 136: Drive In Selector Rod Ball Sleeve

 Drive in ball sleeve - A - for 5th/6th gear selector rod with lock pin 2064 to installation dimension Drive-
in depth for ball sleeves in transmission housing
 Drive in remaining 3 ball sleeves - B - with guide pin 10 - 15 to installation dimension Drive-in depth
for ball sleeves in transmission housing.
Insert bearing sleeve in inscribed side (greater thickness) facing toward guide pin 10 - 15 or lock pin 2064.
Drive-in depth for ball sleeves in transmission housing
2:57:55 AM Page 100

Fig. 137: Drive-In Depth For Ball Sleeves In Transmission Housing

 Drive in 5th/6th gear selector rod ball sleeve - 1 - to dimension - a - = 143.5 ± 0.5 mm.
 Drive in 5th/6th gear selector rod ball sleeve - 2 - to dimension - a - = 133.5 ± 0.5 mm.
 Drive in 1st/2nd gear selector rod ball sleeve - 3 - to dimension - a - = 116.5 ± 0.5 mm.
 Drive in ball sleeve for reverse gear selector rod - 4 - to dimension - a - = 116.5 ± 0.5 mm.
NOTE:  Measure with a depth gauge from housing joint surface to respective ball
sleeve.
35 - GEARS, SHAFTS
INPUT SHAFT
Input shaft, assembly overview
Disassembling and assembling input shaft, assembly sequence --> Input shaft, disassembling and assembling
- assembly sequence
NOTE:  When installing new gears, note technical data --> 00 TECHNICAL DATA .
 When replacing synchronizer rings, the intermediate ring and
synchronizer ring for the respective gear must be replaced together.
 Insert all bearings and synchronizer rings on input shaft with transmission
fluid.
 On transmissions with spring-loaded shifter forks --> 3rd/4th gear selector
rod with spring-loaded shift fork - arrow - , items 8, 11 to 14, 18 to 21, 25,
28 to 31 and 34 to 37 were changed.
2:57:56 AM Page 101

Fig. 138: Input Shaft, Assembly Overview

1 - Circlip
 Replacing with transmission removed, not disassembled --> Input shaft grooved ball bearing,
replacing in uninstalled but not disassembled transmission
4 - Needle bearing
5 - Circlip
2:57:56 AM Page 102

 Determine thickness --> Determine thickness of circlip and shim as follows:
6 - Washer
 Determine thickness --> Determine thickness of circlip and shim as follows:
 Has left threads
8 - Drive gear for 4th gear
9 - Needle bearing
 For 4th gear
 For 4th gear selector gear
11 - Inner race for 4th gear
 Installed location Installation location of synchronizer rings for 3rd to 6th gears
12 - Intermediate ring for 4th gear
 Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear
13 - Synchronizer ring for 4th gear
14 - Locking collar for 3rd and 4th gear
 Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 3rd and
4th gear
15 - Locking piece
 Installation position: insert with convex side in locking collar Assembly of locking collar/synchronizer
hub for 3rd and 4th gear
2:57:56 AM Page 103

 Installing locking pieces (qty. 3) Assembly of locking collar/synchronizer hub for 3rd and 4th gear
16 - Thrust plate
 Installing thrust pieces (3x) Assembly of locking collar/synchronizer hub for 3rd and 4th gear
17 - Synchronizer hub for 3rd and 4th gears
 Pressing off
 Pressing on
 Installation position: small shoulder on collar faces toward 3rd gear 3rd/4th gear synchronizer hub
installation location
 Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 3rd and
4th gear
18 - Synchronizer ring for 3rd gear
19 - Intermediate ring for 3rd gear
20 - Inner race for 3rd gear
21 - Drive gear for 3rd gear
22 - Needle bearing
 For 3rd gear
 For 3rd gear selector gear
24 - Thrust washer
 For 3rd and 6th gear selector gears
2:57:56 AM Page 104

25 - Selector gear for 6th gear
26 - Needle bearing
 For 6th gear
 For 6th gear selector gear
31 - Locking collar for 5th and 6th gear
 Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 5th and
6th gear
32 - Synchronizer hub for 5th and 6th gears
 Installation position: High inner collar faces 5th gear gear-wheel

 Pressing off
 Pressing on
 Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 5th and
6th gear
33 - Thrust plate
 Installing thrust pieces (3x) Assembly of locking collar/synchronizer hub for 5th and 6th gear
2:57:56 AM Page 105

38 - Needle bearing
 For 5th gear
39 - Roller bearing
 For input shaft

 Do not interchange with hollow shaft roller bearing
 Pressing off
 Pressing on
 Roller bearing outer race must not have any radial play in bearing bracket
41 - Input shaft
 Differentiation of input shafts Differentiation of input shafts

 Change: with additional PTFE washer for 5th gear needle bearing system Differentiation of input shafts
42 - Roller sleeve
 For input shaft mounting in transmission cover

 Always replace
Differentiation of input shafts
2:57:56 AM Page 106

Fig. 139: Differentiation Of Input Shafts

Dimension x = 31 mm on an input shaft without PTFE washer
Dimension x = 29 mm on an input shaft with PTFE washer - A -
NOTE:  After removing 5th gear needle bearing, slide PTFE washer - A - onto input
shaft - arrow - to stop.
Input shaft, disassembling and assembling - assembly sequence
2:57:56 AM Page 107

Fig. 140: Identifying Special Tools - Input Shaft, Disassembling And Assembling - Assembly Sequence (1
Of 2)

 Punch VW 412
 Tube VW 415 A

2:57:56 AM Page 108

Fig. 141: Identifying Special Tools - Input Shaft, Disassembling And Assembling - Assembly Sequence (2
Of 2)

 Tube 2040
 Guide sleeve 3039
 Tube for wheel bearing 3345
 Thrust plate T10084 A

 Feeler gauge
2:57:56 AM Page 109

Fig. 142: Clamp T10306

 Clamp T10306
Fig. 143: Wrench T10307

 Wrench T10307
Input shaft, disassembling
 With input shaft removed, you must first remove circlip and washer in front of twelve-point nut.
2:57:56 AM Page 110

Fig. 144: Placing Key T10307 On Twelve-Point Nut

 Place key T10307 on twelve-point nut.

 For the following step, the input shaft must be inserted in the clamp T10306 with clutch plate splines and
clamped into a vise.
A - Torque wrench
NOTE:  Due to the input shafts center of gravity, it must be supported, e.g. by a
second technician.
 The twelve-point nut has left threads and it must be turned clockwise to
loosen.
 Remove twelve-point nut in direction of - arrow -.

 Then remove 4th gear selector gear with needle bearing and synchronizer ring.
2:57:56 AM Page 111

Fig. 145: Pressing Of 3rd, 5th And 6th Gear Selector Gears Together With Synchronizer Hub And Inner
Races/Needle Bearings
 Press of 3rd, 5th and 6th gear selector gears together with synchronizer hub and inner races/needle
bearings.
NOTE:  Pressing force may be up to 200 kN (20 t).
Fig. 146: Placing Bearing Bracket Over Roller Bearing On Input Shaft So That Rollers Are Not Pressed
Out Of Bearing Cage
 Place bearing bracket - A - over roller bearing on input shaft so that the rollers are not pressed out of the
bearing cage.
 Press roller bearing off input shaft.
2:57:56 AM Page 112

 Clean twelve-point nut threads on input shaft from locking compound residue.
NOTE:  Clean thread on input shaft.

 Lubricate all needle bearings and synchronizer rings with transmission
fluid before inserting.
 Before pressing needle bearing inner races off, warm to a maximum of
130°C while wearing protective gloves.
 Warm synchronizer ring before pressing off to a maximum of 100°C while
wearing protective gloves.
 Always press roller bearing, needle bearing inner races and synchronizer
body to stop so that selector gears have the recommended axial
clearance.
Synchronizer rings for 3rd to 6th gears, checking for wear

 Check inner race on outer friction surface arrow for scoring or signs of wear, replace if necessary.
 Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
 Place inner race, intermediate ring and synchronizer ring on selector gear taper and screw in.
NOTE:  Screw in means: Turn synchronizer ring approx. one turn while pressing
on the ring at the same time.
 Then measure gap - a - with a feeler gauge.
Gap dimension - a - Wear limit

3rd to 6th gears 0.7 mm
2:57:56 AM Page 113

NOTE:  Replace inner race, intermediate ring and synchronizer ring for the
respective gear together.
Installation location of synchronizer rings for 3rd to 6th gears
Fig. 148: Installation Position Of Synchronizer Rings For 1st And 2nd Gear
NOTE:  If the components are not to be replaced, make sure they are reallocated
to their original gear.
 Place inner race - 2 - on sliding gear - 1 -.

 Install intermediate ring - 3 -. Tab - B - must be inserted into recess - A -.
 Insert synchronizer ring - 4 -. Guide tabs - C - through recess - arrow -.
Fig. 149: Pressing Roller Bearing Onto Input Shaft To Stop

 Press roller bearing onto input shaft to stop, shoulder of tube VW 415 A faces toward roller bearing when
doing so.
 Insert 5th gear selector gear together with needle bearing and synchronizer ring.
2:57:56 AM Page 114

With an input shaft with additional PTFE washer Differentiation of input shafts you must now insert PTFE
washer.
Assembly of locking collar/synchronizer hub for 5th and 6th gear
Fig. 150: Assembly Of Locking Collar/Synchronizer Hub For 5th And 6th Gear
 Slide locking collar - 1 - over synchronizer hub - 2 -.
 Groove - arrow A - on locking collar and high inner shoulder - arrow B - on synchronizer hub must face
toward 5th gear selector gear.
 Recesses - arrow C - for thrust pieces - 3 - in synchronizer hub and notches - arrow D - in locking collar
must align.
 Then place thrust pieces - 3 - in synchronizer hub and press thrust pieces into notches in locking collar.
Pressing on synchronizer hub with locking collar for 5th and 6th gears
2:57:56 AM Page 115

Fig. 151: Pressing On Synchronizer Hub With Locking Collar For 5th And 6th Gears
Note the follow when performing the next steps:
 Synchronizer hub installation location: High inner collar faces 5th gear gear-wheel
 Place input shaft in hole in pressure plate VW 401.

 Place pressing tool in center of warmed components (synchronizer hub and needle bearing inner races).
 After pressing briefly on components, stop and align pressing tool again at center and press to stop.
 On an input shaft with PTFE washer , washer must be inserted before pressing 5th/6th gear synchronizer
hub.
 When pressing, synchronizer ring tabs - arrow 1 - and notches - arrow 2 - on synchronizer hub must
align.
Inner race/needle bearing - arrow A - for 6th gear selector gear, pressing on
2:57:56 AM Page 116

Fig. 152: Inner Race/Needle Bearing For 6th Gear Selector Gear, Pressing On
Fig. 153: Removing 6th Gear Selector Gear Together With Needle Bearing And Synchronizer Rings
 Remove 6th gear selector gear - A - together with needle bearing and synchronizer rings.
 Place 3rd and 6th gear selector gears thrust washer - B - on 6th gear selector gear.
Inner race/needle bearing - arrow A - for 3rd gear selector gear, pressing on
2:57:56 AM Page 117

Fig. 154: Inner Race/Needle Bearing For 3rd Gear Selector Gear, Pressing On
 Remove 3rd gear selector gear together with needle bearing and synchronizer ring.
3rd/4th gear synchronizer hub installation location
Fig. 155: 3rd/4th Gear Synchronizer Hub Installation Location

 Synchronizer hub shoulder - arrow - must face toward 3rd gear selector gear.
Pressing on synchronizer hub for 3rd and 4th gears
2:57:56 AM Page 118

Fig. 156: Pressing On Synchronizer Hub For 3rd And 4th Gears
 Note installation location of synchronizer hub 3rd/4th gear synchronizer hub installation location
 When pressing on, synchronizer ring tabs and synchronizer hub recesses must align.
3rd/4th gear locking collar installation location
Fig. 157: 3rd/4th Gear Locking Collar Installation Location

 Groove - arrow - on locking collar must face toward 3rd gear selector gear.
Assembly of locking collar/synchronizer hub for 3rd and 4th gear
2:57:56 AM Page 119

Fig. 158: Assembly Of Locking Collar/Synchronizer Hub For 3rd And 4th Gear
 3rd and 4th gear synchronizer hub is pressed on.
 Coat 3 locking pieces - A - with some grease on convex side - arrow 1 -.

 Insert 3 locking pieces with convex side in recesses in locking collar - B -.
 Note locking collar installation location 3rd/4th gear locking collar installation location
 Then place locking collar over synchronizer hub - C - so that the synchronizer hub recesses - arrow 2 -
align with locking pieces.
 Then place thrust pieces - D - in synchronizer hub and press them in direction of - arrow 3 - into recesses
in locking collar. When doing so, locking collar must be held in middle position.
Inner race/needle bearing for 4th gear selector gear, pressing on
2:57:56 AM Page 120

Fig. 159: Inner Race/Needle Bearing For 4th Gear Selector Gear, Pressing On
 Remove 4th gear selector gear together with needle bearing and synchronizer ring.
 Clean threads of twelve-point nut that was removed.
 Hand-tighten twelve-point nut on input shaft.
Fig. 160: Place Key T10307 On Twelve-Point Nut.

 Place key T10307 on twelve-point nut.

 For the following step, the input shaft must be inserted in clamp T10306 with clutch plate splines and
clamped into a vise.
NOTE:  Due to the input shafts center of gravity, it must be supported, e.g. by a
second technician.
2:57:56 AM Page 121

 Twelve-point nut has left threads and so must be turned counterclockwise

to tighten.
A - Torque wrench
 Tighten twelve-point nut in direction of - arrow - to 75 Nm.

 Check all selector gears for ease of movement and axial play.
 Selector gear axial play must be at least 0.10 mm.
Determine thickness of circlip - 1 - and shim - 2 - as follows:
Fig. 161: Determine Thickness Of Circlip And Shim -

 Measure a gap of 0.10 mm max. between the shim available as a replacement part and circlips, measured
between circlip and shim.
 Check gap with a feeler gauge - 3 -.
NOTE:  When measuring, circlip - 1 - must be fully seated in groove.

1.70 1.80 1.90
1.75 1.85
Shim thickness (mm)

0.9 1.1 1.3
1.0 1.2
2:57:56 AM Page 122

 Install shim and circlip.
DRIVE PINION AND HOLLOW SHAFT
Drive pinion and hollow shaft, assembly overview
Drive pinion, disassembling and assembling --> Drive pinion, disassembling and assembling
Hollow shaft, disassembling and assembling --> Hollow shaft, disassembling and assembling
NOTE:  When installing new gears or gear set, note technical data --> 00
TECHNICAL DATA .
 Insert all needle bearings and synchronizer rings with transmission fluid.
 When replacing synchronizer rings, the intermediate ring and
synchronizer ring for the respective gear must be replaced together.
 If the synchronizer rings are not to be replaced, make sure they are
reallocated to their original gear. Do not interchange reverse gear
synchronizer rings with 1st and 2nd gear synchronizer rings -->
Differentiation of reverse gear synchronization rings and 1st/2nd gear.
 Items 22 to 29, 32 and 49 were changed in the version with selector rod for
1st/2nd gear with spring-loaded shift fork --> 1st/2nd gear selector rod with
spring-loaded shift fork.
 Adjustments are required when replacing components marked with 1) . List
of adjustments --> Adjustment overview.
2:57:56 AM Page 123

Fig. 162: Drive Pinion And Hollow Shaft, Assembly Overview

1 - Transmission housing 1)
3 - Drive pinion 1)
 Is mated with ring gear, always replace together as a set

 Disassembling and assembling --> Drive pinion, disassembling and assembling
 Drive pinion and ring gear, adjusting --> Pinion and ring gear, adjusting
2:57:56 AM Page 124

4 - Needle bearing
 For flange shaft mounting in drive pinion

 Pulling out Flange shaft mounting needle bearing, removing from drive pinion
 Driving in Flange shaft mounting needle bearing, driving in flush in drive pinion
5 - Double angular contact ball bearing
 No adjustment is needed if only this bearing is replaced

 Pressing off Double angular contact ball bearing, pressing off
 Pressing on Double angular contact ball bearing, pressing on
 Installation position: shoulder on outer race faces toward pinion face
 Determine thickness --> Shim " S 5 " for positioning inner race/tapered ball bearing, redetermining
 Pressing off Pressing off inner race/tapered roller bearing

 Pressing on Pressing on inner race/tapered roller bearing
8 - Washer
9 - Circlip
 Determine thickness
10 - Needle bearing
 For drive pinion in hollow shaft

12 - Holding plate
 Installation position: sanded side faces toward transmission housing, fits only in one position
13 - Bolt, 30 Nm
 Qty. 6
2:57:56 AM Page 125

14 - Hollow shaft
 With 3rd and 4th gears

 Disassembling and assembling --> Hollow shaft, disassembling and assembling
 Pressing off 6th gear selector gear, pressing off

 Pressing on 6th gear drive gear, pressing on
 Installation position: High inner collar faces 5th gear drive gear
 Pressing off Pressing off 5th-gear gear wheel

 Pressing on Pressing on 5th-gear gear wheel
 Installation position: High inner collar faces 6th gear drive gear
17 - Roller bearing
 For hollow shaft

 Do not exchange with input shaft roller bearing
 Press off together with drive gear for 5th gear Pressing off 5th-gear gear wheel
 Pressing on Hollow shaft roller bearing, pressing on
 Roller bearing outer race must not have any radial play in bearing bracket.
 For positioning 2nd gear selector gear

 Determine thickness --> Shim " S 6 " for positioning 2nd gear selector gear, redetermining
 For selector gear of 2nd gear

 Press off together with drive gear for 5th gear Pressing off 5th-gear gear wheel
 Pressing on Inner race/needle bearing for 2nd gear selector gear, pressing on
21 - Needle bearing
2:57:56 AM Page 126

 For 2nd gear
22 - Selector gear for 2nd gear
23 - Inner race for 2nd gear
gear
gear
25 - Synchronizer ring for 2nd gear
gear
26 - Locking sleeve with synchronizer hub for 1st and 2nd gears

 Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 1st and
2nd gear
27 - Synchronizer ring for 1st gear
gear
gear
29 - Inner race for 1st gear
2:57:56 AM Page 127

gear
 For 1st gear selector gear
31 - Needle bearing
 For 1st gear
32 - Drive gear for 1st gear
33 - Thrust washer
 For 1st gear and reverse gear selector gears
 With reverse gear locking collar

 Locking collar and reverse gear selector gear, disassembling and assembling Assemble locking collar
and reverse gear selector gear
35 - Synchronizer ring for reverse gear
gear
36 - Reverse gear intermediate ring
gear
37 - Reverse gear inner race
gear
2:57:56 AM Page 128

38 - Needle bearing
 For reverse gear selector gear
39 - Clutch hub
42 - Spacer ring
45 - Washer
 Note thickness
 Determine thickness --> Determine thickness of circlip and shim(s) as follows:
46 - Circlip
 Note thickness
 Determine thickness --> Determine thickness of circlip and shim(s) as follows:
47 - Synchronizer hub for 1st and 2nd gear
48 - Thrust plate
 Installing thrust pieces (3x) Assembly of locking collar/synchronizer hub for 1st and 2nd gear
49 - Locking collar for 1st and 2nd gear
50 - Thrust plate
 Installing thrust pieces (3x) Assemble locking collar and reverse gear selector gear
2:57:56 AM Page 129

52 - Reverse gear selector gear locking collar
Drive pinion, disassembling and assembling
Fig. 163: Identifying Special Tools - Drive Pinion, Disassembling And Assembling (1 Of 2)

 Punch VW 407
 Punch VW 412
 Tube VW 415 A
2:57:56 AM Page 130

 Support channels VW 457
Fig. 164: Identifying Special Tools - Drive Pinion, Disassembling And Assembling (2 Of 2)

 Driver 3013

2:57:56 AM Page 131

Fig. 165: Sleeve T40103

 Sleeve T40103
Fig. 166: Kukko 21/2 Internal puller, Kukko 21/4 Internal puller, Kukko 22/2 Counter support
Flange shaft mounting needle bearing, removing from drive pinion
2:57:56 AM Page 132

Fig. 167: Pulling Out Flange Shaft/Pinion Needle Bearing

A - Internal puller 12 to 14.5 mm , e.g. Kukko 21/1
Flange shaft mounting needle bearing, driving in flush in drive pinion
Fig. 168: Driving In Flange Shaft/Pinion Needle Bearing Flush

Install needle bearings with lettering on bearing (the side with thicker metal) facing towards drift 3013.
Pressing off inner race/tapered roller bearing
2:57:56 AM Page 133

Fig. 169: Pressing Off Inner Race/Tapered Roller Bearing

 Remove circlip and washer before pressing off.

 Attach grip V.A.G 1582/7 and clamp behind bearing rollers.
 Then carefully press inner race/tapered roller bearing out.
 Remove shim " S 5 " from drive pinion.
NOTE:  You can also press the inner race/tapered roller bearing out together with
the double angular contact ball bearing Double angular contact ball
bearing, pressing off
Double angular contact ball bearing, pressing off
Fig. 170: Double Angular Contact Ball Bearing, Pressing Off

2:57:56 AM Page 134

Double angular contact ball bearing, pressing on
Fig. 171: Double Angular Contact Ball Bearing, Pressing On

 Installation position: Shoulder on bearing outer race faces toward drive pinion face.
 Place tube VW 415 A smaller outer diameter on bearing inner race.

 Press double angular contact ball bearing on down to stop.
 When replacing drive pinion (gear set), you must redetermine the shim " S 5 " --> Shim " S 5 " for
positioning inner race/tapered ball bearing, redetermining.
Pressing on inner race/tapered roller bearing
Fig. 172: Pressing On Inner Race/Tapered Roller Bearing

2:57:56 AM Page 135

 Place shim " S 5 " on drive pinion double angular contact ball bearing beforehand.
 Warm inner race to approx. 100°C and press on.
 Lay washer - A - on inner race.
 Determine circlip - B - and insert.
Fig. 173: Identifying Washer & Circlip

Circlip - B - , determining
 Determine thickest circlip that can still be installed and insert, part no.

1.50 1.90 2.30
1.55 1.95 2.35
1.60 2.00 2.40
1.65 2.05 2.45
1.70 2.10 2.50
1.75 2.15 2.55
1.80 2.20 2.60
1.85 2.25
Shim " S 5 " for positioning inner race/tapered ball bearing, redetermining
2:57:57 AM Page 136

Fig. 174: Positioning Of Inner Race/Tapered Ball Bearing (On Drive Pinion) For Location Of Hollow
Shaft In Transmission Is Determined With This Shim
This is necessary when replacing gear set.
- A -.
Fig. 175: Identifying Shim Actual Dimension

The actual dimension "A1" - arrow - that you need for this shim " S 5 " is inscribed on gear set ring gear.
In the example, dimension "A1" = 98.86 mm
Determine shim needed according to table.
Actual dimension "A1" Adjustment shim " S 5 "

Inscribed value (mm) Thickness (mm)
99.30 to 99.21 2.30
99.20 to 99.11 2.40
2:57:57 AM Page 137

99.10 to 99.01 2.50

99.00 to 98.91 2.60
98.90 to 98.81 2.70
98.80 to 98.70 2.80
NOTE:  In the example, shim " S 5 " determined is 2.70 mm.
Hollow shaft, disassembling and assembling
NOTE:  The removal and installation of 1st, 2nd and reverse gear selector gears is
described in Transmission, disassembling and assembling --> Assembly
sequence.
Fig. 176: Identifying Special Tools - Hollow Shaft, Disassembling And Assembling
2:57:57 AM Page 138


 Punch VW 412
 Tube VW 415 A

 - 3 - Separating tool Kukko 17/2
 Feeler gauge
Pressing off 5th-gear gear wheel
Fig. 177: Pressing Off 5th-Gear Gear Wheel

 Press 5th gear drive gear together with roller bearing and 2nd gear selector gear inner race/needle bearing
off of hollow shaft.
6th gear selector gear, pressing off
2:57:57 AM Page 139

Fig. 178: 6th Gear Selector Gear, Pressing Off

A - Separating device 22 to 115 mm , e.g. Kukko 17/2
6th gear drive gear, pressing on
Fig. 179: 6th Gear Drive Gear, Pressing On

High inner collar faces 5th gear.
 Thrust piece 3118 shoulder faces toward 6th gear drive gear.
Pressing on 5th-gear gear wheel
Fig. 180: Pressing On 5th-Gear Gear Wheel

High inner collar faces 6th gear.
2:57:57 AM Page 140

Hollow shaft roller bearing, pressing on
Fig. 181: Hollow Shaft Roller Bearing, Pressing On

 Thrust piece 3118 shoulder faces toward roller bearing.
If you have replaced the transmission housing, gear set, hollow shaft or gears on hollow shaft, you must now
redetermine the shim " S 6 " for positioning 2nd gear selector gear --> Shim " S 6 " for positioning 2nd gear
selector gear, redetermining.
Inner race/needle bearing for 2nd gear selector gear, pressing on
2:57:57 AM Page 141

Fig. 182: Inner Race/Needle Bearing For 2nd Gear Selector Gear, Pressing On
 Place shim " S 6 " - A - on roller bearing beforehand.

 Then press on 2nd gear selector gear inner race/needle bearing - B -.
Shim " S 6 " for positioning 2nd gear selector gear, redetermining
Fig. 183: Positioning Of 2nd Gear Selector Gear And Of Gear Set In Transmission Is Determined With
This Shim
Positioning of 2nd gear selector gear and of gear set in transmission is determined with this shim - A -.
This adjustment is required when the following components are replaced:
 Transmission housing
2:57:57 AM Page 142

 Gear set
 Hollow shaft
Or
 Gears on hollow shaft
Fig. 184: Universal Measuring Device VW 385

 Universal measuring device VW 385
Fig. 185: Straight-Edge T 40100

 Straight-edge T 40100
 Digital depth gauge (e.g. VAS 6087)
2:57:57 AM Page 143

Fig. 186: Setting Adjusting Rings Of Measuring Bar VW 385/1

 Set adjustment rings of universal mandrel VW 385/1 to the following values:
Fig. 187: Assemble Universal Mandrel VW 385/1

 Assemble universal mandrel VW 385/1 as shown in the illustration:
Dimension -A-, determining
 Outer races/tapered roller bearings for differential mounting are installed in transmission housing and
final drive cover.
 Insert universal mandrel VW 385/1 with centering disc VW 385/4 facing toward transmission housing.
 Insert final drive cover with integrated O-ring and tighten 4 screws to 24 Nm.
 Using adjustable ring, pull centering disc outward until universal mandrel can no longer be turned by
hand.
2:57:57 AM Page 144

 Round side of universal mandrel must face upward toward depth gauge.
Fig. 188: Using Digital Depth Gauge, Measuring At Highest Point Of Universal Mandrel VW 385/1
 Place straight edge T 40100 on cleaned transmission housing join surface.

 Using a digital depth gauge - 1 - (e.g. Digital Depth Gauge VAS 6087), measure at highest point of
universal mandrel VW 385/1.
In the example, dimension - a - = 143.80 mm
 Subtract height of straight edge T 40100 from this dimension and add half of universal mandrel VW
385/1 diameter to it. This value is 16 mm.
Example:
Value reading on digital depth 143.80 mm
gauge
- Height of straight edge T 40100 40.00 mm
+ Half of diameter of universal 16.00 mm
mandrel VW 385/1
= Dimension -A- 119.80 mm
Dimension -B-, determining
 Drive pinion is installed with shim " S 3 " and " S 4 ".
2:57:57 AM Page 145

Fig. 189: Measuring From Inner Race/Roller Bearing To Straight Edge Using Digital Depth Gauge
 Retaining plate connecting screws - arrows - are tightened to 30 Nm.
 Install input shaft, hollow shaft with roller bearing pressed on and bearing bracket - 1 -.
 Place straight edge T 40100 on cleaned transmission housing join surface.
 Measure from inner race/roller bearing to straight edge using a digital depth gauge - 2 - (e.g. Digital
Depth Gauge VAS 6087).
In the example, dimension - b - = 172.00 mm
 Add height of straight edge T 40100 to this dimension.
Example:
Value reading on digital depth 172.00 mm
gauge
+ Height of straight edge T 40100 40.00 mm
= Dimension -B- 212.00 mm
Determining thickness of adjustment shim " S 6 "
Formula: Measuring range (total dimension) = Dimension -A- + Dimension -B-
Example:
Dimension -A- 119.80 mm
+ Dimension -B- 212.00 mm
= Measuring range (total dimension) 331.80 mm
Measuring range (total dimension) Adjustment shim " S 6 "

331.38 to 331.43 4.70
2:57:57 AM Page 146

331.44 to 331.53 4.60

331.54 to 331.63 4.50
331.64 to 331.73 4.40
331.74 to 331.83 4.30
331.84 to 331.93 4.20
331.94 to 332.03 4.10
332.04 to 332.08 4.00
NOTE:  The thickness of shim " S 6 " in this example is 4.30 mm.
Torsen differential bearing, servicing
Fig. 190: Identifying Special Tools - Torsen Differential Bearing, Servicing

2:57:57 AM Page 147


 Punch VW 407
 Punch VW 412
 Thrust piece VW 432

 Sleeve 40 - 103

 - 3 - Separating tool Kukko 17/2
2:57:57 AM Page 148

Fig. 192: Identifying Grooved ball bearing,

 Pressing off Pressing off grooved ball bearing from Torsen differential
 Pressing on Pressing grooved ball bearing onto Torsen differential
 Do not disassemble
 Service by manufacturer only
3 - Needle bearing
2:57:57 AM Page 149

 For drive pinion in torsen differential

 Pulling out Pulling out needle bearing
 Pressing in Needle bearing, pressing in
Pressing off grooved ball bearing from Torsen differential
Fig. 193: Pressing Off Grooved Ball Bearing From Torsen Differential
A - Separating device 22 to 115 mm , e.g. Kukko 17/2
Pressing grooved ball bearing onto Torsen differential
Fig. 194: Pressing Grooved Ball Bearing Onto Torsen Differential

Pulling out needle bearing
2:57:57 AM Page 150

Fig. 195: Pulling Out Needle Bearing

 Remove needle bearing - C - for drive pinion mounting in torsen differential.
Needle bearing, pressing in
Fig. 196: Needle Bearing, Pressing In

 Press needle bearing in flush up to thrust piece VW 432 stop.
39 - FRONT FINAL DRIVE, DIFFERENTIAL

FLANGE SHAFT SEALS, REPLACING
Replacing left and right flange shaft sealing ring with transmission installed --> 39 FINAL DRIVE,
DIFFERENTIAL .
2:57:57 AM Page 151

Replacing left and right flange shaft sealing ring with transmission removed --> Differential, removing and
installing.
DIFFERENTIAL, REMOVING AND INSTALLING
Fig. 197: Identifying Special Tools - Differential, Removing And Installing

 Drift VW 295
 Driver 2062
 Puller T10037
2:57:57 AM Page 152

NOTE:  Removal and installation is also possible with transmission installed.

 Differential can be removed and installed without removing shifter, input
shaft, drive pinion/hollow shaft and transmission cover. The removal of
the above-mentioned parts is necessary when the differential must be
adjusted.
Fig. 198: Differential, Removing And Installing Overview

2 - Seal
2:57:57 AM Page 153

 Removing Flange shaft sealing ring, removing

 Installing left Left flange shaft sealing ring, installing
 Installing right Right flange shaft sealing ring, installing
3 - Circlip
 Replace
 Removing and installing Removing and installing securing ring
4 - Flange shaft
 Removing left Left flange shaft, removing

 Removing right Removing flange shaft (right side)
 Driving in using drift VW 295
5 - Differential with ring gear 1)
 Disassembling and assembling --> Differential, disassembling and assembling
6 - O-ring
 Always replace
7 - Final drive cover 1)
8 - Torx bolt, 24 Nm
Left flange shaft, removing
Fig. 199: Left Flange Shaft, Removing

2:57:57 AM Page 154

 Remove left flange shaft by fastening puller T10037 to final drive cover - arrow -.
Removing flange shaft (right side)
Fig. 200: Removing Flange Shaft (Right Side)

 Remove right flange shaft by fastening puller T10037 to transmission housing - arrow -.
Removing and installing securing ring

 Clamp flange shaft in vise, using jaw protectors. Press previous circlip out of flange shaft grooved with
new circlip - A -.
Flange shaft sealing ring, removing
2:57:57 AM Page 155

Fig. 202: Flange Shaft Sealing Ring, Removing

 Pry out flange shaft seal using a lever.
Left flange shaft sealing ring, installing
Fig. 203: Left Flange Shaft Sealing Ring, Installing


 Drive in new flange shaft sealing ring with drift 2062 without tilting seal.
 Drive-in depth: 5.65 ± 0.15 mm under surface of cover.
Right flange shaft sealing ring, installing
2:57:57 AM Page 156

Fig. 204: Right Flange Shaft Sealing Ring, Installing


 Drive in new flange shaft sealing ring with drift 2062 without tilting seal.
 Drive-in depth: 5.65 ± 0.15 mm below housing surface.
DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
Differential, disassembling and assembling
2:57:57 AM Page 157

Fig. 205: Identifying Special Tools - Differential, Disassembling And Assembling (1 Of 3)

 Drift VW 295
 Punch VW 408 A
 Punch VW 411
 Punch VW 412
2:57:57 AM Page 158


 Thrust pad VW 447 H

 Thrust shell for drive pinion bearing VW 470
 Sleeve 30 - 14
 Press tube 30 - 23
 Sleeve 40 - 103
2:57:57 AM Page 159



Differential, removing and installing --> Differential, removing and installing.
NOTE:  Always replace both taper roller bearings together as a set.

2:57:57 AM Page 160

Fig. 208: Exploded View Of Differential, Disassembling And Assembling

 Note thickness
3 - Outer race for right tapered roller bearing 1)
 Pulling out Pulling outer race for right tapered roller bearing out of transmission housing
 Driving in Right tapered roller bearing outer race, driving into transmission housing
2:57:57 AM Page 161

4 - Inner race for right tapered roller bearing 1)
 Pulling off Tapered roller bearing inner races, removing

 Pressing on Pressing off left and right tapered roller bearing inner race
5 - Ring gear 1)
 Mated with drive pinion (final drive set)

 Press off of housing using drift Driving ring gear from housing
 Install on differential housing --> Heat Ring Gear To Approx. 100°C And Install
6 - Differential housing 1)
7 - Bolt, 60 Nm plus an additional 45°turn
 Always replace
 Lightly fasten bolts, then tighten in a diagonal sequence to torque specification
8 - Inner race for left tapered roller bearing 1)
 Pulling off Tapered roller bearing inner races, removing

 Pressing on Pressing off left and right tapered roller bearing inner race
9 - Outer race for left tapered roller bearing 1)
 Pulling out Left tapered roller bearing outer race, removing from final drive cover
 Pressing in Left tapered roller bearing outer race, pressing into final drive cover
 Note thickness
 With O-ring
12 - Thrust washer union
 Install coated with gear oil
13 - Large differential bevel gear
2:57:57 AM Page 162

 Installing Differential planetary gears, installing
14 - Axle for differential bevel gears
 Drive out with drift after removing spring pin
15 - Roll pin
 For securing axle for differential bevel gears

 Sheared off at removal Differential planetary gear axle, removing
 Drive in flush
16 - Small differential bevel gear
 Installing Differential planetary gears, installing
Pulling outer race for right tapered roller bearing out of transmission housing
Fig. 209: Pulling Outer For Right Tapered Roller Bearing Out Of Transmission Housing
 After removing, check shims for damage.
Right tapered roller bearing outer race, driving into transmission housing
2:57:57 AM Page 163

Fig. 210: Driving Outer Race For Right Tapered Roller Bearing Together With Shim Into Differential
Housing
Tapered roller bearing inner races, removing
Fig. 211: Tapered Roller Bearing Inner Races, Removing

 Before installing puller, set thrust pad VW 447 H onto differential housing.
NOTE:  Removing differential left and right tapered roller bearing inner race is
identical.
Pressing off left and right tapered roller bearing inner race
2:57:57 AM Page 164

Fig. 212: Pressing Off Left And Right Tapered Roller Bearing Inner Race
NOTE:  Left and right tapered roller bearing inner races are pressed off with the
same tools.
 Heat inner race to approx. 100°C, fit in position and press in.
Left tapered roller bearing outer race, removing from final drive cover
Fig. 213: Left Tapered Roller Bearing Outer Race, Removing From Final Drive Cover
2:57:57 AM Page 165

Left tapered roller bearing outer race, pressing into final drive cover
Fig. 214: Pressing Tapered Roller Bearing Outer Race (Left-Side) Into Cover For Final Drive
Driving ring gear from housing
Fig. 215: Driving Out Ring Gear From Housing

Heat ring gear to approx. 100°C and install
2:57:57 AM Page 166

Fig. 216: Installing Ring Gear

 When installing ring gear, guide with centering pins - A - (self-made).
 Before installing new screws, allow to cool off somewhat. Then tighten to specified torque.
Differential planetary gear axle, removing
Fig. 217: Differential Planetary Gear Axle, Removing

Spring pin is sheared off when pressing out.
2:57:57 AM Page 167

 Drive remaining spring pin parts out of differential housing and differential planetary gear axle.
Differential planetary gears, installing
Fig. 218: Installing Small Differential Bevel Gears

 Insert thrust washer union with transmission fluid.

 Insert large differential planetary gears.
 Install small differential bevel gears at 180° from their final position and rotate into place - arrow -.
 Align holes of thrust washer union, small planetary gears and differential housing.
 Drive axle for differential bevel gears into final position and secure.
PINION AND RING GEAR, ADJUSTING
Pinion and ring gear, adjusting
NOTE:  Careful adjustment of pinion and ring gear is important for service life and
smooth running of final drive. For this reason, the drive pinion and ring
gear are matched together during manufacture, and checked to ensure a
good mesh pattern and quiet running in both directions of rotation. The
location for the smoothest running is determined by moving drive pinion
axially whereby ring gear is moved far enough out of the backlash-free
position so that the backlash is within specified tolerances.
 The object of the adjustment is to reproduce the setting for quietest
possible running, as obtained on the test machine in production.
 The final drive set (drive pinion and ring gear) may only be replaced
together as a matched pair.
 Observe the general repair instructions for bearings and shims.
 If gear set is replaced, then always replace double angular contact ball
bearing on drive pinion with it.
2:57:57 AM Page 168

Gear sets, adjustments and markings
There are 2 versions of gear seat adjustments and markings.
1. Gear seats where dimension E is indicated on outer circumference of ring gear.

2. Gear seats where dimension e is indicated on outer circumference of ring gear.
Adjustment and marking gear set, dimension "E" indicated
NOTE:  Dimension - E - is the length for this gear seat that must be adjusted on
the master gauge VW 385/30.
Fig. 219: Adjustment And Marking Gear Set, Dimension "E" Indicated
1 - Pairing number "197" for gearing set
2:57:57 AM Page 169

2 - Dimension "A1" is dimension between ring gear axle and rear side of pinion face. This dimension is needed
for shim " S 5 " and positioning of inner race/tapered roller bearing --> Shim " S 5 " for positioning inner
race/tapered ball bearing, redetermining.
3 - Dimension "A2" is not needed for adjusting gear set.
4 - Dimension "E" is the actual dimension between ring gear axle and drive pinion facing side in position of
quietest running for this gear set; dimension "E" in this example = 62.50 mm. Dimension "E" is adjusted on the
master gauge VW 385/30.
5 - Dimension "F" is not needed for adjusting gear set.
Vo - Hypoid offset
Adjustment and marking gear set, dimension "e" indicated
NOTE:  That length that must be adjusted on the master gauge VW 385/30 is
always 62.17 mm (= Eo - dimension) with this gear set
2:57:58 AM Page 170

Fig. 220: Adjustment And Marking Gear Set, Dimension "E" Indicated
1 - Pairing number "1211" for gearing set
2 - Dimension "A1" is the dimension between ring gear axle and rear side of pinion face. This dimension is
needed for the shim " S 5 " and positioning of inner race/tapered roller bearing --> Shim " S 5 " for positioning
inner race/tapered ball bearing, redetermining.
3 - Dimension "e" is based on the master gauge used on the test bench during production. Dimension "e" is
always given in 1/100 mm. Example: "33" means "e" = 0.33 mm
4 - Dimension "F" is not always present, is not needed for adjusting gear set
Eo - Length of master gauge used on the test bench; dimension "Eo" = 62.17 mm.
2:57:58 AM Page 171

E - Actual dimension between ring gear axis and face of drive pinion in position of quietest running for this gear
set.
Vo - Hypoid offset
Location of shims
NOTE:  Adjustment overview when replacing individual components of differential

--> Adjustment overview.
Fig. 221: Location Of Shims

S1 - Ring gear adjustment shim in final drive cover
S2 - Shim for ring gear in transmission housing
2:57:58 AM Page 172

S3 - Shim for positioning drive pinion in transmission housing
S4 - Shim for pre-load of double angular contact ball bearing on drive pinion
S5 - Shim for positioning inner race/tapered roller bearing on drive pinion
 Shim, determining --> Shim " S 5 " for positioning inner race/tapered ball bearing, redetermining.
Adjustment overview
NOTE:  When working on transmission, drive pinion, ring gear or gear set only
need to be replaced if components were replaced which directly influence
the final drive.
 No adjustment is needed when replacing drive pinion double angular
contact ball bearing.
 Refer to the following table to avoid unnecessary adjustments:
To be adjusted: Pinion Ring gear Torsional backlash

(" S 3 " + " S 4 ") (" S 1 " + " S 2 ") 0,12 - 0,22
--> Pinion, adjusting --> Ring gear, adjusting
Replaced component
Transmission housing X X X
Differential housing X X
Taper roller bearing for X X
differential
Gear set * See note X X X
Cover for final drive X X
*Drive pinion and ring gear; only replace together.
Recommended sequence for adjusting gear set
2:57:58 AM Page 173

Fig. 222: Recommended Sequence For Adjusting Gear Set

If drive pinion and gear ring have to be adjusted, the following sequence is recommended for maximum
efficiency:
 Determine shim " S 3 " so that the dimension from center of ring gear to facing drive of drive pinion
corresponds to the installation dimension determined during production.
 Determine shim " S 4 " for double angular contact ball bearing preload.
 Total shim thickness " S total " Determine (S 1 plus S 2 ) for specified preload of tapered roller
bearing/differential.
 Total shim thickness " S total " Distribute (S 1 plus S 2 ) so that the specified torsional backlash is present
between ring gear and drive pinion.
Pinion, adjusting
Procedures after which the drive pinion must be adjusted --> Adjustment overview.
There are 2 procedures when adjusting drive pinions.
1. Adjusting gear seats where dimension E is indicated on the outer circumference of ring gear.
2. Adjusting gear seats where dimension e is indicated on outer circumference of ring gear.
Adjusting gear seats where dimension "E" is indicated on outer circumference of ring gear
2:57:58 AM Page 174




 Dial gauge
Determine thickness of previous shim " S 3 " and " S 4 "
 Differential removed.
 Double angular contact ball bearing is pressed onto drive pinion.
NOTE:  For the initial measurement, an adjustment shim " S 3 " of 1.00 mm is
inserted. It is designated as " S 3 * " in the following. After adjusting
dimension "E" , " S 3 * " is replaced by the final shim " S 3 ".
2:57:58 AM Page 175

 Secure transmission housing to transmission mounting VW 353. To do so, transmission housing must be
vertical.
 Place shim " S 3 * " in transmission housing.

 Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
area, if necessary.
Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, seal - 6 - can be
damaged by pinion face - 5 -.
If double angular contact ball bearing seal is damaged, the bearing must be replaced.
Determine previous shim " S 4 " as follows:
2:57:58 AM Page 176

Fig. 226: Using Digital Depth Gauge To Measure From Outer Race/Double Angular Contact Ball
Bearing To Retaining Plate Bolting Surface
 Using a digital depth gauge (e.g Digital Depth Gauge VAS 6087), measure from outer race/double
angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.
In the example, gap dimension - a - = 1.14 mm. Determine previous shim " S 4 " according to --> Available
adjustment shims for " S 4 ".
dimension "E" , " S 4 * " is replaced by the final shim " S 4 ".

 Place previous shim " S 4 * " (0.95 mm in example) and retaining plate - A - (only fits in one position) on
transmission housing bolting surface.
 Clean threads of previous screws - arrows - with a wire brush. Then tighten screws diagonally to 30 Nm.
2:57:58 AM Page 177

Dimension "E" , adjusting
NOTE:  Dimension "E" must be adjusted at master gauge VW 385/30 to determine

final shim thickness of " S 3 " and " S 4 ".

Fig. 229: Assembling Universal Mandrel VW 385/1

 Assemble universal mandrel VW 385/1 as shown in the illustration:
 Dial gauge extension VW 385/16 , 12.3 mm long
 Set master gauge VW 385/30 to dimension "E" in example = 62.50 mm and place on universal mandrel
VW 385/1.
2:57:58 AM Page 178

 Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.
Fig. 230: Placing Magnetic Plate VW 385/33 Onto Head Of Drive Pinion
 Place magnetic plate VW 385/33 onto head of drive pinion.
NOTE:  Make sure magnetic plate VW 385/33 is precisely installed and free of oil.
Fig. 231: Removing Master Gauge VW 385/30 And Inserting Universal Mandrel In Transmission
Housing
 Remove master gauge VW 385/30 and insert universal mandrel in transmission housing.
 A dial gauge extension - A - = 12.3 mm long must be screwed in.
2:57:58 AM Page 179

 Dial gauge faces final drive cover.

 O-ring is inserted in final drive cover.
 Install final drive cover and tighten 4 bolts to 24 Nm.

 Using adjustable ring, pull 2nd centering disc VW 385/36 out far enough, so that the universal mandrel
can only just be turned by hand.
Fig. 232: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion
Shaft Head And Measure Maximum Runout
 Turn universal mandrel until dial gauge tip touches magnetic plate on head of pinion and indicates max.
runout (return point).
 Measured value in following example: = 0.15 mm (red number range)
NOTE:  After removing universal mandrel - check again whether dial gauge stands
at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is
attached.
 If measured in red numbered area, measured value must be subtracted.

 If measured in black numbered area, measured value must be added.
Example:
Inserted shim " S 3 * " 1.00 mm
- Value determined (red number 0.15 mm
range)
= Thickness of adjustment shim " S 0.85 mm
3"
2:57:58 AM Page 180

Available adjustment shims for " S 3 "
Shim thickness (mm) * See note

0.55 0.75 0.95
0.60 0.80 1.00
0.65 0.85 1.05
0.70 0.90
 Remove previous shims " S 3 * " and " S 4 * ".

 Insert determined shim " S 3 " , 0.85 mm in example, in transmission housing.
 Determined shim " S 3 " is installed in transmission housing.

2:57:58 AM Page 181

area, if necessary.
Determine shim " S 4 " as follows:
In the example, gap dimension - a - = 0.99 mm. Determine shim " S 4 " according to --> Available adjustment
shims for " S 4 ".

Gap dimension - a - Adjustment shim " S 4 " * See note
0.67 to 0.71 0.72 to 0.76 0.77 to 0.81 0.50 0.55 0.60
0.82 to 0.86 0.87 to 0.91 0.92 to 0.96 0.65 0.70 0.75
0.97 to 1.01 1.02 to 1.06 1.07 to 1.11 0.80 0.85 0.90
1.12 to 1.16 1.17 to 1.21 1.22 to 1.26 0.95 1.00 1.05
1.27 to 1.31 1.32 to 1.36 1.37 to 1.41 1.10 1.15 1.20
1.42 to 1.46 1.47 to 1.51 1.52 to 1.56 1.25 1.30 1.35
1.57 to 1.61 1.40
2:57:58 AM Page 182

NOTE:

 Place determined shim " S 4 " (0.80 mm in example) and retaining plate - A
- (only fits in one position) on transmission housing bolting surface.
 Then tighten bolts - arrows - diagonally to 30 Nm.
Performing measuring check, checking dimension "E"
 Install drive pinion with measured adjustment shims " S 3 " and " S 4 ".
 Install universal mandrel and perform measurement check.

 Read dial indicator counterclockwise (red numbered area).
 If adjustment shims were determined correctly, dimension "E" must have a clearance of ± 0.04 mm.
2:57:58 AM Page 183


attached.
Adjusting gear seats where dimension "e" is indicated on outer circumference of ring gear



 Dial gauge
Determining thickness of previous shims " S 3 " and " S 4 "
2:57:58 AM Page 184

 Double angular contact ball bearing is pressed onto drive pinion.
dimension "e" , " S 3 * " is replaced by the final shim " S 3 ".
 Secure transmission housing to transmission mounting VW 353. To do so, transmission housing must be
vertical.
 Place shim " S 3 * " in transmission housing.

area, if necessary.
2:57:58 AM Page 185

Determine previous shim " S 4 " as follows:
In the example, gap dimension - a - = 1.14 mm. Determine previous shim " S 4 " according to --> Available
adjustment shims for " S 4 ".
dimension "e" , " S 4 * " is replaced by the final shim " S 4 ".

 Place previous shim " S 4 * " (0.95 mm in example) and retaining plate - A - (only fits in one position) on
transmission housing bolting surface.
2:57:58 AM Page 186

 Clean threads of previous bolts - arrows - with a wire brush. Then tighten bolts diagonally to 30 Nm.
Dimension "e" , adjusting
NOTE:  Dimension "e" must be adjusted to determine final shim thickness of " S 3
" and " S 4 " for this gear set.

Fig. 243: Assembling Universal Mandrel VW 385/1

 Assemble universal mandrel VW 385/1 as shown in illustration:
 Dial gauge extension VW 385/16 , 12.3 mm long
2:57:58 AM Page 187

 Set master gauge VW 385/30 to dimension "Eo" = 62.50 mm and place on universal mandrel VW 385/1.
 Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.
Fig. 244: Placing Magnetic Plate VW 385/33 Onto Head Of Drive Pinion
 Place magnetic plate VW 385/33 onto head of drive pinion.
NOTE:  Make sure magnetic plate VW 385/33 is precisely installed and free of oil.
Fig. 245: Removing Master Gauge VW 385/30 And Inserting Universal Mandrel In Transmission
Housing
 Remove master gauge VW 385/30 and insert universal mandrel in transmission housing.
2:57:58 AM Page 188

 A dial gauge extension - A - = 12.3 mm long must be screwed in.

 Dial gauge faces final drive cover.

 Using adjustable ring, pull 2nd centering disc VW 385/36 out far enough, so that the universal mandrel
can only just be turned by hand.
 Turn universal mandrel until dial gauge tip touches magnetic plate on head of pinion and indicates max.
runout (return point).
 Measured value in following example: = 0.43 mm (red number range)
attached.
 Dimension "e" which is based on the master gauge "Eo" is measured for the final drive sets supplied as
replacement parts and marked on outer circumference of ring gear.
 If measured in red numbered area, measured value must be subtracted.
 If measured in black numbered area, measured value must be added.
Formula:
" S 3 " = " S 3 * " + "e" + "measured value" ("measured value" in black numbered area)
2:57:58 AM Page 189

" S 3 " = " S 3 * " + "e" - "measured value" ("measured value" in red numbered area)
Example:
Inserted shim " S 3 * " 1.00 mm
+ Dimension "e" 0.33 mm
- Determined value (red numbered 0.43 mm
area)
3"

0.55 0.75 0.95
0.60 0.80 1.00
0.65 0.85 1.05
0.70 0.90
 Remove previous shims " S 3 * " and " S 4 * ".

 Insert determined shim " S 3 " , 0.90 mm in example, in transmission housing.
 Determined shim " S 3 " is installed in transmission housing.
2:57:58 AM Page 190


area, if necessary.
Determine shim " S 4 " as follows:
2:57:58 AM Page 191

In the example, gap dimension - a - = 1.04 mm. Determine shim " S 4 " according to --> Available adjustment
shims for " S 4 ".

Gap dimension - a - Adjustment shim " S 4 " * See note
0.67 to 0.71 0.72 to 0.76 0.77 0.81 0.50 0.55 0.60
0.82 to 0.86 0.87 to 0.91 0.92 to 0.96 0.65 0.70 0.75
0.97 to 1.01 1.02 to 1.06 1.07 to 1.11 0.80 0.85 0.90
1.12 to 1.16 1.17 to 1.21 1.22 to 1.26 0.95 1.00 1.05
1.27 to 1.31 1.32 to 1.36 1.37 to 1.41 1.10 1.15 1.20
1.42 to 1.46 1.47 to 1.51 1.52 to 1.56 1.25 1.30 1.35
1.57 to 1.61 1.40
NOTE:
2:57:58 AM Page 192


 Place determined shim " S 4 " (0.85 mm in example) and retaining plate - A
- (only fits in one position) on transmission housing bolting surface.
 Then tighten screws - arrows - diagonally to 30 Nm.
Performing measuring check, checking dimension "E"
 Install drive pinion with measured adjustment shims " S 3 " and " S 4 ".
 Install universal mandrel and perform measurement check.

 Read dial indicator counterclockwise (red numbered area).
 If shims have been determined correctly, deviation "e" (as marked on outer circumference of ring gear)
should be indicated on dial within a tolerance of ± 0.04 mm.
NOTE:
2:57:58 AM Page 193

 After removing universal mandrel - check again whether dial gauge stands
attached.
Ring gear, adjusting
(Adjusting differential)
Fig. 251: Identifying Special Tools - Ring Gear, Adjusting (1 Of 2)

 Drift VW 295
 Dial gauge extension VW 382/10
2:57:58 AM Page 194

 Magnetic plate VW 385/17

 Dial gauge holder VW 387
 Measuring lever, adjustable VW 388

Fig. 252: Identifying Special Tools - Ring Gear, Adjusting (2 Of 2)

 Punch VW 408 A
 Ring gear adjustment device VW 521
 Sleeve 30 - 14
2:57:58 AM Page 195


 Dial gauge
 Dial gauge extension 30 mm
A new ring gear adjustment is required when the following components have been replaced:
Transmission housing, final drive cover, differential tapered roller bearings, differential housing or the
gear set
Adjustment overview --> Adjustment overview
Determine total shim thickness " S total " for adjustment shims " S 1 " + " S 2 "
(Setting preload of taper roller bearing for differential)
 Drive pinion removed.

 If only the tapered roller bearing for differential has been replaced, ring gear can be removed from
differential housing. Drive pinion then does not need to be removed.
 Remove flange shaft sealing rings.

 Remove outer races/tapered roller bearings for differential and remove adjustment shims --> Differential,
disassembling and assembling.
Fig. 253: Driving Outer Race For Right Tapered Roller Bearing Together With Shim Into Differential
Housing
 Drive outer race for right tapered roller bearing together with shim " S 2 " into differential housing. Use a
shim " S 2 * " with a 1.30 mm thickness for measurement purposes (2 shims with 0.65 mm).
NOTE:  For the initial measurement, an adjustment shim " S 2 " with a thickness of
1.30 mm is inserted. It is designated as " S 2 * " in the following. After
2:57:58 AM Page 196

determining backlash, " S 2 * " is replaced by final " S 2 ".
 Pressing outer race for tapered roller bearing without shim " S 1 " into final drive cover.
 Insert differential into transmission housing. Ring gear is located on left side in front of final drive cover.
 Install final drive cover with 4 screws (24 Nm).

 Turn transmission so that final drive cover faces upward.
 Turn differential 5 turns in both directions so that the taper roller bearings settle.
 Place magnetic plate VW 385/17 on differential.
2:57:58 AM Page 197

Fig. 255: Installing Magnetic Plate 50mm Dia. VW 385/17 And Dial Gauge
 Assemble measuring tool, use 30 mm dial gauge extension.

 Set gauge (3 mm measuring range) - A - to "0" with 2 mm pre-load.
NOTE:  Tip of dial indicator must be positioned on the center of the differential.
 Lift differential without turning it, read backlash on dial indicator and note.
 Measured value in following example: 0.62 mm
Fig. 256: Securing Special Tools VW 521/4 And VW 521/8 At Right On Differential (Housing Side)
NOTE:  To raise differential, secure special tools VW 521/4 and VW 521/8 at right
on differential (housing side).
 If measurement is repeated, differential must first be rotated 5 complete
revolutions in both directions again to seat tapered roller bearing.
Formula: " S total " = " S 2 * " + measured value + bearing preload
Example:
Inserted shim(s) " S 2 * " 1.30 mm
+ Measured value 0.62 mm
+ Bearing preload (constant) 0.30 mm
= Total shim thickness " S total " for 2.22 mm
"S1"+"S2"
Determining thickness of adjustment shim " S 1 * "
2:57:58 AM Page 198

NOTE:  Initial shim " S 1 * " is replaced with final shim " S 1 " after backlash has
been determined.
 The total shim thickness " S total " remains unchanged.
Formula: " S 1 * " = " S total " - " S 2 * "
Example:
Total shim thickness " S total " for 2.22 mm
"S1"+"S2"
- Inserted shim(s) " S 2 * " 1.30 mm
1*"
Torsional backlash, measuring
 Drive shaft installed with shims " S 3 " and " S 4 ".
 Install differential with ring gear: " S 1 " is on cover side, " S 2 " is installed in transmission housing.
 Install cover for final drive and tighten bolts to 24 Nm.
 Insert locking sleeve VW 521/4 and VW 521/8.
Fig. 257: Securing Dial Gauge Holder VW 387 To Transmission Housing

 Secure dial gauge holder VW 387 to transmission housing.

 Insert dial gauge with extension pin VW 382/10 (6 mm).
 Set measuring lever VW 388 to dimension "a" = 75 mm (for ring gear dia. 186 mm).
2:57:58 AM Page 199

 Determine play between teeth flanks as follows:
 Turn ring gear until it makes contact with a tooth flank (end of backlash travel).
 Set dial gauge to "0" with 2 mm pre-load.
 Turn ring gear back until lying against an opposite tooth flank (backlash).
 Read off backlash and note measured value.
 Turn ring through 90° and repeat measurements 3 times.
NOTE:  If drive pinion - 1 - turns when measuring, counter hold drive pinion so
that an exact torsional backlash can be measured.
Determining average backlash
 Add four measured values together and divide total by 4 to determine average.
Example:
1st measured value 0.28 mm
+ 2nd measured value 0.30 mm
+ 3rd measured value 0.30 mm
+ 4th measured value 0.28 mm
= Total of measurements 1.16 mm
 Result: Average backlash is 1.16: 4 = 0.29 mm
NOTE:  If measurements vary more than 0.06 mm from each other, ring gear or
gear set is not installed correctly. Check installation, replace final drive set
if necessary.
Formula: " S 2 " = " S 2 * " - measured torsional backlash + specified torsional backlash
Example:
Inserted adjustment shim " S 2 * " 1.30 mm
- Measured torsional backlash 0.29 mm
+ Specified torsional backlash 0.15 mm
2"
2:57:58 AM Page 200


0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
Formula: " S 1 " = " S total " - " S 2 "
Example:
Total shim thickness " S total " for 2.22 mm
"S1"+"S2"
- Thickness of adjustment shim " S 1.16 mm
2"
1"

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
2:57:59 AM Page 201

Fig. 258: Securing Dial Gauge Holder VW 387 To Transmission Housing

Measurement check
 After installing adjustment shims " S 1 " and " S 2 " , rotate differential 5 rotations in both directions so
that tapered roller bearings settle.
 Measure backlash four times on circumference.
 Specified value: 0.12 to 0.22 mm
NOTE:  If drive pinion - 1 - turns when measuring, counter hold drive pinion so
that an exact torsional backlash can be measured.
 If backlash is outside tolerance, repeat adjustments. Do not change total
shim thickness " S total " while doing so.
 The individual measurement values can deviate a maximum of 0.06 mm
from each other
2:57:59 AM Page 202


FINAL DRIVE, SERVICING
Fig. 247: Identifying Special Tools - Left Flange Shaft Oil Seal, Replacing
 Drift VW 295
 Drift 2062
 Puller T10037
2:56:57 AM
2:57:00 Page 1


Removing

 Remove front left wheel.


 Disconnect drive shaft - 1 - from flange shaft and tie up as far as possible to the front, taking care not to
damage surface coating.
2:56:57 AM Page 2
Fig. 250: Removing Flange Shaft (Left-Side)


Installing
2:56:57 AM Page 3

flange shaft.
 Drive new oil seal for flange shaft in to a depth of 5.65 ± 0.15 mm below outer surface of cover, making
sure you keep seal straight.
2:56:57 AM Page 4

Tightening torque
Component Nm
Right flange shaft oil seal, replacing
Fig. 254: Identifying Special Tools - Right Flange Shaft Oil Seal, Replacing
2:56:57 AM Page 5
 Drift VW 295
 Drift 2062
 Puller T10037

Removing

 Loosen bolt for right-side drive shaft/wheel hub.

 Remove front right wheel.

2:56:57 AM Page 6

 Remove heat shield - arrows - for drive shaft (right-side).

 Remove drive shaft (right-side) --> 40 - FRONT SUSPENSION .
Fig. 257: Removing Flange Shaft (Right-Side)

 Remove flange shaft (right-side); to do so, secure puller T10037 to transmission housing - arrow -.
2:56:57 AM Page 7

Installing

flange shaft.
2:56:57 AM Page 8
Fig. 260: Driving New Oil Seal For Flange Shaft In Below Outer Surface Of Housing
 Drive new oil seal for flange shaft in to a depth of 5.65 ± 0.15 mm below outer surface of housing,
making sure you keep seal straight.

Tightening torque
Component Nm
2:56:57 AM Page 9
TRANSMISSION
5 Spd. Manual Transmission 01A All Wheel Drive
00 GENERAL, TECHNICAL DATA

Manual transmission 01A all wheel drive is a 5-speed transmission installed in connection with the 4-cylinder
turbo engines and the 6-cylinder injection engines in the Audi A4 from 2002.

Manual transmission 01A (arrow 2)
code letters (arrow 3)
2:20:21 AM
2:20:45 Page 1
Fig. 2: Manual transmission 01A All Wheel Drive

Manual transmission 01A (arrow 2)
Fig. 3: Code Letters And Date Of Manufacture Of Transmission

Code letters and date of manufacture of transmission (arrow 1)
Example: FNU 18 11 0
I I I I
I I I I
Code Day Month Year (2000)
letters of production
Additional data depend on manufacture.
NOTE: Additionally, the code letters of the transmission are embossed on the
underside of the transmission cover and listed in the data carriers of the
vehicle.
Code letters, assignment of mechanical units, transmission ratios and capacities
Manual transmission 5-speed 01A all wheel drive

Code letters FJV FNU
to
Assignment Type Audi A4 from 2002 Audi A4 from 2002
Engine 3.0 l - 162 kW 1.8 l - 110 kW
1.8 l - 125 kW 1)
Transmission ratio: Z2 : Final drive 35 : 9 = 3.889 35 : 9 = 3.889
Z1
2:20:21 AM Page 2
1st gear 35 : 10 = 3.500 34 : 9 = 3.778

2nd gear 35 : 18 = 1.944 37 : 17 = 2.176
3rd gear 34 : 25 = 1.360 40 : 28 = 1.429
4th gear 30 : 29 = 1.034 36 : 33 = 1.091
5th gear 27 : 32 = 0.844 32 : 36 = 0.889
6th gear - -
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444
Speedometer Electronic Electronic
Code letters FJV FNU

Capacity 2.75 liters
Specification Gear oil G 052 911 A 1 SAE 75 W 90 (synthetic oil)
Clutch mechanism Hydraulic Hydraulic
Clutch plate diameter 240 mm 228 mm
Drive axle flange diameter 75.5 mm 100 mm
i total in top gear 3.281 3.457
Rear final drive assignment ETS ETT
Code letters
REAR FINAL DRIVE, IDENTIFICATION
Rear final drive, identification
The final drive 01R is assigned to the manual transmission 01A all wheel drive.
Assignment of mechanical units
Refer to 00 GENERAL, TECHNICAL DATA

2:20:21 AM Page 3
Final drive 01R (arrow 2)

Fig. 6: Code Letters And Date Of Manufacture Of Final Drive

Code letters and date of manufacture of final drive
Example: ETS 26 04 00
I I I I
I I I I
Code Day Month Year (2000)
letters of production
Additional data depend on manufacture.
Code letters, transmission ratios, capacities
2:20:21 AM Page 4
Refer to 00 GENERAL, TECHNICAL DATA
TRANSMISSION LAYOUT
Transmission layout
Fig. 7: Power Transfer, Overview

1 - Engine
2 - Clutch
2:20:21 AM Page 5
5 - Front pinion (output shaft)
6 - Hollow shaft
9 - Drive shaft
10 - Rear pinion
Fig. 8: Power Transfer, Overview

2:20:21 AM Page 6
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
T - Speedometer drive
NOTE: Arrows point in direction of travel.
CALCULATIONS
Calculation of transmission ratios "i"
Transmission ratio
Transmission ratio = No. of teeth on driven gear : No. of teeth on driving gear
Transmission ratios Formula

iG = gear ratio ZG2 : ZG1
iA = final drive ratio ZA2 : ZA1
i total = overall gear ratio iG x iA
Example:
Driving gear ZG1 = 36 ZA1 = 9
Calculations:
iG = 32 : 36 = 0.889
iA = 35 : 9 = 3.889
i total = 0.889 x 3.889 = 3.457
GENERAL REPAIR INSTRUCTIONS
2:20:21 AM Page 7
transmission repairs. The usual basic safety precautions naturally also apply when carrying out vehicle repairs.
A number of general instructions for individual repair procedures - otherwise listed several times in many
places in the article - are grouped together in the following paragraphs and apply to this article.
Transmission
 When replacing manual transmission, check oil level and top up as necessary. Refer to Transmission oil
level, checking.
 Capacities and specifications. Refer to Code letters, assignment of mechanical units, transmission
ratios and capacities onward
 When replacing rear final drive, check and adjust oil level in rear final drive as necessary:
Refer to 39 FINAL DRIVE, DIFFERENTIAL

 When installing transmission ensure proper seating of the dowel sleeves.
 Always replace O-rings, oil seals and gaskets.

 After removing gaskets, examine contact surface on housing/shaft for burrs resulting from removal or for
 Carefully clean sealing surfaces of housing before assembly.

 Before installing radial shaft oil seals, lubricate outer diameter slightly and half fill space between sealing
lips (arrow) with sealing grease G 052 128 A1.
 Open side of oil seal faces fluid.
2:20:21 AM Page 8
 Press in new oil seal such that sealing lip is not at same location as sealing lip of old oil seal (make use of
insertion depth tolerance).
 Lubricate O-rings slightly beforehand to prevent their being pinched on assembly.
 Check oil level after replacing gaskets and oil seals. Refer to Transmission oil level, checking.
Sealant
 Carefully clean sealing surfaces of housing before applying sealing paste.

 Apply sealing paste AMV 188 001 02 evenly and not too thickly.
 Sealing paste must not enter vent holes.
Locking elements
 Take care not to overstretch circlips.

 Always replace damaged or overstretched circlips.
 Circlips must be properly positioned in groove.

 Replace spring pins. Installation position: Slot -A- in line with direction of force (arrow).
Nuts and bolts
 Remove nuts and bolts in reverse of tightening sequence.

 Loosen and tighten nuts and bolts for securing covers and housings in diagonal sequence.
2:20:21 AM Page 9
 Particularly delicate parts - e.g. clutch pressure plates - must be kept straight and should be loosened off
and tightened gradually in diagonal sequence.
 Tightening torques specified apply to non-lubricated nuts and bolts.
 Always replace self-locking nuts and bolts.

 Clean threads of bolts screwed in with a locking agent with a wire brush. Then install bolts using AMV
185 101 A1.
 Threaded holes which held self-locking bolts or bolts with locking agent need to be cleaned (e.g. using a
thread tap). Otherwise bolts will be at risk of stripping when removed.
Bearings
 Install needle bearings with labelled side (thicker metal) facing installation tool.
 Grease needle bearing for rear transmission input shaft in flywheel.
 Lubricate all bearings for installation in transmission housing with gear oil.
 Heat inner races of tapered roller bearings to approx. 100 ° C before installing. Press home as far as stop
on assembly so that there is no axial clearance.
 Never confuse outer and inner races of bearings of the same size.
 Always replace tapered roller bearings on one shaft together, and use parts from the same manufacturer.
 Tapered roller bearings in the transmission for the output shaft and differential are low-friction. Do not
treat new tapered roller bearings with oil before the friction torque measurement. The bearings have been
treated with a special oil at the factory for this purpose.
Shims
 Perform a dimensional check at several points on shims using a micrometer. Different tolerances make it
possible to obtain the exact shim thickness required.
 Only install undamaged shims in perfect condition.
Gears, synchro-hubs, inner races for sliding gears
 Heat gears and sychro-hubs to approx. 100 ° C before installing. Press home as far as stop on assembly so
that there is no axial clearance.
 Heat inner races for sliding gears to approx. 100 ° C before installing.
 The temperature can be checked using temperature probe V.A.G 1558.
 Note installation position.
Sliding gears
 After installation check sliding gears for 1st to 5th gear and sliding gear for reverse gear for axial
clearance of 0.15 to 0.35 mm and check for ease of movement.
2:20:21 AM Page 10
Synchro-rings
 Do not confuse synchro-rings, assign to the same gear wheel when re-using.
 Check for wear and replace if necessary.
 Apply transmission oil before installing.
Clutch mechanism
 For removal of transmission remove clutch slave cylinder without opening hydraulic circuit.
 If slave cylinder is removed with hydraulic pipe attached, do not depress clutch pedal. Otherwise piston
will be pushed out of slave cylinder.
 Make sure clutch pressure plate is kept straight; loosen and tighten bolts gradually in a diagonal sequence.
 To reduce the odor nuisance of a scorched clutch, thoroughly clean bell housing, flywheel and parts of
engine facing transmission.
30 CLUTCH
CLUTCH MECHANISM COMPONENTS (ON CHASSIS)
Clutch mechanism components (on chassis)


Cabriolet
.

2:20:21 AM Page 11
Cabriolet
.
Clutch mechanism components (on chassis), servicing
II - Exploded view of hydraulic system. Refer to Hydraulic system, component overview
NOTE:  Lubricate all bearing and contact surfaces with polycarbamide grease G
052 142 A 2.
 Remove cover panel under instrument panel before carrying out work on
2:20:21 AM Page 12
pedal cluster:
Refer to
 Make sure brake fluid does not escape into footwell or plenum chamber or
onto transmission below. If it does, clean affected area thoroughly.
fluid spillage.

2:20:21 AM Page 13
2 - Mounting pin for clutch and brake pedal
3 - Locking element
5 - Brake pedal
 Attachment maintenance-free, do not lubricate
2:20:21 AM Page 14

 For securing mounting pin for clutch and brake pedal
8 - Clutch pedal
9 - Locking element
10 - Mount
 Removing and installing. Refer to Hydraulic system, component overview
2:20:21 AM Page 15

 Do not remove gasket (arrow)

 Black side facing clutch pedal

 Assignment
2:20:21 AM Page 16
14 - Clutch pedal starter interlock switch -F194-
 For attaching brake master cylinder/brake booster to mounting bracket

 T40025 Mounting clip
Removing
Refer to
2:20:21 AM Page 17

 Tension over-center spring with clutch pedal and press on mounting clip T40025.
 Move clutch pedal to home position and pull over-center spring together with mounting clip T40025
downward to remove.
Installing

 Install over-center spring with mounting clip T40025, press clutch pedal and remove mounting clip.
Hydraulic system, component overview
2:20:21 AM Page 18

2 - Supply hose
3 - Hose/line assembly
 For push-on connections on master/slave cylinder

 Separating from master cylinder and installing. Refer to Master cylinder, removing and installing
 Separating from slave cylinder. See Separating slave cylinder from hose/pipe assembly
4 - Grommet
2:20:21 AM Page 19
6 - Clutch pedal

7 - Master cylinder

 Do not remove clip (arrow A) or gasket (arrow B)
 To remove hose/pipe assembly pull out clip (arrow A) as far as it will go.
9 - Mount
2:20:21 AM Page 20
 Only replace when master cylinder removed

 Detaching. See Prying off mount
 Pressing on. See Pressing master cylinder operating rod into mount
10 - Transmission

11 - Slave cylinder

 Removing and installing. Refer to Lubricating clutch slave cylinder with grease before installing
 Bleed slave cylinder after working on hydraulic clutch mechanism. Refer to Clutch system, bleeding
 Separate from hose/line assembly. See Separating slave cylinder from hose/pipe assembly
2:20:21 AM Page 21
 Brake fluid must not escape onto transmission
12 - Bleeder valve
 Follow work sequence for bleeding. Refer to Clutch system, bleeding
13 - Dust cap
14 - Clip
 To remove tube pull out clip as far as it will go. Refer to Separating slave cylinder from hose/pipe
assembly.

2:20:21 AM Page 22
15 - Bracket


 Self-locking
 Always replace
17 - Holding clip
18 - Gasket
19 - Bolt
Prying off mount

Pressing master cylinder operating rod into mount
2:20:21 AM Page 23


Removing
To remove the hose/pipe assembly use a screwdriver to pry out clip -A- as far as it will go. Only then can the
Installing

2:20:21 AM Page 24

 3094 Hose clamp

 VAG 1922 Pliers
Removing
 Pull off gasket on plenum chamber in direction of arrow.
2:20:21 AM Page 25

 Remove cover -1- on top of plenum chamber.

 First check if a coded radio is installed. In this case obtain anti-theft code.
See Caution for disconnecting Telematics battery. Refer to Clutch mechanism components (on chassis)

 Pry off two covers -3- with a screwdriver.

 Remove nuts -4- and two wiper arms -2-.
2:20:21 AM Page 26

 Remove bolts (arrows) and take off cover lid.
 Carefully pry off mount bar with screwdriver (arrow).
2:20:21 AM Page 27
 Loosen connector locks (arrows) and unplug connectors -1- and -2- from engine control module.

 Remove connectors -2- from connector strip.

 Disconnect electrical connection -1-.

 Release locks (arrows) and pull auxiliary relay carrier in electronics box upward and off.
 Pull engine wiring harness together with grommet out of recess in electronics box.
2:20:21 AM Page 28

 Remove nuts (arrows) and lift out electronics box -1-.
NOTE:  During the following steps make sure that brake fluid does not escape into
plenum chamber or onto transmission below. If it does, clean affected area
thoroughly.
fluid spillage.

 Disconnect supply hose -A- to brake fluid reservoir with special tool 3094, disconnect from master
cylinder and seal with plug.
 On bulkhead remove grommet above connecting tube for supply hose.
 Pry out securing clip -C- with screwdriver and then pull tube -B- out slightly.
2:20:21 AM Page 29

 Remove bolt for brake fluid reservoir -1- and unplug connector for monitoring fluid level by pulling
downward.
NOTE: Do not remove brake fluid reservoir.
NOTE:  Brake fluid reservoir not shown for purpose of clearer illustration.
 To remove the top TORX bolt; swivel brake fluid reservoir sideways
slightly.

 Remove two TORX bolts (arrows).

 Remove vacuum tube to brake booster -1-.
 Remove driver's storage compartment.
Refer to
2:20:21 AM Page 30

 Separate brake pedal from brake booster.
 Separate steering column from steering box (arrow A).
2:20:21 AM Page 31
 Disconnect connectors from clutch pedal switch -1-, brake pedal switch -2- and accelerator pedal module
-3-.
 Remove bolt for mounting bracket (arrow B) and remove pedal cluster assembly.
 Remove over-center spring. Refer to Over-center spring, removing and installing.
NOTE:
Fig. 40: Pressing Retainer Together And Detaching Clutch Pedal From Master
Cylinder Using VAG 1922
 When releasing make sure clutch pedal does not bounce against clutch
pedal switch mount (arrow). Otherwise the mount might break.
 In order to assure sufficiently secure fitting of clutch pedal switch. Refer to
Pedal cluster, assembly overview Item 6- as well as Clutch pedal starter
interlock switch -F194-. Refer to Pedal cluster, assembly overview Item 14-
in pedal cluster, these switches must not be installed more than once.
 Insert pliers VAG 1922 into recesses in clutch pedal, compress mount (arrows) and separate clutch pedal
from master cylinder.
2:20:22 AM Page 32
 Remove securing clip -1- and clutch pedal -2-.

 Remove bolts -3- and master cylinder -4-.
Installing
Clutch Pedal
 Insert mount -1- in clutch pedal.

 Push clutch pedal in direction of arrow to lock into place, while making sure mount -1- is properly
secured in clutch pedal.
 Installing over-center spring. Refer to Over-center spring, removing and installing.
2:20:22 AM Page 33
For the next step a second technician is required.
 Insert pedal cluster assembly and tighten bolt -1- hand-tight. Simultaneously, second technician feeds
tube from plenum chamber side into master cylinder.

 Tighten brake booster bolts (arrows) to 25 Nm.
2:20:22 AM Page 34

 Push in securing clip -C- as far as it will go.

 Insert tube -B- in master cylinder until it clicks into position.
 Install grommet -D- over connecting tube/supply hose -A- and into bulkhead.
 Push on supply hose -A- to brake fluid reservoir as far as it will go.

 Screw in brake fluid reservoir bolt.
Fig. 47: Locating Connectors

 Tighten hex socket-head bolt (arrow B) which secures pedal cluster to instrument panel carrier to 25 Nm.
 Attach connectors -1-, -2- and -3-.
 Connect brake pedal to brake booster.
 Attach steering column to steering box (arrow A).
2:20:22 AM Page 35
 Install driver's storage compartment:
Refer to

 Insert electronics box and tighten nuts (arrows) to 4 Nm.

 Route engine wiring harness and attach connection in connector station.
 Install engine control module plus auxiliary relay carrier and auxiliary fuse holder, if installed.
Refer to 97 WIRING r.
 Push on cover lid by hand and tighten bolts diagonally - 4 Nm.
See Caution for connecting Telematics battery. Refer to Clutch mechanism components (on chassis)
NOTE: If the battery is reconnected remember to check and activate vehicle equipment
Refer to
2:20:22 AM Page 36
Fig. 49: Identifying Brake Filler And Bleeder Unit V.A.G 1869
 Brake system brake filler and bleeder unit VAS 5234
Brake fluid specification:
NOTE:  Open bleeder valve before switching on bleeding equipment.

 Make sure no brake fluid escapes onto transmission when performing
subsequent work.
 Bleed system after working on hydraulic clutch mechanism.
 Before bleeding the system pull out clutch pedal and fill brake fluid
reservoir with brake fluid up to "max".
 Connect brake system brake filler and bleeder unit VAS 5234, but do not switch on at this point.
 Remove sound insulation below transmission, if installed.
2:20:22 AM Page 37
 Attach bleeder hose -A- to slave cylinder (arrow) and open bleeder valve.
 Connect bleeder hose to pressure hose of collecting bottle.
 Then switch on bleeding appliance and allow approx. 100 cm3 of brake fluid to drain out.
NOTE: Make sure bleed hose is correctly installed when bleeding.
 Tighten bleeder valve to 4.5 Nm.

 Press clutch pedal several times following completion of bleeding process.
 Bleed system again if necessary.
CLUTCH RELEASE MECHANISM COMPONENTS (ON TRANSMISSION), SERVICING
Clutch release mechanism components (on transmission), servicing
2:20:22 AM Page 38

1 - Transmission
2 - Ball pivot, 25 Nm
4 - Dished washer
 Small diameter (convex side) facing guide sleeve
5 - O-ring
2:20:22 AM Page 39
 Always replace
6 - Oil seal for input shaft
 Available together with guide sleeve -item 7 as one part

7 - Guide sleeve
 Available together with oil seal -item 6 as one part

 Installation position: Oil drain hole facing downward
 To protect oil seal -item 7 place shrink down tube over input shaft splines
2:20:22 AM Page 40
 Attach to clutch release lever
9 - Internal TORX head bolt, 35 Nm
 Self-locking
 Always replace
 Before installing lubricate locating recess for plunger of clutch slave cylinder with copper paste e.g. Z
381 351 TE

11 - Release bearing
2:20:22 AM Page 41
 With or without plastic ring. See Servicing release bearing with plastic ring, depending on design
 Glue on detached plastic ring. See Servicing release bearing with plastic ring
 Never wash out bearing; only wipe
 Lock retaining tabs on release bearing in release lever
12 - Slave cylinder

 Separating from hose/pipe assembly. See Separating slave cylinder from hose/pipe assembly
 Installing. See Lubricating clutch slave cylinder with grease before installing and see Installing
clutch slave cylinder
 Pre-load slave cylinder so that securing bolt can be installed easily
 Tighten bleeder valve to 4.5 Nm

 Bleed clutch system. Refer to Clutch system, bleeding
2:20:22 AM Page 42


 Self-locking
 Always replace
14 - Bracket

2:20:22 AM Page 43
15 - Plunger
 Lubricate end of plunger with copper paste, e.g. Z 381 351 TE

Removing
To remove hose/pipe assembly use a screwdriver to pry out clip -A- as far as it will go. Only then can the
Installing

Lubricating clutch slave cylinder with grease before installing
2:20:22 AM Page 44
 Apply a thin layer of copper paste, e.g. Z 381 351 TE, to contact surface for plunger on clutch release
lever
 Before installing slave cylinder in transmission housing lubricate area -a- of boot with lithium base grease
G 052 150 A2.

 Lock bracket for hose/pipe assembly -3- on slave cylinder -4- and bolt onto transmission together with
slave cylinder.
 Insert clutch slave cylinder into hole of transmission housing without major lateral deviation from
direction of motion of plunger.
NOTE:  If clutch slave cylinder -4- is not kept straight during insertion there is a
risk that the plunger might move past the clutch release lever.
 Pre-load clutch slave cylinder so that securing bolt can be installed easily.
2:20:22 AM Page 45

In the case of release bearings with plastic ring, the latter may become detached from the release bearing
during the removal of the transmission or the release bearing. This does not mean that the release
bearing has to be replaced.
 Before installing transmission glue loose plastic ring onto bearing ring with adhesive AMV 195 KD1 01.
Three square lugs (arrows) of plastic ring locate in recesses of bearing ring.
NOTE: If running face of plastic ring is worn by more than 0.5 mm, replace the release
bearing.
CLUTCH, SERVICING
Clutch, servicing
2:20:22 AM Page 46

 3067 Counterhold
NOTE:  Follow general repair instructions. Refer to General repair instructions.

 Replace clutch plates and pressure plates where riveted joint is damaged
or loose.
 Assign clutch plate and pressure plate by way of engine code.
 Clean input shaft splines and - in the case of used clutch plates - hub
2:20:22 AM Page 47
splines, remove corrosion and apply extremely thin layer of grease G 000
100 to splines. Then move clutch plate back and forth on input shaft until
hub moves freely on shaft. Excess grease must be removed.
contact surface may be cleaned, as otherwise the clutch service life will be
considerably shortened.
 To reduce the odor nuisance of a scorched clutch, thoroughly clean bell
housing, flywheel and parts of engine facing transmission.

For servicing the clutch first remove the transmission. Refer to Transmission, removing and installing.
A - Paint dot on dual-mass flywheel
2:20:22 AM Page 48
pressure plate
B - Paint dot on pressure plate
pressure plate

 Make sure centering pins are a tight fit

 Locating face for clutch lining must be free from grooves, oil and grease
2:20:22 AM Page 49
 Always replace
 Bolt length 22.5 mm: 60 Nm 1/4turn (90 ° )
 Bolt length 43 mm: 60 Nm plus 1/2 turn (180 ° )

3 - Clutch plate
 Damping set (coil springs) toward pressure plate or transmission
2:20:22 AM Page 50
 Lining of clutch plate must be located against flywheel

 Writing "Getriebeseite", if present, toward pressure plate or transmission
 Do not lubricate
 Diameter of clutch plate. Refer to Code letters, assignment of mechanical units, transmission ratios
and capacities onward
 Centering. See Centering clutch plate and removing/installing pressure plate
 Slightly lubricate splines

4 - Pressure plate
 Removing and installing. See Centering clutch plate and removing/installing pressure plate
2:20:22 AM Page 51
 Checking ends of diaphragm spring. See Checking ends of diaphragm spring

 Checking spring attachment and rivet attachments. See Checking spring attachment and rivet
attachments
 If present, line up white paint dots on flywheel -A- and pressure plate -B-, with one another during
assembly.
5 - Bolt, 25 Nm
 Loosen and tighten gradually in diagonal sequence
6 - Needle bearing
Centering clutch plate and removing/installing pressure plate
 Loosen and tighten bolts gradually in diagonal sequence, 25 Nm.
NOTE:  Reverse position of counterhold 3067 when removing.

 Installation position of clutch plate: Damping set (coil springs) or writing
"Getriebeseite" must face pressure plate or transmission.
 Only install attachment bolts once contact surface of pressure plate and
lining of clutch plate are located completely on flywheel.
 Use centering mandrel 3176 to center clutch plate.
 During assembly ensure that white paint dots, if present, on dual-mass
flywheel -A- and pressure plate -B- are lined up with one another.
2:20:22 AM Page 52

 Wear down to half the diaphragm spring thickness is permissible.
NOTE: When performing repairs, always assign clutch pressure plate and clutch plate
by way of engine code.
Checking spring attachment and rivet attachments

 Check spring attachment between pressure plate and cover for cracks, check rivet attachments are secure.
 Replace clutches showing damaged springs or loose rivet attachments (arrows).
34 MANUAL TRANSMISSION - CONTROLS, HOUSING

Shift mechanism, servicing
2:20:22 AM Page 53


Cabriolet
.


Cabriolet
.
Shift mechanism, installation position
2:20:22 AM Page 54
Fig. 67: Installation Position Of Gear Selector Mechanism

1 - Selector rod
2 - Front push rod
3 - Selector lever on transmission
Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
2:20:22 AM Page 55
Fig. 68: Shift Lever Knob And Protective Boot Remove/Install Components, Shift Lever And - Rear Push
Rod And Shift Lever And - Front Push Rod
I - Removing and installing gear shift knob and cover. Refer to Gear shift knob and cover, removing and
installing
II - Servicing gear shift and rear push rod. Refer to Gear shift and rear push rod, servicing
III - Servicing selector rod and front push rod. Refer to Selector rod and front push rod, servicing
Removing and installing shift mechanism. Refer to Shift mechanism, removing and installing
Adjusting shift mechanism. Refer to Shift mechanism, adjusting
See Caution for disconnecting Telematics battery. Refer to Shift mechanism, servicing
2:20:22 AM Page 56
NOTE:  Disconnect Ground strap from battery in engine compartment before

working on shift mechanism.
 Heed radio code on vehicles with encoded radio.
Gear shift knob and cover, removing and installing
Fig. 69: Shift Lever Knob And Protective Boot Remove/Install Components
1 - Gear shift knob
 Detach and install together with cover

 Removing. Refer to Removing
2 - Cover
2:20:22 AM Page 57
 Detach and install together with gear shift knob

3 - Connection piece
 For locking gear shift knob onto gear shift

 Opening catch. Refer to Fig. 78
 Connects cover to gear shift knob
4 - Cover for center console
 Removing and installing. Refer to Removing
2:20:22 AM Page 58
5 - Damping washer
 Installation position: Convex side face up
 Installation position: Arrow on noise insulation points in direction of travel
7 - Hex nut, 10 Nm
8 - Anti-noise cover
9 - Hex nut, 10 Nm
10 - Gear shift
 Removing and installing. Refer to Shift mechanism, removing and installing
Gear shift and rear push rod, servicing
2:20:22 AM Page 59
Fig. 71: Shift Lever And Rear Push Rod Remove/Install Components
NOTE: Lubricate bearing and contact surfaces with polycarbamide grease, part no. G
052 142 A2.
1 - Gear shift
 Lubricate area around hole at bottom with polycarbamide grease G 052 142 A2
 Lubricate ball with polycarbamide grease G 052 142 A2
2 - Spacer tube
 Lubricate with polycarbamide grease G 052 142 A2
3 - Circlip
2:20:22 AM Page 60
 Always replace
4 - Washer
 Collar faces ball guide (item 6)
5 - Rubber ring
6 - Ball guide
 Removing and installing. Refer to Gear shift and rear push rod, removing and installing
7 - Rubber ring
2:20:22 AM Page 61
8 - Rear push rod
 With ball housing

9 - Bolt, 6 Nm
 Qty. 4
 For fixing rear push rod to gear shift housing
Selector rod and front push rod, servicing
Fig. 73: Shift Rod And Pivot Rod, Overview

1 - Rear push rod
2:20:22 AM Page 62
2 - Bolt, 6 Nm
 Qty. 4
4 - Washer
6 - Clamp
7 - Hex nut, 10 Nm
 Qty. 4
 For fixing gear shift housing to body
2:20:22 AM Page 63

8 - Hex nut, 10 Nm
 Self-locking
 Always replace
9 - Gear shift
10 - Spacer tube
11 - Selector fork
2:20:22 AM Page 64
12 - Bolt
13 - Gear shift housing
14 - Tensioning ring
15 - Boot
 Remove catalytic converter and front heat shield before removal and assembly
NOTE:  Carefully pull boot over selector rod

 Position boot on markings of selector rod and push rod

2:20:22 AM Page 65
16 - Selector rod
 With gearshift linkage
17 - Bolt, 23 Nm
 Self-locking
 Always replace
 Cannot be removed from mounting bushing of front push rod
19 - Front push rod
Gear shift and rear push rod, removing and installing
Removing
Remove gear shift knob together with gear shift cover and cover of center console.

 Lift cover of center console upward (arrows) and off.
2:20:22 AM Page 66

 Release connection piece -1- in direction of arrow and pull gear shift knob together with gear shift cover
upward to remove.
 First lift cover -1- up in direction of arrow -A- and pull out in direction of arrow -B-.
 Remove bolts (arrows C) and then remove ashtray -2- from center console.
2:20:22 AM Page 67
Fig. 79: Lifting Out Damping Washer And Noise Insulation

 Lift damping washer -1- and noise insulation -2- upward and out.
 Remove noise insulation for gear shift housing (arrows).
Fig. 81: Locating Securing Nuts For Shift Lever Housing

2:20:22 AM Page 68
 Remove securing nuts (arrows) for gear shift housing.
This lowers the gear shift housing.
Fig. 82: Shift Mechanism Housing Fasteners

 Disconnect push rod by unscrewing hex socket-head bolt -2-.

 Disconnect selector rod by unscrewing hex socket-head bolt -3-.
 Disconnect rear push rod assembly from gear shift housing (arrows).
 Remove gear shift and rear push rod from gear shift housing.
Installing
 Adjusting shift mechanism. Refer to Shift mechanism, adjusting.
Fig. 83: Turning Connector Piece Till It Stops

 Position gear shift knob together with gear shift cover on gear shift and turn connection piece -1- in
direction of arrow as far as it will go.
2:20:22 AM Page 69
Tightening torques
Rear push rod to gear shift housing 6 Nm

Selector rod to selector fork/gear shift 25 Nm
Front push rod to rear push rod 25 Nm
Gear shift housing to body 10 Nm
Cover to rear push rod 10 Nm
Removing
NOTE: Remove gear shift knob together with gear shift cover and cover of center
console.

2:20:22 AM Page 70

upward to remove.
 Unscrew bolts (arrows C) and then remove ashtray -2- from center console.
2:20:22 AM Page 71

 Unscrew noise insulation for gear shift housing (arrows).

2:20:22 AM Page 72
 Unscrew securing nuts (arrows) for gear shift housing.

 Unscrew heat shield for drive shaft from Torsen differential housing (arrows).
Fig. 91: Locating Heat Shield, Exhaust System Clamp And Driveshaft At Transmission
 Disconnect exhaust system from clamp(s) -1- onward.

 Disconnect driveshaft -2- from transmission and secure at side with wire. Refer to Fig. 92.
Driveshaft, removing and installing:
 Remove heat shield -3- above exhaust system (arrows).
2:20:23 AM Page 73
Fig. 92: Drive Shaft Secured With Wire And Locating Speed Nut
 Re-insert speed nut which was previously removed (arrow) and attach drive shaft to it with a wire.
Fig. 93: Identifying Transmission Shift And Pivot Rods

 Remove gearshift linkage (arrow -A-).

 Unscrew hex socket head bolt of push rod (arrow -B-).
 Swivel gear shift housing with selector rod and push rod down and remove.
Installing
Install in reverse order.
 Push on gearshift linkage until bolt is located in counterbore of selector shaft.
2:20:23 AM Page 74

 Bolt selector rod firmly in place (arrow -A-).

 Secure push rod to transmission (arrow -B-).
 Install heat shield -3- above exhaust system (arrows).

 Bolt driveshaft -2- to transmission.
 Secure clamp(s) -1-.
2:20:23 AM Page 75

 Secure heat shield for drive shaft to Torsen differential housing (arrows).
 Adjust shift mechanism. Refer to Shift mechanism, adjusting.

Tightening torques
Component Nm
Gear shift housing to body 10
Gearshift linkage to transmission 1) 23
Driveshaft to transmission 1) 55
Heat shield for drive shaft to Torsen differential housing 25
Noise insulation for gear shift housing to rear push rod 10
2:20:23 AM Page 76
1) Replace bolt
NOTE: The following points are essential to ensure proper adjustment:
 Moving parts of shift mechanism and transmission elements are in perfect

condition
 Shift mechanism moves freely
 Transmission, clutch and shift mechanism are in perfect condition.
Removing
console.

2:20:23 AM Page 77

upward to remove.
 Remove bolts (arrows -C-) and then remove ashtray -2- from center console.
2:20:23 AM Page 78


 Measure distance -a- between two studs in shift mechanism
NOTE: Measure from center of stud to center of stud.
2:20:23 AM Page 79

 Specification: Dimension a = 85 mm
 If specification is not obtained, produce distance -a- as follows:

 Loosen bolt (arrow) for push rod.
 Rear push rod (in shift mechanism) must move easily backward and forward on slider
 Adjust dimension -a- by moving rear push rod (in shift mechanism).
 Tighten bolt for push rod (arrow) to 25 Nm.

 Loosen bolt for selector rod (arrow).
 Selector rod/shift mechanism connection must move freely
Aligning gear shift
2:20:23 AM Page 80

 Center bottom of gear shift in ball socket.
 Bottom of gear shift must be at same distance from all points of ball socket (arrows).
 Gear shift is vertical in direction of travel.
 Secure gear shift in this position.

 Tighten bolt for selector rod (arrow) to 25 Nm.
NOTE: Take care not to alter position of gear shift when tightening the bolt.
 Install covers and gear shift knob.
Shift adjustment, checking
 Gear shift must be in 3rd/4th gear gate with transmission in neutral.
2:20:23 AM Page 81
 Press clutch.
 Check shifting to all gears.
 Gear shift must not come into contact with cover of center console when shifting.
 Gear shift must automatically return from 5th/reverse gear gate to 3rd/4th gear gate.
 Reverse gear can only be selected when gear shift is in 3rd/4th gear gate with transmission in neutral
beforehand.
 It is not possible to shift from 5th gear directly to reverse gear.
NOTE: If gear shift can be shifted directly from 5th gear to reverse, or if only 5th gear
and reverse gear cannot be engaged, check locking unit for 5th and reverse
gear and replace if necessary. Refer to Removing and installing locking unit for
5th gear and reverse gear.


Cabriolet
.


Cabriolet
.
2:20:23 AM Page 82
Fig. 107: Identifying Special Tools - Transmission, Removing And Installing

 3282 Transmission support

 3282/10 Adjustment plate
 V.A.G 1331 Torque wrench
 V.A.G 1383 A Engine/transmission lifter
2:20:23 AM Page 83
Fig. 108: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine
 10-222A Support bar
Transmission, removing
See Caution before beginning repairs on the electrical system. Refer to Transmission, removing and installing

2:20:23 AM Page 84
Fig. 110: Support Bar 10-222 A With Supports 10-222 A/1 Installed On Engine
 Set up support bar 10-222 A with supports 10-222 A/1.

 Pre-tension engine slightly using spindle of support bar.

 Remove sound insulation (arrows).
2:20:23 AM Page 85
 Remove heat shield for driveshaft from Torsen differential housing (arrows).
Fig. 113: Exhaust Pipe Clamp And Driveshaft At Transmission

 Release clamp -1- and remove front part of exhaust pipe -2-.
Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS
 Disconnect driveshaft -3- from transmission and secure at side with wire (see following illustration).
 Re-insert speed nut (arrow) slightly and secure drive shaft with wire.
2:20:23 AM Page 86
Fig. 115: Removing Noise Insulation Bracket

 Remove bracket for sound insulation (arrow).
Fig. 116: Three Lower Engine And Transmission Connecting Bolts

 Remove three engine/transmission connecting bolts underneath (arrow).
Fig. 117: Detaching Heat Shields And Right-Hand Axle Shaft

2:20:23 AM Page 87
 Remove heat shields (arrow -1- and arrow -2-) above right drive axle.
Fig. 118: Drive Shafts And Flange Shafts

 Disconnect drive axles -1- from drive flanges and tie up out of way.
NOTE: Take care not to damage surface protection of drive axles.
 Support transmission slightly with engine/transmission lifter V.A.G 1383 A.

 Remove bolts -2-, then bolts -3- on tunnel crossmember.

 Remove two nuts -4- and remove tunnel crossmember.
 Lower engine/transmission lifter V.A.G 1383 A and place to one side.
2:20:23 AM Page 88

 Disconnect selector rod (arrow A-).

 Remove hex socket head bolt of push rod (arrow -B-).
Fig. 121: Identifying Connectors For Vehicle Speed Sensor (VSS) And Back-Up Lights
 Disconnect connector from speedometer vehicle speed sensor (arrow -A-).

 Disconnect connector from back-up light switch (multi-function sensor, arrow B-).
 Disconnect all other electrical connections and Ground wires from transmission and from
engine/transmission connecting bolts.
2:20:23 AM Page 89
 If installed, remove Engine speed (RPM) sensor -G28- from left of transmission (arrow) and place to one
side.
Fig. 123: Removing Starter Bolt

 Disconnect engine/transmission starter and secure against inadvertent operation if necessary.
Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
NOTE: There is no need to disconnect starter cables.
2:20:23 AM Page 90
Fig. 124: Lower Engine And Transmission Connecting Bolts Which Should Not Be Removed
 Remove engine/transmission connecting bolts underneath with exception of bolts (arrow -A- and arrow -
B-).
Fig. 125: Transmission Support 3282 Attachment Plate

 To remove manual transmission 012, align transmission support 3282 using adjustment plate 3282/10 and
position on transmission lifter V.A.G 1383 A.
A - Support elements
NOTE:  Drawing shows only symbolic representation of support elements -A-.

Arrow -B- points in direction of travel.
 Adjustment plate 3282/10 only fits in one position.
2:20:23 AM Page 91
Fig. 126: Setting Transmission Jack Under Vehicle

 Position transmission jack under vehicle with arrow symbol -B- (Refer to Fig. 125) on adjustment plate
pointing in direction of travel/vehicle.
Fig. 127: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Support On
Transmission
 Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.
2:20:23 AM Page 92
 Remove remaining engine/transmission connecting bolts (arrows -A- and -B-).

 Press transmission out of dowel sleeves and carefully lower slightly using transmission lifter V.A.G 1383
A until slave cylinder is just about accessible.
NOTE: When lowering transmission take care not to damage hydraulic pipe to slave
cylinder.
Fig. 129: Identifying Clutch Slave Cylinder Bracket And Fastener

 Remove clutch slave cylinder (arrow) and secure with wire, do not open hydraulic circuit.
NOTE: Do not press clutch pedal once slave cylinder has been removed.
NOTE: When lowering ensure clearance from drive axles.
Fig. 130: Transmission Mount
2:20:23 AM Page 93
 If removed transmission is to be replaced, first modify transmission mount to suit replacement

transmission (arrows).
For repairs, secure transmission to repair stand by means of transmission support VW 353 and retaining plate
VW 309.
Lifting tackle 2024 A in conjunction with auxiliary hook 10-222 A can be used for transporting the
transmission.
Fig. 131: Lifting Engine With 2024A Engine Sling

 Bolt on two brackets of lifting tackle 2024 A using bolts -A- M10 x 50.
 Attach lifting tackle 2024 A and raise slightly with workshop crane.
 Hook 4th hole of each hole rail into position -3- and position -6- of lifting tackle 2024 A.
CAUTION: Use locking pins for hooks and setting pins.
Transmission, installing
 Clean splines of input shaft and apply a little lubricating grease G000 100.
2:20:23 AM Page 94
Clutch plate must slide easily back and forth on input shaft.
 Apply a thin coat of copper grease, e.g. Z 381 351 TE, to contact surface for plunger on clutch release
lever.

 If plastic ring of release bearing is loose, stick back onto bearing ring with adhesive AMV 195 KD1 01.
Three rectangular lugs (arrows) on plastic ring engage in recesses in bearing ring.
If scores deeper than 0.5 mm are present, replace release bearing.
 Check whether dowel sleeves for centering engine/transmission in cylinder block have been installed and
install if necessary.
 Make sure intermediate plate, if installed, is correctly positioned at engine.
 Using a thread tap, remove residual locking fluid from all threaded holes bearing self-locking bolts.
 Replace all self-locking nuts.

2:20:23 AM Page 95
 Raise transmission until clutch slave cylinder can be installed together with holder for hose/pipe assembly
(arrow).
 Install bolts for lower engine/transmission connection and for starter; to do so, insert starter.

 Bolt tunnel crossmember onto transmission mount -4-.

 Lift transmission using engine/transmission lifter V.A.G 1383 A and firmly bolt tunnel crossmember to
body.
 Bolt driveshaft to transmission:
 Align exhaust system free of stress:
 Check oil level in manual transmission. Refer to Transmission oil level, checking.
 Check shift adjustment, re-adjust if necessary. Refer to Shift mechanism, adjusting.
See Caution for connecting Telematics battery. Refer to Transmission, removing and installing
 After connecting battery, enter radio anti-theft code.
Refer to Radio operating instructions
 Connect battery.
NOTE: On re-connecting the battery, remember to check and activate vehicle

equipment (radio, clock, convenience electronics etc.).
2:20:23 AM Page 96
Refer to
Tightening torques
Fig. 135: 4Identifying Engine/Transmission Mountings (Automatic/Manual Transmission)

1.8 Liter engine to transmission
Item Bolt Nm
1, 3, 4 M12 x 67 65
2, 6 M12 x 90 65
5, 11 M12 x 110 65
7 through 10 M10 x 45 45
A: Dowel sleeves for centering
Transmission mount with console to transmission (arrows) 23 Nm
1 - Drive axle to drive flange M8 40 Nm

M10 70 Nm
2 - Tunnel crossmember to body 1) M10 55 Nm
3 - Tunnel crossmember to body 1) 110 Nm
+ 90 °
4 - Tunnel crossmember to transmission mount 23 Nm
1) Always replace bolt and washer
Component Nm
2:20:23 AM Page 97
Engine speed (RPM) sensor -G28- 10

Clutch slave cylinder to transmission1) 23
Heat shield for driveshaft to cover plate for Torsen differential 25
1) Replace bolt
TORSEN DIFFERENTIAL HOUSING, REMOVING AND INSTALLING
Torsen differential housing, removing and installing


Cabriolet
.


Cabriolet
.
2:20:23 AM Page 98


Removing
 Obtain (if necessary) radio code for vehicles with encoded radio.
 Place drip tray V.A.G 1306 underneath and drain gear oil.
Vehicles with 4-cylinder engine
2:20:23 AM Page 99

 Separate exhaust system at clamp -1-.

 Disconnect driveshaft from transmission.
2:20:23 AM Page 100

 Re-insert speed nut (arrow) slightly and secure drive shaft to stud with wire.


 Lower engine/transmission lifter V.A.G 1383 A
2:20:23 AM Page 101


 Remove transmission mount (arrows).
Fig. 143: Identifying Cover, Transmission Cover , and Compression Spring

 Remove Torsen differential housing -A- from transmission cover -B-.
NOTE: Shown in illustration with transmission removed.
 Remove spring -C- from pinion.
Removing and installing Torsen differential. Refer to Torsen differential housing, servicing, and Torsen
differential, removing and installing.
Servicing housing. Refer to Torsen differential housing, servicing, and Torsen differential, removing and
installing
Installing
2:20:23 AM Page 102

 Clean sealing surface and coat with AMV 188 001 02.

 Check whether dowel sleeves for housing -A- (arrows) are present in transmission cover -B-.
 Place spring -C- over pinion on hollow shaft.
 Lift transmission with engine/transmission lifter V.A.G 1383 A.
 Install transmission mount.

 Install tunnel crossmember onto transmission mount -4- and body -2- and -3-.
 Top up gear oil and check oil level in transmission. Refer to Transmission oil level, checking.
 Bolt driveshaft to transmission.
 Align exhaust system stress-free
2:20:23 AM Page 103

See Caution for connecting Telematics battery. Refer to Torsen differential housing, removing and installing
NOTE: On re-connecting battery, remember to check and activate vehicle equipment

Refer to

Tightening torque
Component Nm

+ 90 °
1) Always replace bolt including washer
2:20:23 AM Page 104

Torsen differential housing to transmission 25

Heat shield for driveshaft to Torsen differential housing 25
1) Replace bolt
TRANSMISSION OIL LEVEL, CHECKING
Transmission oil level, checking

 3357 Allen key extension

NOTE:  The vehicle must be level for checking the oil level. An inspection pit or 4-
2:20:23 AM Page 105

pillar lifting platform are the most suitable methods.

 The oil filler plug is situated on the left of the transmission below the
speedometer vehicle speed sensor and may be concealed by the heat
shield for the drive axle.
 Use special tool 3357 to loosen oil drain plug.
Fig. 149: Checking Oil Level At Oil Filler Hole

 Remove oil filler plug to check gear oil level (arrow).
 Specification: Oil level up to lower edge of filler hole
 Top up gear oil if necessary. Specification. Refer to Code letters, assignment of mechanical units,
transmission ratios and capacities onward.
 Install oil filler plug.
Tightening torque
Component Nm
Oil filler plug 25
2:20:23 AM Page 106

Fig. 150: Transmission, Overview

Assembly sequence. Refer to Ball bearing for input shaft, multi-function sensor, pinion, selector rods,
transmission cover and Torsen differential housing, removing and installing.
Transmission, assembly overview
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
2:20:23 AM Page 107

5 - 5th gear
6 - Reverse gear
 Removing and installing reverse idler gear. Refer to Reverse idler gear, removing and installing
7 - Tapered roller bearing
 Adjusting. Refer to Pinion, adjusting onward

 Only repaired at factory
2:20:23 AM Page 108

 Removing and installing with housing. Refer to Torsen differential housing, removing and installing
9 - Ball bearing
10 - Ball bearing
11 - Drive flange
12 - Torsen differential Housing
13 - Spring
 Between Torsen differential and hollow shaft
14 - Input shaft
 Disassembling and assembling. Refer to Input shaft, disassembling and assembling
2:20:23 AM Page 109


17 - Ball bearing
 Adjusting. Refer to Input shaft, adjusting
18 - Differential
 Removing and installing. Refer to Differential, removing and installing

 Disassembling and assembling. Refer to Differential, disassembling and assembling
19 - Pinion
2:20:23 AM Page 110

 Disassembling and assembling hollow shaft and pinion. Refer to Pinion and hollow shaft,
disassembling and assembling
20 - Radial-tapered roller bearing
21 - Hollow shaft
Transmission, sub-assembly overviews
Fig. 153: Transmission, Assembly Overview

2:20:23 AM Page 111

I - Removing and installing ball bearing for input shaft and multi-function sensor. Refer to Ball bearing
for input shaft and multi-function sensor, removing and installing
II - Removing and installing input shaft, pinion, hollow shaft, selector rods, transmission cover and
Torsen differential housing. Refer to Input shaft, pinion, hollow shaft, selector rods, transmission cover
and Torsen differential housing, removing and installing
Ball bearing for input shaft and multi-function sensor, removing and installing
Fig. 154: Transmission Housing, Input Shaft Ball Bearing And Multi-Function Sensor, Overview
 With differential and drive flanges

 Removing and installing drive flanges. Refer to Oil seal for drive flange, replacing
2:20:24 AM Page 112

 Removing and installing differential. Refer to Differential, removing and installing

 Removing and installing sensor and driving gear for speedometer. Refer to Speedometer vehicle speed
sensor and drive-wheel, removing and installing
 Installation position of bleeder valve. See Installation position of bleeder valve
2 - Internal TORX screw, 35 Nm
 Self-locking
 Replace
3 - Guide bushing
 With O-ring and oil seal for input shaft. Refer to Clutch release mechanism components (on
transmission), servicing
2:20:24 AM Page 113

4 - Dished washer
 Small diameter (convex side) facing guide bushing
5 - Circlip
 Defining thickness. Refer to Input shaft, adjusting
6 - Ball bearing
 Removing and installing. Refer to Ball bearing for input shaft, multi-function sensor, pinion, selector
rods, transmission cover and Torsen differential housing, removing and installing
7 - Circlip
8 - Input shaft
 Removing and installing. Refer to Input shaft, pinion, hollow shaft, selector rods, transmission cover
 Servicing mounting for input shaft. Refer to Input shaft, disassembling and assembling
2:20:24 AM Page 114

9 - Bolt, 25 Nm
10 - Locking plate
 For multi-function sensor
11 - Multi-function switch
12 - Connector
 For multi-function switch
13 - Bolt, 10 Nm
2:20:24 AM Page 115

14 - Cover for selector shaft
 Removing and installing. Refer to Transmission shift mechanism, disassembling and assembling
15 - Locking unit for 5th gear and reverse gear
 Removing and installing. Refer to Removing and installing locking unit for 5th gear and reverse gear
Installation position of bleeder valve
Fig. 157: Identifying Installed Position Of Breather

When pressed in, bleeder valve must protrude 21 mm out of housing.
Input shaft, pinion, hollow shaft, selector rods, transmission cover and Torsen differential housing, removing and
installing
2:20:24 AM Page 116

Fig. 158: Input Shaft, Pinion Shaft, Hollow Shaft, Shift Rods, Transmission Cover And Cover With
Torsen Differential, Removing And Installing
2 - Input shaft

3 - Selector rod with 3rd and 4th gear selector fork
 Disassembling and assembling. Refer to Transmission shift mechanism, disassembling and

assembling
2:20:24 AM Page 117

 Replacing mounting bushings. Refer to Transmission shift mechanism, disassembling and assembling
4 - Left stop bolt, 40 Nm
5 - Damping washer
6 - Guide shaft
 Installation position. Refer to Transmission shift mechanism, disassembling and assembling
7 - Damping washer
2:20:24 AM Page 118

8 - Right stop bolt, 40 Nm
9 - Selector shaft

 Replacing oil seal for selector shaft. Refer to Torsen differential housing, servicing, and Torsen
differential, removing and installing
10 - Detent segment
2:20:24 AM Page 119

 With collar for securing spring of detent segment
12 - Selector rod with selector fork for 1st/2nd/5th and reverse gears

assembling
 Removing and installing ball sleeves. Refer to Removing and installing ball sleeve
13 - Pinion with hollow shaft
 Disassembling and assembling. Refer to Pinion and hollow shaft, disassembling and assembling
 Adjusting. Refer to General
 Servicing mounting for pinion and hollow shaft. Refer to Pinion and hollow shaft, disassembling and
assembling
 Removing and installing oil drain plug. See Removing and installing oil drain plug
2:20:24 AM Page 120

16 - Spring
17 - Torsen differential housing
 Removing and installing with transmission installed. Refer to Torsen differential housing, removing
and installing
 Removing Torsen differential from housing, installing. Refer to Torsen differential housing, servicing,
and Torsen differential, removing and installing
 Servicing housing. Refer to Torsen differential housing, servicing, and Torsen differential, removing
and installing
2:20:24 AM Page 121

Removing and installing oil drain plug
Fig. 162: Identifying Oil Collector Tray

Removing
 Turn oil drain plug (arrow) and pull out.
Installing
 Push oil drain plug into transmission cover until catch engages.
 Installation position: Oil drain plug faces upward in transmission cover
Ball bearing for input shaft, multi-function sensor, pinion, selector rods, transmission cover and Torsen differential
housing, removing and installing
NOTE:  The differential does not have to be removed in order to remove the above-
mentioned components.
 Removal is only necessary when adjustment work must be performed.
Refer to Adjustment table.
2:20:24 AM Page 122


 Allen key extension 3357
2:20:24 AM Page 123

Fig. 164: Identifying Special Tools - Disassembly And Assembly

 VW 309 Holding plate

 VW 353 Transmission support
 3235 Pressing-in tool
 V.A.G 1582 Tapered roller bearing puller

 V.A.G 1582/2 Gripper

 V.A.G 1306 Drip tray

2:20:24 AM Page 124


 Sealant AMV 188 001 02
Removing

 Drain oil using Allen key extension 3357.
Fig. 167: Securing Transmission In Assembly Stand

 Clamp transmission in repair stand.
NOTE:  To protect oil seal, pull shrink down tube over splines of input shaft before
pulling off guide sleeve.
2:20:24 AM Page 125

Fig. 168: Clutch Release Lever Components

 Remove clutch release lever -A- with release bearing.

 Remove guide sleeve -B-.
 Remove washer -C-.
 Remove circlip -D- in front of input shaft ball bearing.
 Make a note of thickness of circlip if not replacing ball bearing, input shaft or transmission housing.
Fig. 169: Pulling Input Shaft Ball Bearing Out Of Transmission Housing
 Pull ball bearing of input shaft out of transmission housing.
Fig. 170: Location Of Rear Circlip For Input Shaft Ball Bearing
 Remove circlip (arrow) behind input shaft ball bearing.

2:20:24 AM Page 126

Fig. 171: Identifying Cover, Transmission Cover , and Transmission Housing

 Disconnect Torsen differential housing -A- from transmission cover -B-.

 Remove spring from pinion.
 Remove transmission cover -B- from transmission housing -C-.
Fig. 172: Location Of Multi-Function Sensor

 Remove bolts (arrows) and pull out multi-function switch.
2:20:24 AM Page 127

Fig. 173: Identifying Threaded Bolts At Both Ends Of Relay Shaft

 Remove bolts for guide shaft (arrows).
Fig. 174: Identifying Shift Detent Fastener

 Remove screw for detent segment (arrow) and remove segment by swivelling out.
Fig. 175: Identifying Input Shaft, Pinion Shaft , Relay Shaft , Shift Rods and Shift Forks
2:20:24 AM Page 128

 Carefully pull out input shaft -A-, pinion -B-, guide shaft -C-, selector rods -D- and selector shaft and
selector forks -E- altogether.
Installing
NOTE: If the input shaft ball bearing, the input shaft or the transmission housing have
been replaced, first define the thickness of the circlips for the input shaft. Refer
to Input shaft, adjusting.
Fig. 176: Swing Transmission Housing Into Position Shown

 Swivel transmission housing into position as illustrated. It is then easier to insert components mentioned
below.
Fig. 177: Identifying Input Shaft, Pinion Shaft , Relay Shaft , Selector Rods and Selector Forks
2:20:24 AM Page 129

 Assemble input shaft -A-, pinion -B-, guide shaft -C-, selector rods -D- and selector shaft and selector
forks -E-.
 Insert these components in transmission housing altogether.
NOTE: Guide shaft -C- and selector shaft can also be inserted afterward if necessary.
Refer to Fig. 178 and Fig. 180.
Fig. 178: Identifying Installed Position Of Complete Selector Mechanism In Transmission

Position of shift mechanism in transmission
1 - 5th and reverse gear selector fork
2 - 3rd and 4th gear selector fork
3 - 1st and 2nd gear selector fork
4 - Guide shaft
5 - Shifting catch
6 - Selector shaft
NOTE: Shown in illustration without input shaft and pinion.
2:20:24 AM Page 130

Fig. 179: Move Transmission To Engage 3rd Gear

 Swivel transmission housing and then engage 3rd gear (direction of arrow).
Fig. 180: Installing Relay Shaft And Shift Rod

 Insert guide shaft -A-.
 Place selector shaft -B- sideways in hole in transmission housing and join to retaining eyelet.
 Swivel selector shaft carefully in direction of arrow.
2:20:24 AM Page 131


 Insert detent segment and tighten screw (arrow).

 Install bolts for guide shaft (arrows)

 Replace O-ring for multi-function switch.
2:20:24 AM Page 132

 Carefully insert multi-function switch and tighten screws (arrows).
Fig. 184: Identifying Cover and Transmission Cover

 Check whether dowel sleeves for transmission cover -A- (arrows) are present in transmission housing -B-
.
 Install transmission cover on transmission housing.

 Install spring -C-.
 Install Torsen differential housing -A- on transmission cover -B-.
2:20:24 AM Page 133

 Remove rear circlip (arrow) for input shaft ball bearing.

 Push ball bearing onto input shaft.
 Installation position: Solid side of ball cage faces transmission housing
Fig. 187: Pressing In Ball Bearing

 Press in ball bearing:
 Push thrust pad -A- of pressing-in tool onto input shaft.

 Position pressing-in tool behind splines for clutch plate.
 Pre-load bolts -B-.
 Bolts are supported in counterbores of thrust pad -A-
 Press ball bearing in as far as it will go by tightening bolts alternately (1/2 turn).
2:20:24 AM Page 134


 Install front circlip -D- for input shaft ball bearing.

 Mount dished washer -C-.
 Installation position: Convex side faces guide sleeve -B-
pushing on guide sleeve.
 Replace guide sleeve together with oil seal and O-ring.
 Install new guide sleeve -B- for release bearing.

 Install clutch release lever -A- and release bearing.
TORSEN DIFFERENTIAL HOUSING, SERVICING, AND TORSEN DIFFERENTIAL, REMOVING

AND INSTALLING
Torsen differential housing, servicing, and Torsen differential, removing and installing
2:20:24 AM Page 135

Fig. 189: Identifying Special Tools - Torsen Differential Housing, Servicing, And Torsen Differential,
Removing And Installing (1 Of 2)
 VW 401 Pressure plate

 VW 407 Press tool
 VW 416 B Tubular section

 VW 421 Tubular section
2:20:24 AM Page 136

 VW 439 Guide section

 VW 681 Extractor lever
 40-21 Sleeve
 2040 Tubular section

 3002 Pressure piece
2:20:24 AM Page 137


 VW 771/15 from universal tools VW 771
 Separating tool Kukko 17/2

 Internal puller Kukko 21/4
2:20:24 AM Page 138

Fig. 193: Transmission Cover, Overview

2 - Spring
3 - Front needle bearing
 Extracting. See Extracting needle bearing

 Installation position. See Installation position of front needle bearing
 Pressing in. See Pressing in needle bearing
2:20:24 AM Page 139

 Press out after removing flange shaft. See Pressing out Torsen differential
 Pressing in. See Pressing in Torsen differential
5 - Rear needle bearing

 Installation position. See Installation position of rear needle bearing

6 - Ball bearing
2:20:24 AM Page 140

 For Torsen differential

 Pressing off. See Pressing off ball bearing of Torsen differential
 Pressing on. See Pressing ball bearing onto Torsen differential
7 - Circlip
8 - Circlip
 Remove and install together with drive flange. See Removing and installing drive flange
9 - Ball bearing
 For drive flange

 Pressing out. See Pressing out ball bearing for drive flange
 Pressing in. See Pressing in ball bearing for drive flange
11 - Circlip
12 - Sealing cap
 Removing. See Removing sealing cap
2:20:24 AM Page 141


13 - O-ring
 Always replace
 Install with grease
15 - Oil seal
 Extract with extractor lever VW 681

 Driving in. See Driving in oil seal
16 - Dampener
2:20:24 AM Page 142

17 - Circlip
 Self-locking
 Always replace
19 - Drive flange
 Removing and installing. See Removing and installing drive flange
Removing sealing cap
Fig. 196: Identifying Circlip And Sealing Cap

 Remove circlip -A-.

 Install an M8 bolt into threaded hole of sealing cap -B-.
 Pull out sealing cap -B- with bolt.
Removing and installing drive flange
Fig. 197: Drive Flange, Removal And Installation
2:20:24 AM Page 143

 Expand circlip and pull out drive flange.
NOTE:  When installing drive flange circlip must be installed at same time.
 Circlip must be properly positioned in groove.
Pressing out Torsen differential
Fig. 198: Pressing Out Torsen Differential

 Place pressure piece 3002 through hole (arrow) directly onto Torsen differential.
Pressing off ball bearing of Torsen differential
Fig. 199: Pressing Off Ball Bearing From Torsen Differential

A - Separating tool 22 to 115 mm, e.g. Kukko 17/2
Pressing ball bearing onto Torsen differential
2:20:24 AM Page 144

Fig. 200: Pressing On Ball Bearing On Torsen Differential

 Press on ball bearing as far as it will go.
Pressing out ball bearing for drive flange

 Remove circlip before pressing out.
Pressing in ball bearing for drive flange
2:20:24 AM Page 145


 Install circlip after pressing in.
Extracting needle bearing

A - Internal puller, e. g. Kukko 21/4, 22 to 28 mm
Both needle bearings in Torsen differential are extracted using the same internal puller.
Installation position of front needle bearing
2:20:24 AM Page 146

Fig. 204: Installation Position Of Front Needle Bearing

 Dimension a = 32.5 mm
Installation position of rear needle bearing
Fig. 205: Installation Position Of Rear Needle Bearing, Dimension

 Dimension a = 14 mm
Pressing in needle bearing
2:20:24 AM Page 147

Fig. 206: Pressing In Needle Bearing

Both needle bearings in Torsen differential are pressed in using the same special tool.
Pressing in Torsen differential
Fig. 207: Pressing In Torsen Differential

Driving in oil seal
Fig. 208: Driving In Sealing Ring
2:20:25 AM Page 148

 Slightly oil circumference of oil seal.
 Installation position: 2 mm below surface of housing
 Fill space between sealing lip and dust lip with sealing grease G 052 128 A1.
TRANSMISSION SHIFT MECHANISM, DISASSEMBLING AND ASSEMBLING
Transmission shift mechanism, disassembling and assembling
Fig. 209: Identifying Special Tools - Shift Mechanism On Transmission Side, Disassembling And
Assembling
2:20:25 AM Page 149

 VW 295 Mandrel
 VW 295 A Adapter

 VW 472/2 Spacer sleeve

 VW 771 Multi-purpose tool
 1 - Kukko 21/4 Internal puller
NOTE: Installation position of shift mechanism assembly in transmission. See

Installation position of shift mechanism assembly in transmission
2:20:25 AM Page 150

Fig. 212: Shift Mechanism In Transmission, Overview

3 - O-ring
 Always replace
5 - Damping washer
2:20:25 AM Page 151

6 - Guide shaft
7 - Damping washer
9 - Detent segment

11 - Spring pin
2:20:25 AM Page 152

 Installation position. See Installation position of 5th and reverse gear selector fork and of driver for
selector rod
13 - Selector rod for 1st and 2nd gear and for 5th and reverse gear
14 - Ball sleeve
 Removing and installing. See Removing and installing ball sleeve
16 - Driver
selector rod
17 - Mounting bushing for 3rd and 4th gear
 Extracting. See Pulling out mounting bushing for 3rd and 4th gear selector rod
 Driving in. See Driving in mounting bushing for 3rd and 4th gear selector rod as far as it will go
2:20:25 AM Page 153


18 - Ball sleeve
 Pry away from selector rod using a screwdriver

 Press onto selector rod
19 - Selector rod for 3rd. and 4th gear
21 - Spring pin
22 - Cover
2:20:25 AM Page 154

24 - Selector shaft
25 - Oil seal
 Pry out with screwdriver

 Installation position. See Installation position of oil seal
Installation position of 5th and reverse gear selector fork and of driver for selector rod
Fig. 215: Identifying Installed Position For 5th/Reverse Gear Shift Fork And Coupling Plate For Shift
Rod
 Dimension b = 60 mm
Removing and installing ball sleeve
Fig. 216: Removing/Installing Ball Sleeve
2:20:25 AM Page 155

Pulling out mounting bushing for 3rd and 4th gear selector rod
Fig. 217: Removing Bushing For 3rd And 4th Gear Shift Rod
A - Internal puller 22 to 28 mm, e.g. Kukko 21/4 in conjunction with multi-purpose tool VW 771
Driving in mounting bushing for 3rd and 4th gear selector rod as far as it will go
Fig. 218: Driving In Bushing For 3rd And 4th Gear Shift Rod
Installation position of oil seal
2:20:25 AM Page 156

Fig. 219: Identifying Installed Position Of Sealing Washer

 Half-fill space between sealing lip and dust lip with sealing grease G 052 128 A1.
 Slightly oil circumference of sealing ring.
 Insert oil seal with tubular section VW 420

4 - Guide shaft
5 - Shifting catch
2:20:25 AM Page 157

6 - Selector shaft
Removing and installing locking unit for 5th gear and reverse gear

 Detach heat shield (arrow -2-) above right drive axle.

 Loosen heat shield (arrow -1-) above right drive axle and swivel downward.
Fig. 222: Identifying Gear Lock

 Remove locking unit (arrow).
Assembling locking unit
2:20:25 AM Page 158

Fig. 223: Assembling Gear Lock

 Insert spring -1- in housing -2- and turn counter-clockwise with slight pressure until spring engages in
base of housing.
 Position bushing -3- on spring in such a way that bent end of spring is located in the groove intended for
this purpose.
 With bushing -3-, compress spring and rotate approx. 1 turn counter-clockwise until lug of bushing is
located above groove in housing -2-.
 Press lug of bushing -3- into groove of housing -2- as far as it will go.
 Turn bushing -3- clockwise and release, bushing -3- jumps into installation position.

Installation position of bushing:
Lug (arrow -A-) of bushing must always be positioned opposite groove (arrow -B-) of housing.
Checking installation position:
 Turn bushing counter-clockwise and release.
2:20:25 AM Page 159

 Bushing must always spring back into position, lug must be pushed on as far as it will go -direction of
arrow A-
Fig. 225: Installed Position Of Complete Gear Lock In Transmission

Installation position of locking unit assembly in transmission:
Recess (arrow -A-) faces bolt (arrow -B-)
35 MANUAL TRANSMISSION - GEARS, SHAFTS

INPUT SHAFT, DISASSEMBLING AND ASSEMBLING
2:20:25 AM Page 160

Fig. 226: Identifying Special Tools - Input Shaft, Disassembling And Assembling
 VW 295 Mandrel

 VW 408 A Press tool
2:20:25 AM Page 161

 VW 415 A Tubular section

 VW 447 i Thrust pad
 30-100 Press tube

 40-105 Thrust plate
2:20:25 AM Page 162

 VW 222 A Mandrel
 30-24 Mandrel
 40-202 Pressing-out element
 3 - Kukko 17/2 Separating tool
NOTE:
2:20:25 AM Page 163

Fig. 229: Input Shaft, Overview

 Observe technical data when installing new gear wheels or the input shaft.
Refer to Code letters, assignment of mechanical units, transmission ratios
and capacities.
 Replacing components -items 2, 4 and 6 --> Input shaft, disassembling and
assembling influences the position of the ball bearing. In this case, input
shaft must be re-adjusted. Refer to Input shaft, adjusting.
1 - Circlip
 Mark
 Installation position Installation position of circlips- item 1
 Determining thickness. Refer to Adjusting input shaft: Refer to Input shaft, adjusting
2:20:25 AM Page 164

2 - Ball bearing
3 - Circlip
 Mark
 Installation position Installation position of circlips - item 2

2:20:25 AM Page 165

5 - Needle bearing
 Secured with bolt. See Locking bolt for needle bearing

 Installation position. See Installation position of needle bearing
6 - Input shaft
 With oiling sleeve

 Driving in oiling sleeve. See Driving oiling sleeve into input shaft
7 - Needle bearing for 3rd gear
8 - Sliding gear for 3rd gear
2:20:25 AM Page 166


9 - Spring
 Inserting in 3rd gear sliding gear. See Inserting spring into sliding gear
 Assignment to sliding gear
10 - 3rd gear synchro-ring
 Checking for wear. See Checking synchro-ring for wear
11 - Circlip
 Mark
2:20:25 AM Page 167

12 - 3rd and 4th gear synchro-hub
 High collar faces 3rd gear

 Pressing off. See Pressing out 3rd and 4th gear synchro-hub
 Pressing on. See Pressing on 3rd and 4th gear synchro-hub
13 - Circlip
 Mark
 Re-determine when replacing synchro-hub. See Determining circlip

2:20:25 AM Page 168

14 - 3rd and 4th gear locking collar
 Installation position. See Installation position of locking collar
15 - 4th gear synchro-ring
16 - Spring
 Inserting in 4th gear sliding gear. See Inserting spring into sliding gear
17 - 4th gear sliding gear
18 - 4th gear needle bearing
19 - 5th gear wheel
 Pressing off. See Pressing out 5th gear wheel

 Pressing on. See Pressing on 5th gear wheel
20 - Circlip
 Mark
 Re-determine when replacing 5th gear wheel. See Determining circlip
2:20:25 AM Page 169


21 - Roller sleeve
 Replace
 Is damaged on removal
 Extracting. See Extracting roller sleeve
 Installation position. See Installation position of roller sleeve
 Driving in. See Driving in roller sleeve
22 - Sleeve
 Plastic
2:20:25 AM Page 170

Locking bolt for needle bearing
Fig. 234: Location Of Securing Bolt

 Remove locking bolt (arrow).
NOTE: Bolt is not always installed.
Fig. 235: Driving Out Needle Bearing

Installation position of needle bearing
2:20:25 AM Page 171

Fig. 236: Installation Position Of Needle Bearing

Dimension -a- from bottom edge of rule to top edge of needle bearing = 39.5 mm
NOTE: Measure from top edge of rule and subtract height of rule from measured value.

2:20:25 AM Page 172


 If installed, screw in locking bolt and tighten to 25 Nm.
Driving oiling sleeve into input shaft
Fig. 239: Driving In Oiling Sleeve Into Input Shaft

Item Oiling sleeve diameter Driving-in tool

A 14 mm VW 222 A
B 16 mm 30-24
Flared edge of oiling sleeve faces driving-in tool
 Drive-in depth:
3.5 mm below top edge
Extracting roller sleeve
2:20:25 AM Page 173

Fig. 240: Removing Roller Sleeve

A - Internal puller 22 to 28 mm, e.g. Kukko 21/4
 Before installing internal puller, destroy plastic bushing inside roller sleeve.
Installation position of roller sleeve
Fig. 241: Installed Position Of Roller Sleeve

Driving in roller sleeve
2:20:25 AM Page 174

Fig. 242: Driving In Roller Sleeve

Pressing out 5th gear wheel
Fig. 243: Pressing Off 5th Gear

Pressing out 3rd and 4th gear synchro-hub
2:20:25 AM Page 175

Fig. 244: Pressing Off Synchro-Hub For 3rd And 4th Gear

 Push 3rd gear synchro-ring (arrow) toward sliding gear for 3rd gear, then install separating tool -A-.
Inserting spring into sliding gear
Fig. 245: Inserting Spring Into Gear

Bent end of spring (arrow) must be hooked into hole of sliding gear.
Checking synchro-ring for wear
2:20:25 AM Page 176

Fig. 246: Checking Synchronizer For Wear

 Push synchro-ring into locking collar and use feeler gauge to measure gap -a- at positions -A-, -B- and -
C-.
 Add up measured values and divide by 3.
Obtained value must not be lower than 0.5 mm.
Installation position of circlips
Fig. 247: Identifying Installed Positions Of Circlips

 Circlips -1- and -2- secure ball bearing of input shaft.
Determining thickness. Refer to Input shaft, adjusting.
2:20:25 AM Page 177

 Circlip -3- secures synchro-hub for 3rd and 4th gear.
Thickness 2.00 mm. Identifiable by: Color brown.
Determining thickness. Refer to Available circlips for 3rd and 4th gear synchro-hub. Identifiable by: Color
blue.
 Circlip -5- secures 5th gear wheel.
Determining thickness. Refer to Available circlips for 5th gear wheel.
Determining circlip
Fig. 248: Determining Circlip Fit

 Determine and install thickest circlip which can be inserted.

 Determine circlip as accurately as possible using chart. Part numbers:
Available circlips for 3rd and 4th gear synchro-hub

1.90 1.96 2.02
1.93 1.99 2.05
Available circlips for 5th gear wheel
2:20:25 AM Page 178


1.90 1.96 2.02
1.93 1.99
Pressing on 3rd and 4th gear synchro-hub
High collar on inside faces 3rd gear
Installation position of locking collar
Fig. 250: Identifying Installed Position Of Operating Sleeve Up To Transmission Manufacture Date 22 06
3
2:20:25 AM Page 179

Locking collars with chamfer -A- and locking collars with high shoulder -B- are used for assembly.
Chamfer (arrow -1-) faces 4th gear
Low shoulder (arrow -2-) faces 3rd gear
High shoulder (arrow -3-) faces 4th gear
Pressing on 5th gear wheel
Fig. 251: Pressing On 5th Gear

WARNING: Wear protective gloves.
 Heat 5th gear wheel to approx. 100 ° C before pressing on.
High collar faces reverse gear
INPUT SHAFT, ADJUSTING
Input shaft, adjusting
(Determining input shaft circlips)
2:20:26 AM Page 180

Fig. 252: Press Tube 30-100Identifying Special Tools - Oil Pump/Front Sealing Flange, Drive Chain And
Chain Sprocket For Oil Pump, Removing And Installing
Fig. 253: Spacer Gauge 3167

 3167 Distance gauge

 Depth slide gauge
Input shaft must be re-adjusted if
 Input shaft
or
 Ball bearing
is/are replaced.
2:20:26 AM Page 181

Fig. 254: Placing Transmission Housing Over Input Shaft Onto Spacer Gauge
 Clamp input shaft with soft jaws -A- in vice.

 Position distance gauge 3167 on 3rd gear sliding gear.
 Position transmission housing over input shaft onto distance gauge.
Fig. 255: Determining Circlip Thickness, Measuring Value "a"

 Position depth slide gauge on transmission housing and measure up to lower groove for circlip in input
shaft.
 Measured value in following example: -a- = 28.50 mm
2:20:26 AM Page 182

Fig. 256: Determining Circlip Thickness, Measuring Value "b"

 Position depth slide gauge on transmission housing and measure up to contact surface of ball bearing.
 Measured value in following example: -b- = 26.80 mm
Determining circlip behind ball bearing for input shaft
Formula:
"x" = dimension "a" - dimension "b"
Example:
Dimension "a" 28.50 mm
- Dimension "b" 26.80 mm
= Dimension "x" (circlip thickness) 1.70 mm
 Determine circlip using chart. Part numbers
Available circlips
Dimension "x" Thickness (mm)

1.48 to 1.56 1.54
1.57 to 1.65 1.63
1.66 to 1.74 1.72
1.75 to 1.83 1.81
1.84 to 1.92 1.90
1.93 to 2.01 1.99
2.02 to 2.10 2.08
2.11 to 2.20 2.17
2.21 to 2.27 2.25
2.28 to 2.35 2.33
2:20:26 AM Page 183

Determining circlip in front of ball bearing for input shaft
 Drive determined rear circlip and ball bearing onto input shaft using Press tube 30-100.
Fig. 257: Input Shaft And Thickest Circlip Which Can Still Just Be Installed

Available circlips

1.45 1.72 1.99
1.54 1.81 2.08
1.63 1.90 2.17
PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING
Pinion and hollow shaft, disassembling and assembling
2:20:26 AM Page 184

Fig. 258: Identifying Special Tools - Pinion Shaft And Hollow Shaft, Disassembling And Assembling


2:20:26 AM Page 185


 VW 429 Thrust collar
 VW 447i Thrust pad
 VW 454 Pressure piece

2:20:26 AM Page 186


 40-103 Base
 3062 Thrust pad
 3128 Puller
 Kukko 17/2 Separating tool
 Kukko 21/1 Internal puller
NOTE:
2:20:26 AM Page 187

Fig. 261: Transmission Housing, Overview

 Observe technical data when installing new gear wheels or drive unit.
and capacities.
 When replacing parts marked 1) adjustments are required. Refer to
Adjustment table.
2 - Shim "S3"
 Adjustment table. Refer to Adjustment table
3 - Outer race for double tapered roller bearing 1)
2:20:26 AM Page 188

 Replace together with -item 5

 Extracting. See Extracting outer race for double tapered roller bearing
 Pressing in. See Pressing in outer race for double tapered roller bearing

4 - Pinion1)
 Paired with ring gear, replace as assembly

 Adjusting pinion and ring gear. Refer to General
5 - Inner race for double tapered roller bearing 1)
 Replace
2:20:26 AM Page 189

 Gets damaged on removal

 Pressing off. See Pressing off inner race for double tapered roller bearing
 Pressing on. See Pressing on inner race for double tapered roller bearing
6 - Circlip
 Determine thickness when replacing double tapered roller bearing. See Determining circlip
7 - Needle bearing
 For pinion in hollow shaft


2:20:26 AM Page 190

8 - Hollow shaft 1)
9 - Needle bearing for 1st gear
11 - 1st gear sliding gear
12 - Spring
 Inserting in 1st gear sliding gear. See Inserting spring into sliding gear
13 - 1st gear synchro-ring
14 - 1st and 2nd gear synchro-hub
 Pressing off. See Pressing off 1st and 2nd gear synchro-hub
 Pressing on. See Pressing on synchro-hub for 1st and 2nd gear
2:20:26 AM Page 191


15 - Circlip
 Mark
 Re-determining when replacing synchro-hub. See Determining circlip
16 - Needle bearing for 2nd gear
17 - 1st and 2nd gear locking collar
 Installation position. See Installation position of locking collar for 1st and 2nd gear
18 - 2nd gear synchro-ring
2:20:26 AM Page 192

19 - Spring
 Inserting in 2nd gear sliding gear. See Inserting spring into sliding gear
20 - 2nd gear sliding gear

21 - Circlip
 Mark
2:20:26 AM Page 193

22 - 3rd gear wheel
 Pressing off. See Pressing off 3rd gear wheel

 Pressing on. See Pressing on 3rd gear wheel
23 - Circlip
 Mark
 Re-determining when replacing 3rd gear wheel. See Determining circlip
24 - 4th gear wheel
 Pressing off. See Pressing off 4th gear wheel

25 - Circlip
 Mark
 Re-determining when replacing 4th gear wheel. See Determining circlip
2:20:26 AM Page 194


26 - Needle bearing
28 - Spring
2:20:26 AM Page 195

30 - Circlip
 Mark
31 - Synchro-hub 5th gear and reverse gear
 Pressing off. See Pressing off 5th gear and reverse gear synchro-hub
 Pressing on. See Pressing on synchro-hub for 5th gear and reverse gear

32 - Circlip
 Mark
2:20:26 AM Page 196


33 - Needle bearing
34 - Locking collar for 5th gear and reverse gear
 Installation position. See Installation position of locking collar for 5th gear and reverse gear
35 - Reverse gear synchro-ring
36 - Spring
 Inserting in reverse gear sliding gear. See Inserting spring into sliding gear
2:20:26 AM Page 197


37 - Reverse gear sliding gear
38 - Circlip
 Mark
 Installation position Installation position of circlips item 7
39 - Inner race for tapered roller bearing 1)
 Pressing off. See Pressing off inner race for tapered roller bearing
 Pressing on. See Pressing on inner race for tapered roller bearing
40 - Bushing
2:20:26 AM Page 198

 For securing outer race of small tapered roller bearing

 Extracting. See Pulling out locking bushing for outer race of small tapered roller bearing
 Does not need to be installed after small tapered roller bearing has been replaced

41 - Outer race for tapered roller bearing1)
 Pressing out. See Pressing out outer race for tapered roller bearing
 Pressing in. See Pressing in outer race for tapered roller bearing
42 - Shim "S4"
2:20:26 AM Page 199

43 - Ring
 For holding rubber washer

 Assignment
44 - Rubber washer
 For length compensation

 Assignment
Extracting outer race for double tapered roller bearing
Fig. 270: Pulling Out Outer Race For Double Tapered Roller Bearing
Removing differential. Refer to Differential, removing and installing.
 Position pressure piece of puller 3128 beneath outer race.

 Install threaded section of puller 3128 together with pressure plate VW 401 onto transmission housing.
When bolt is tightened, outer race is pulled out of housing.
Pressing off inner race for double tapered roller bearing
2:20:26 AM Page 200

Fig. 271: Pressing Off Inner Race For Double Tapered Roller Bearing
 Remove circlip before pressing off.
NOTE:  Outer race -A- must be mounted before inner race can be removed.
 Inner race of double tapered roller bearing will be destroyed during
pressing off.
Pressing in outer race for double tapered roller bearing
Fig. 272: Pressing In Outer Race For Double Tapered Roller Bearing
Smaller diameter of thrust pad 3062 faces outer race.
Pressing on inner race for double tapered roller bearing
2:20:26 AM Page 201

Fig. 273: Pressing On Inner Race For Double Tapered Roller Bearing
Determining circlip
Fig. 274: Determining Circlip To Be Installed


 Determine circlips for synchro-hubs, needle bearings and gear wheels of individual gears as shown for
double tapered roller bearing.
Available circlips and their part numbers:
Pulling out locking bushing for outer race of small tapered roller bearing
2:20:26 AM Page 202

Fig. 275: Pulling Off Securing Bushing For Small Tapered Roller Bearing Outer Race
Pressing out outer race for tapered roller bearing
Fig. 276: Pressing Out Outer Race For Tapered Roller Bearing
 Press outer race out together with ring -item 43: Refer to Pinion and hollow shaft, disassembling and
assembling, shim "S4" -item 42: Refer to Pinion and hollow shaft, disassembling and assembling and
rubber washer for length compensation -item 44: Refer to Pinion and hollow shaft, disassembling and
assembling.
Pressing in outer race for tapered roller bearing
2:20:26 AM Page 203

Fig. 277: Pressing In Tapered Roller Bearing Outer Race

Pressing off inner race for tapered roller bearing
Fig. 278: Pressing Off Inner Race For Tapered Roller Bearing
 Press off inner race together with reverse gear sliding gear.
Pressing on inner race for tapered roller bearing
2:20:26 AM Page 204

Fig. 279: Pressing On Tapered Roller Bearing Inner Race

 Install circlip before pressing on inner race.
Pressing off 5th gear and reverse gear synchro-hub
Fig. 280: Pressing Off Synchronizer Hub For 5th Gear And Reverse Gear

 Press off synchro-hub together with 5th gear sliding gear.
Pressing off 4th gear wheel
2:20:27 AM Page 205


Pressing off 3rd gear wheel
Fig. 282: Pressing Off 3Rd-Gear Gear Wheel


 Press off 3rd gear wheel together with 2nd gear sliding gear.
Pressing off 1st and 2nd gear synchro-hub
2:20:27 AM Page 206

Fig. 283: Pressing Off 1st And 2nd Gear Synchro-Hub


 Press off synchro-hub together with 1st gear sliding gear.
Fig. 284: Identifying Installed Position Of Circlips

 Determine circlips for synchro-hubs, needle bearings and gear wheels of individual gears as shown in.
See Determining circlip.
 Circlip -1- secures synchro-hub for 1st and 2nd gear.
Identifiable by color: blue
2:20:27 AM Page 207

1.90 1.96 2.02

1.93 1.99
 Circlip -2- secures 2nd gear needle bearing/sliding gear.

2.50

 Circlip -3- secures 3rd gear wheel.

1.90 1.98 2.06
1.94 2.02

1.86 1.94
1.90 1.98
2:20:27 AM Page 208

 Circlip -5- secures 5th gear needle bearing/sliding gear.
Identifiable by color: brown

2.00

 Circlip -6- secures synchro-hub for 5th gear and reverse gear.

1.90 1.96 2.02
1.93 1.99 2.05
 Circlip -7- secures needle bearing for reverse gear sliding gear.

2.50
 If necessary determine circlips using chart. Part numbers
2:20:27 AM Page 209



C-.
Pressing on synchro-hub for 1st and 2nd gear
2:20:27 AM Page 210

Fig. 289: Pressing On Synchronizer Hub For 1st And 2nd Gears
High collar on inside faces 2nd gear
Installation position of locking collar for 1st and 2nd gear
Fig. 290: Identifying Installed Position Of Operating Sleeve For 1st And 2nd Gear
Chamfer (arrow -1-) faces 2nd gear
Shoulder (arrow -2-) faces 1st gear
Pressing on 3rd gear wheel
2:20:27 AM Page 211

Fig. 291: Pressing On 3rd-Gear Gear Wheel

Groove on gear wheel faces 4th gear

Pressing on synchro-hub for 5th gear and reverse gear
2:20:27 AM Page 212

Fig. 293: Pressing On Synchronizer Hub For 5th Gear And Reverse Gear
High collar on inside faces 5th gear
Installation position of locking collar for 5th gear and reverse gear
3
 Note locking collar assignment to reverse idler gear. See Locking collar assignment to reverse idler
gear
2:20:27 AM Page 213

Chamfer (arrow -1-) faces reverse gear
Low shoulder (arrow -2-) faces 5th gear
High shoulder (arrow -3-) faces reverse gear
Locking collar assignment to reverse idler gear
Fig. 295: Allocation Of Operating Sleeve To Reverse Idler Gear

A Reverse idler gear with Either locking collar type (with chamfer or high shoulder) can be used for
chamfer assembly
B Reverse idler gear without Only locking collars with high shoulder can be used for assembly. Do not
chamfer use locking collars with chamfer.
REVERSE IDLER GEAR, REMOVING AND INSTALLING
Reverse idler gear, removing and installing
2:20:27 AM Page 214

Fig. 296: Reverse Idler Gear, Overview

1 - Circlip
2 - Support plate
3 - Reverse idler gear
 Different versions, Assignment. See Locking collar assignment to reverse idler gear
4 - Needle bearing
5 - Thrust washer
2:20:27 AM Page 215


 With axle for reverse idler gear (arrow)

 Axle for reverse idler gear does not have to be removed in order to remove reverse idler gear
 Axle for reverse idler gear is not available as replacement part
 For additional fastening of axle for reverse idler gear

OIL SEAL FOR DRIVE FLANGE, REPLACING
2:20:27 AM Page 216

Fig. 298: Identifying Special Tools

 Pay attention to general repair instructions. Refer to General repair instructions.
 VW 295 Mandrel
 2062 Insertion mandrel
 T10037 Puller

2:20:27 AM Page 217


 VAG 1306 Drip tray
NOTE:  Use the same procedure for removing both left and right oil seals.
 It is not necessary to remove the exhaust system.
Removing
 Turn steering wheel to left lock.

 Remove cover plates above drive axle (arrows 1 + 2).

 Disconnect drive axle from transmission flange:
 Tie drive axle up as far out of the way as possible. Take care not to damage paintwork on drive axle.
 Place drip tray VAG 1306 under transmission.
2:20:27 AM Page 218

Replacing left oil seal

 Remove drive flange by firmly screwing puller T10037 to cover of differential (arrow).
Replacing right oil seal
Fig. 302: Removing Drive Flange (Right Side)

 Remove drive flange by firmly screwing puller T10037 to transmission housing (arrow).
2:20:27 AM Page 219


 Always replace circlip of drive flange.
 Clamp drive flange with soft jaws in vice. Press circlip out of drive flange groove using new circlip -A-.
 Pull out oil seal of drive flange using VW 681.

Drive flange assembly with mounted polygonal bearing
1 - Drive flange
2 - Needle bearing (polygonal bearing)
2:20:27 AM Page 220

3 - Spacer ring
4 - Circlip
5 - Spacer ring - additionally installed if splined shaft diameter = 30 mm
NOTE:  Polygonal bearings run roughly when drive flange is not installed. This
does not indicate faulty bearings. An acoustic test can only be conducted
when drive flange is installed.
 Look out for damages to polygonal bearings (e.g. cracks in outer race of
bearing)
 Polygonal bearings can only be replaced together with drive flange.
 Drive flanges with a splined shaft diameter of 30 mm have a spacer ring -5-
installed between polygonal bearing and planet pinion.
Installing
NOTE: Repair rim offset 6.5 mm if employing used drive flange.
Fig. 305: Installing Right-Hand Drive Flange Seal

 Drive in new oil seal for right drive flange 5.5 mm below surface of housing, taking care not to tilt it.
2:20:27 AM Page 221

Fig. 306: Installing Left-Hand Drive Flange Seal

 Drive in new oil seal for left drive flange 5.5 mm below surface of cover, taking care not to tilt it.
 Drive in drive flange using mandrel VW 295.
 Screw drive axle to drive flange.
 Screw on cover plates for drive axle, if installed.
 Checking oil level in manual transmission. Refer to Transmission oil level, checking.
Tightening torques
Component Nm
Drive axle to drive flange M8 40
M10 70
Heat shields for drive axles 23
SPEEDOMETER VEHICLE SPEED SENSOR AND DRIVE-WHEEL, REMOVING AND

INSTALLING
Speedometer vehicle speed sensor and drive-wheel, removing and installing
Speedometer vehicle speed sensor -G22-, removing and installing
Removing
2:20:27 AM Page 222

Fig. 307: Identifying Speedometer Vehicle Speed Sensor (VSS) and O-ring
 Unplug connector of sender -A-.

 Press down retainer, swivel sensor to one side and pull upward and out.
Installing
 Replace O-ring -B- during installation.

 Insert sensor and engage.
NOTE: Handle sender with care. If damaged, speed values can no longer be precise.
Speedometer drive wheel, removing and installing
2:20:27 AM Page 223


 VW 295 Mandrel
 T10037 Puller

2:20:27 AM Page 224


Removing

 If installed, remove cover plate above left drive axle.
 Disconnect drive axle from drive flange.

2:20:27 AM Page 225

 Remove speedometer vehicle speed sensor. Refer to Speedometer vehicle speed sensor -G22-,
Removing speedometer driving gear:
Fig. 311: Press Drive Gear Retaining Clips In Direction Of Arrows Using Screwdriver
 Press clips in direction of arrow using a screwdriver.

 Remove driving gear by prying out on all sides.
Installing
NOTE: Install the driving gear carefully ensuring it is not crooked on the differential. Do
not use force or the driving gear could break.
2:20:27 AM Page 226

Fig. 312: Identifying Installed Position Of Drive Gear, Retaining Clip And Seal
Driving tab of driving gear -A- faces oil seal -B- and locks in place in groove of differential.
The clips (arrows) engage in circumferential groove of differential.
 Always replace oil seal -B- and circlip -C-.

 Top up manual transmission with oil and check oil level. Refer to Transmission oil level, checking.
Tightening torques
Component Nm
M10 70
OIL SEAL FOR DRIVE FLANGE/DRIVE SHAFT, REPLACING
Oil seal for drive flange/drive shaft, replacing
2:20:27 AM Page 227

Fig. 313: Identifying Special Tools - Oil Seal For Drive Flange/Drive Shaft, Replacing

 30-505 Insertion mandrel
 30-506 B Press tool
Removing
2:20:27 AM Page 228

 Place drip tray VAG 1306 underneath and drain gear oil.


 Unscrew heat shield for driveshaft from cover of Torsen differential (arrows).
2:20:27 AM Page 229

 Re-insert speed nut (arrow) slightly and secure driveshaft to stud with wire.
 Place drip tray VAG 1306 below cap.
NOTE:

Oil escapes when cap -B- is taken off.

 Install an M8 bolt into threaded hole of cap.
 Remove cap by means of bolt.
2:20:28 AM Page 230


Fig. 319: Pulling Out Oil Seal For Drive Flange Using VW 681
 Pull out oil seal for drive flange using VW 681.
Installing
2:20:28 AM Page 231

Fig. 320: Driving In New Flange Shaft Seal

 Drive in new oil seal for drive flange 2 mm below surface of housing, taking care not to tilt it.
 Insert drive flange.

 Insert drive flange circlip at same time as shaft.
 Insert cap with a new O-ring and secure.

 Align exhaust system stress-free:
2:20:28 AM Page 232

Tightening torques
Component Nm
Drive shaft to manual transmission 1) 55
1) Replace bolt

2:20:28 AM Page 233


 3257 6 mm Allen key extension
NOTE:  The differential can also be removed and installed with the transmission
installed.
 The differential can be removed and installed without disassembling the
transmission, input shaft, pinion or transmission housing. The above-
mentioned parts must be disassembled if the differential is to be adjusted.
 Watch out for visible damages to the polygonal bearings.
 Polygonal bearings run roughly when drive flange is not installed. This
 Drive flanges with a splined shaft diameter of 30 mm have a spacer ring
installed between polygonal bearing and bevel gear. See Drive flange
assembly with polygonal bearings, -item 5-.
Adjustment table.
2:20:28 AM Page 234

Fig. 323: Differential, Removal And Installation, Overview

2 - Oil seal
 Replacing. Refer to Oil seal for drive flange, replacing
3 - Circlip
 Replace
 Removing and installing. See Removing and installing circlip
4 - Spacer ring
2:20:28 AM Page 235

 Only installed on drive flanges with polygonal bearings and splined diameter 30 mm
 Removing. See Removing spacer ring
 Installing. See Installing spacer ring
5 - Drive flange
 Removing and installing. Refer to Oil seal for drive flange, replacing
 Drive flange assembly: See Drive flange assembly with polygonal bearings

 Can also be removed without removing manual transmission
2:20:28 AM Page 236

 Apply a thin coat of sealing paste AMV 188 001 02 to sealing surfaces
9 - Speedometer driving gear
 Removing and installing. Refer to Speedometer drive wheel, removing and installing
 Mount on differential carefully and without tilting. Do not use force, the driving gear could break
Removing and installing circlip

Removing spacer ring
2:20:28 AM Page 237

Fig. 326: Removing Spacer Ring

A - Internal puller 18.5 to 23.5 mm, e.g. Kukko 21/3
 If difficult to move, pull out spacer ring using multi-purpose tool VW 771.
Installing spacer ring
Fig. 327: Installing Spacer Ring

 Push spacer ring in as far as it will go, ensuring it is not crooked.
Drive flange assembly with polygonal bearings
2:20:28 AM Page 238

Fig. 328: Flange Shaft Assembly, Overview

1 - Drive flange
3 - Spacer ring
5 - Circlip
NOTE: Needle bearings (polygonal bearings) do not move freely when drive flange is
removed. This does not indicate faulty bearings.
2:20:28 AM Page 239

Fig. 329: Identifying Special Tools - Differential, Disassembling And Assembling


 VW 447 H Thrust pad

2:20:28 AM Page 240


 VW 472/1 Pressure piece

 3138 Punch-out tool
 3144 Sleeve
 3296 Pipe
2:20:28 AM Page 241


 VW 459 Pressing-out and pressing in tool

 3 - Kukko 204/2 Puller
 4 - Kukko 22/2 Counter-support
 Kukko 44-2 Two-arm puller
NOTE:
2:20:28 AM Page 242

Fig. 332: Differential, Disassembling And Assembling, Overview

 Removing and installing differential. Refer to Differential, removing and

installing.
 Replace both tapered roller bearings together.
Adjustment table.
2 - Shim "S2"
 Make note of thickness

2:20:28 AM Page 243

 Extracting. See Extracting tapered roller bearing outer race from transmission housing
 Pressing in. See Pressing tapered roller bearing outer race into transmission housing

 Pulling off. See Extracting inner race for right tapered roller bearing
 Pressing on. See Pressing on inner race for right tapered roller bearing
5 - Ring gear 1)
 Paired with pinion (drive unit)
2:20:28 AM Page 244

 Assigning by way of transmission code letters. Refer to Code letters, assignment of mechanical units,
transmission ratios and capacities
 Driving out of housing using mandrel. See Driving ring gear out of housing
 Installing to differential housing HEATING RING GEAR TO APPROX. 100 ° C and installing 10
 Assignment

7 - Bolt, 60 Nm plus 1/8 turn (45)
2:20:28 AM Page 245

 Always replace
 Screw in bolts evenly and tighten to torque in diagonal sequence
 Pulling off. See Extracting inner race for left tapered roller bearing
 Pressing on. See Mounting inner race for left tapered roller bearing
 Assignment
2:20:28 AM Page 246

 Driving out. See Driving outer race of left tapered roller bearing out of cover
 Pressing in. See Driving outer race of left tapered roller bearing into cover
 Assignment
11 - Shim "S1"

 Assignment
 Assignment
2:20:28 AM Page 247


13 - Large bevel gear
 Installing. See Installing bevel gears
14 - Differential bevel gear shaft
 Drive out with mandrel after removing spring pin
15 - Spring pin
 For securing bevel gear shaft

 With circumferential groove: Removing and installing. See Removing and installing spring pin
 Without circumferential groove: Drive out with mandrel
2:20:28 AM Page 248

16 - Small bevel gear
17 - One-piece thrust washer
 Apply gear oil on insertion
Extracting tapered roller bearing outer race from transmission housing
Fig. 337: Pulling Outer Race/Tapered Roller Bearing Out Of Transmission Housing
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
 Check shims for damage after removal.
Pressing tapered roller bearing outer race into transmission housing
Fig. 338: Pressing Outer Race/Tapered Roller Bearing Into Transmission Housing
2:20:28 AM Page 249

 Insert tapered section of pressure piece VW 472/1 into outer race.
Extracting inner race for right tapered roller bearing
Fig. 339: Pulling Off Right Tapered Roller Bearing Inner Race
A - Two-arm puller, e.g. Kukko 20/10 or Kukko 44/2
NOTE: The differential features a recess under the bearing seat for applying the puller -
A-.
Pressing on inner race for right tapered roller bearing
Fig. 340: Pressing On Right Tapered Roller Bearing Inner Race

2:20:28 AM Page 250

 Heat inner race to approx. 100 ° C, mount and press into place.
Extracting inner race for left tapered roller bearing
Fig. 341: Pulling Off Left Tapered Roller Bearing Inner Race
A - Two-arm puller, e.g. Kukko 204/2
A-.
Mounting inner race for left tapered roller bearing
Fig. 342: Installing Left Tapered Roller Bearing Inner Race

2:20:28 AM Page 251

Driving outer race of left tapered roller bearing out of cover
Fig. 343: Driving Out Outer Race Of Left Tapered Roller Bearing From Cover
 Screw out webs -A- and -B- until they are positioned on outer race inside recess in housing.
Driving outer race of left tapered roller bearing into cover
Fig. 344: Driving In Outer Race Of Tapered Roller Bearing Into Cover
 Press outer race of left tapered roller bearing into cover using pressure piece 2050.
 Insert tapered section of pressure piece 2050 into outer race.
Driving ring gear out of housing
2:20:28 AM Page 252


Heating ring gear to approx. 100 ° C and installing

 Use locating pins -A- (self-made) to guide ring gear when installing.
 Allow to cool somewhat before screwing in bolts. Then tighten to torque.
Installing bevel gears
2:20:28 AM Page 253


 Lubricate one-piece thrust washer with gear oil and insert.

 Insert large bevel gears.
 Insert small bevel gears offset by 180 ° and swivel into place (arrow).
 Drive bevel gear shaft into final position and secure.
Removing and installing spring pin
Fig. 348: Pulling Out Spring Pin With Side Cutting Pliers
Removing
 Extract spring pin with circumferential groove using side-cutting pliers.

 Knock out spring pin without circumferential groove from behind with mandrel.
Installing
 Drive in spring pin as far as it will go.
2:20:28 AM Page 254

General
 Careful adjustment of the pinion and ring gear is a decisive factor as regards the service life and smooth
running of the final drive. Even during production, the pinion and ring gear are checked together to
ensure a good seating position and low noise in both directions of rotation. The position which achieves
the smoothest running is determined by moving the pinion axially, so that the ring gear is never
absolutely tight against the pinion but remains within the specified tolerance for torsional side clearance.
 The objective of adjustment is to once more achieve the position for smoothest running, which was
originally ascertained on the testing machine during production.
 The dimension "r" referenced to controller "Ro" is written on the circumference of the ring gear. Only
replace drive unit components (pinion and ring gear) together.
Drive units, adjusting and marking
Fig. 349: Identifying Gear Set Markings And Adjustment Dimensions

2:20:28 AM Page 255

1 - Code "0937" stands for Oerlikon drive unit with transmission ratio 37 : 9.
2 - Pair number (312) of drive set
3 - Dimension "r" referenced to controller of testing machine used in production. Dimension "r" is
always stated in 1/100 mm. Example: "25" stands for r = 0.25 mm
Ro - Length of testing machine controller used.
Ro - Ring gear diameter 170 mm = 54.95 mm

R - Actual dimension between ring gear axis and end face of pinion at the point of smoothest running for
this one drive set
2:20:29 AM Page 256

Vo - Hypoid offset
Position of shims
Fig. 351: Identifying Shim Locations

NOTE: Adjustment table for replacing individual transmission components. Refer to

Adjustment table.
S1 - Shim for ring gear in final drive cover
S3 - Shim for pinion in transmission housing
2:20:29 AM Page 257

S4 - Shim for pinion in transmission cover
Adjustment table
NOTE: When performing transmission repair work, the pinion, ring gear or drive unit
must only be re-adjusted if you are replacing components which directly
influence the setting of the final drive. Refer to the following table so as to avoid
unnecessary adjustment.
To be adjusted:
Ring gear Pinion Pinion Torsional side
Replaced component: "S1"+"S2" 1) "S3"+"S4" 1) "S4" 1) clearance
Refer to Ring over Refer to Shim "S4", re- Checking
gear, dimension "r" determining when Refer to
adjusting Refer to replacing transmission Measuring
Pinion, cover torsional side
adjusting clearance
3)
Transmission cover X
Double tapered roller X X
bearing for pinion and
hollow shaft
Differential tapered X X
roller bearing
Drive unit 2) X X X
Final drive cover X X
1) Shims, installation position. Refer to Position of shims
2) Pinion and ring gear, only replace together
3) If transmission housing is replaced, input shaft must also be adjusted. Refer to Input shaft, adjusting.
Drive unit, re-adjustment sequence
2:20:29 AM Page 258

Fig. 352: Adjusting Gear Set, Sequence

If the pinion and ring gear require re-adjustment, please follow the sequence described below in the interest of
rationalized work procedure:
1.) Define total shim thickness "Stotal" of "S1" + "S2" (adjusting pre-load of tapered roller bearing for
differential). Refer to Defining total shim thickness "Stotal" of shims "S1" + "S2" onward.
3.) Distribute total shim thickness "Stotal" of "S3" + "S4" in such a way that dimension from center of
ring gear to end face of pinion corresponds to mounting dimension "R" as defined during production.
Refer to Defining thickness of shim "S3" onward.
4.) Distribute total shim thickness "Stotal" of "S1" + "S2" in such a way that the specified torsional side
clearance is present between ring gear and pinion. Refer to Defining thickness of shim "S2" onward.
NOTE: List of components and shims. Refer to Position of shims.
Pinion, adjusting
2:20:29 AM Page 259

Fig. 353: Identifying Special Tools - Pinion Shaft, Adjusting

(Adjusting pinion and hollow shaft)
Work after which pinion must be adjusted see Table. Refer to Adjustment table.

 VW 385 Universal measuring device
 VW 387 Universal dial indicator holder
2:20:29 AM Page 260



 VW 792 Assembly device
 3062 Thrust pad
 3182 Insertion sleeve
Defining total shim thickness "Stotal" of shims "S3" + "S4"
(Adjusting pre-load of tapered roller bearing for pinion and hollow shaft)
2:20:29 AM Page 261

Fig. 355: Pinion Shaft Component, Overview

 Press inner race -1- of double tapered roller bearing onto pinion and secure. Refer to Pinion and hollow
shaft, disassembling and assembling onward.
 Install needle bearing -2-.

 Position circlip -3- on hollow shaft and press on inner race of tapered roller bearing -4-. Refer to Pinion
and hollow shaft, disassembling and assembling onward.
 Insert pinion shaft in hollow shaft.
NOTE: In the illustration the hollow wheel is shown without gears. The pinion can be
set either with or without gears.
2:20:29 AM Page 262

 Insert outer race of double tapered roller bearing for pinion in transmission housing without shims.
Smaller diameter of pressure plate 3062 faces outer race.

 Insert outer race of pinion tapered roller bearing together with shim "S4*" (1.0 mm thick) in transmission
cover.
NOTE:  A shim "S4" 1.0 mm thick is used provisionally as a reference value. It is

referred to below as "S4*". Once measured value "e" has been determined,
"S4*" will be replaced by actual shim "S4".
 For measurement, always insert rubber washer together with ring for
rubber washer. Refer to item 44 Pinion and hollow shaft, disassembling
and assembling.
 Insert fully assembled pinion and hollow shaft in transmission housing.

 Install transmission cover and tighten bolts to 22 Nm.
 Turn transmission so that transmission cover faces downward.
Fig. 358: Pressing Down On Drive Pinion Head Using Removal Tool VW 296
2:20:29 AM Page 263

 Press head of pinion with lever VW 296 until outer race of tapered roller bearing makes contact with
 Maintaining same pressure, rotate pinion in opposite direction to hollow shaft 5 turns in both directions,
so that double tapered roller bearing slips into place.
 Next, rotate pinion and hollow shaft together 5 turns in both directions, so that tapered roller bearing slips
into place.
Fig. 359: Installing Dial Gauge (3 Mm Range) And Set To "0" With 2 Mm Pre-Load
 Install dial indicator and set to "0" with 1 mm pre-load.
NOTE: Dial indicator extension must be situated on ground surface of pinion head.
 Turn transmission 180 ° so that transmission cover faces upward.

 Rotate pinion and hollow shaft together 5 turns in both directions, so that tapered roller bearing slips into
place. Otherwise, measurement results will be incorrect.
Fig. 360: Turn Transmission 180 Degrees, Settle Tapered Roller Bearing And Read Play On Dial Gauge
2:20:29 AM Page 264

 Read off and note down clearance indicated on dial indicator.
 Example measured value: 0.45 mm
NOTE: If the measurement is repeated, first rotate the pinion and hollow shaft once
more 5 turns in each direction. Set dial indicator to "0" with 1 mm pre-load once
again.
Formula:
"Stotal" = "S4*" + measured value + bearing pre-load
Example:
Inserted shim "S4*" 1.00 mm
+ measured value (example) 0.45 mm
+ bearing pre-load (constant value) 0.15 mm
= Total shim thickness "Stotal" 1.60 mm
of "S3" + "S4"
Defining thickness of shim "S3*"
Formula:
"S3*" = "Stotal" - "S4*"
Example:
Total shim thickness "Stotal" 1.60 mm
of "S3" + "S4"
- inserted shim "S4*" 1.00 mm
= Thickness of shim "S3*" 0.60 mm
 Remove outer race of tapered roller bearing, insert shim "S3*" in transmission housing and re-install
outer race. See Pressing in outer race for double tapered roller bearing
 Re-insert fully assembled pinion in transmission housing.
 Rotate pinion in same direction and in opposite direction to hollow shaft 5 turns in both directions, so that
tapered roller bearings slip into place.
2:20:29 AM Page 265

Fig. 361: Installing Measuring Tools And Secure To Transmission Housing

 Install measuring tools and secure with bolt (arrow) to transmission housing.
 Set dial indicator (3 mm measuring range) to "0" with 2 mm pre-load.
 Loosen bolts of transmission cover and turn pinion freely.
If correct shims were selected, the dial indicator should show the following value:
 0.05 to 0.15 mm
 Tighten bolts of transmission cover to 22 Nm.

 Remove measuring tools.
Defining dimension "e"
NOTE: Dimension "e" is required to determine the definitive shim thickness of "S3"
and "S4".
2:20:29 AM Page 266

 Adjust set rings of multi-purpose measuring mandrel VW 385/1 to following values:
Fig. 363: Assembling Measuring Bar VW 385/1

 Assemble multi-purpose measuring mandrel VW 385/1 as shown in illustration:
 Dial indicator extension -A-, 6.5 mm long
 Adjust controller VW 385/30 to Ro in line with ring gear diameter and place on measuring mandrel.
Ring gear diameter 170 mm = 54.95 mm
Fig. 364: Placing End Gauge On Drive Pinion Face

2:20:29 AM Page 267

 Place gauge block plate on pinion head.
NOTE: Make sure plate fits exactly and contact area is oil free.
Fig. 365: Inserting Measuring Mandrel VW 385/1 Into Housing

 Remove controller and insert measuring mandrel in housing.
 Dial indicator extension -A- = 6.5 mm long must be screwed in

 Dial indicator faces cover of final drive
 Position cover of final drive and tighten 4 bolts to 22 Nm.

 Pull 2nd centering disc outward using moveable set ring until measuring mandrel can only just be turned
by hand.
2:20:29 AM Page 268

 Turn measuring mandrel until tip of dial indicator runs into gauge block plate on pinion head and gauge
displays maximum deflection (point of return).
 Measured value in following example: "e" = 0.26 mm (red zone)
NOTE: After removing multi-purpose measuring mandrel, check again whether dial
indicator with controller VW 385/30 in position is still set to "0" with 2 mm pre-
load.
Defining thickness of shim "S3"
 The dimension "r" referenced to controller "Ro" is measured for the drive units which are delivered as
replacement parts and written on the circumference of the ring gear.
 If measurement is performed in red zone measured value "e" must be deducted.
 If measurement is performed in black zone measured value "e" must be added on.
Formula:
"S3" = "S3*" + "r" + "e"
("e" in black zone)
"S3" = "S3*" + "r" - "e"
("e" in red zone)
Example:
+ dimension "r" 0.38 mm
- obtained value "e" (red zone) 0.26 mm
= Thickness of shim "S3" 0.72 mm
 Define shim(s) as accurately as possible using chart. Part numbers
Available shims for "S3"
Shim thickness (mm) 1)

0.40 0.55 0.70
0.45 0.60 0.75
0.50 0.65
1) Due to shim tolerances any shim thickness can be obtained. Insert 2 shims if required.
2:20:29 AM Page 269

Formula:
"S4" = "Stotal" - "S3"
Example:
of "S3" + "S4"
- thickness of shim "S3" 0.72 mm

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Checking measurement
Checking dimension "r"
 Install pinion/hollow shaft with defined shims "S3" and "S4".

 Rotate hollow shaft against pinion 5 turns in both directions, so that tapered roller bearing slips into place.
place.
2:20:29 AM Page 270

 Insert multi-purpose measuring mandrel. Refer to Defining dimension "e", and check measurement.
 Read off dial indicator counter-clockwise (red zone).
 If correct shims were selected, dimension "r" (written on circumference of ring gear) must be displayed
showing a tolerance of ± 0.04 mm
Shim "S4", re-determining when replacing transmission cover
 2 x centering disc VW 385/3

 Measuring plate VW 385/17
 Universal dial indicator holder VW 387
 Assembly device VW 792
 Dial indicator
 Dial indicator extension
 Depth caliper gauge with minimum measuring accuracy of 5/100 mm
 Clean joint surfaces of cover.
Fig. 368: Measuring Difference In Depth On Old And New Transmission Cover
 Measure difference in depth "a" on old and new transmission covers.
Example:
2:20:29 AM Page 271

Depth "a" of old transmission cover 257.40 mm

Depth "a" of new transmission cover 257.55 mm
= Difference 0.15 mm
 Install thicker shim "S4" if new transmission cover is deeper.

 Install thinner shim "S4" if old transmission cover is deeper.
Example:
Old shim "S4" 0.95 mm

+ Difference 0.15 mm
= New shim "S4" 1.10 mm
Available shims. Refer to Available shims for "S4".
 Insert outer race for tapered roller bearing together with shim "S4" in transmission cover. See Pressing in
outer race for tapered roller bearing

 Install measuring tools and secure with bolt (arrow) to transmission cover.
 0.05 to 0.15 mm
2:20:29 AM Page 272

If this value is not obtained, the setting must be corrected.
Fig. 370: Identifying Special Tools - Ring Gear, Adjusting

 VW 382/10 Dial indicator extension

 VW 385/17 Gauge block plate
 VW 386 A Clamp for pinion
2:20:29 AM Page 273

 VW 388 Measuring lever



 VW 521 Adjusting device for ring gear

 Dial indicator
The ring gear must be re-adjusted if:
2:20:29 AM Page 274

transmission housing, final drive cover, differential tapered roller bearing, differential housing or drive unit are
replaced.
Adjustment table. Refer to Adjustment table
(Adjusting pre-load of differential tapered roller bearing)
 Pinion removed
 If only differential tapered roller bearings are replaced, the ring gear can be removed from the differential
housing. In this case, the pinion does not have to be removed.
 Pull out oil seals for drive flanges using extractor lever VW 681.
 Remove outer races of differential tapered roller bearings and take out shims. Refer to Differential,
 Drive outer race of small tapered roller bearing and shim "S2" into transmission housing. For
measurement purposes, a shim "S2*" 1.20 mm thick is used (2 shims of 0.60 mm).
NOTE: A shim "S2" 1.20 mm thick is used provisionally as a reference value. It is

referred to below as "S2*". Once torsional side clearance is determined, "S2*" is
replaced by the definitive "S2".
2:20:29 AM Page 275

 Press outer race of tapered roller bearing into cover of differential without shim "S1".
 Insert differential without driving gear for sender of speedometer -G22 in transmission housing.
 Install cover of differential using 4 bolts (25 Nm).
 Position transmission so that cover of differential faces upward.
 Rotate differential 5 turns in both directions, so that tapered roller bearing slips into place.
 Lay measuring plate VW 385/17 on differential.
Fig. 374: Installing Magnetic Plate 50Mm Dia. VW 385/17 And Dial Gauge
 Set up measuring tools using a 30 mm dial indicator extension.

 Set dial indicator (3 mm measuring range) -A- to "0" with 2 mm pre-load.
2:20:29 AM Page 276

NOTE: Measuring tip of dial indicator must be positioned on center of differential.
 Lift differential without turning; read and note clearance indicated on dial indicator.
NOTE:
Fig. 375: Securing Special Tools VW 521/4 And VW 521/12 At Right On

Differential (Housing Side)
 To raise differential, fasten special tools VW 521/4 and VW 521/12 to right

of differential (housing side).
 If the measurement is repeated, first rotate the pinion and hollow shaft
once more 5 turns in each direction, so that the tapered roller bearing slips
into place.
Formula:
Example:
Inserted shim(s) "S2*" 1.20 mm
+ measured value 0.62 mm
for "S1" + "S2"
NOTE:  Provisional shim "S1*" is replaced by definitive "S1" after torsional side
clearance has been determined.
 Total shim thickness "Stotal" remains unchanged.
2:20:29 AM Page 277

Formula:
"S1*" = "Stotal" - "S2*"
Example:
for "S1" + "S2"
- inserted shim(s) "S2*" 1.20 mm
Assigning shims
Measuring torsional side clearance
 Pinion installed with shims "S3*" and "S4*"
 Install differential with ring gear: S1* is installed on cover side, S2* in transmission housing.
 Mount final drive cover and tighten bolts to 25 Nm.
 Insert adjustment tool for ring gear VW 521/4 and VW 521/12.
 Rotate differential 5 turns in both directions, so that tapered roller bearings slip into place.
Fig. 376: Measuring Backlash

 Secure dial indicator holder VW 387 to housing.

 Insert dial indicator together with dial indicator extension VW 382/10 (6 mm plane).
 Set measuring lever VW 388 to dimension "a" = 67 mm (for ring gear diameter 170 mm).
 Determine clearance between flanks of teeth as follows:
2:20:29 AM Page 278

 Rotate ring gear until it makes contact with one tooth flank (end of clearance).
 Set dial indicator to "0" with 2 mm pre-load.
 Turn ring gear back until it makes contact with opposite tooth flank (torsional side clearance).
 Read off torsional side clearance and note down measured value.
 Turn ring gear additional 90 ° turn in each direction and repeat measurement 3 times.
NOTE:
Fig. 377: Installing Clamping Piece VW 386 A

 If pinion turns when differential is rotated, install VW 386 A to ensure that

exact torsional side clearance can be measured.
 Release clamp for turning ring gear.
Determining mean torsional side clearance
 Add up 4 measured values and divide total by 4.
Example:
= Sum total of measured values 1.16 mm
 Result: The mean torsional side clearance equals 1.16 mm : 4 = 0.29 mm
NOTE: If during measurement the individual values differ from one another by more
than 0.06 mm, the ring gear or drive unit itself have not been correctly installed.
Check repair work and replace drive unit if necessary.
2:20:29 AM Page 279

Formula:
"S2" = "S2*" - torsional side clearance + lift
Example:
- mean torsional side clearance 0.29 mm
+ lift (constant value) 0.15 mm

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Formula:
"S1" = "Stotal" - "S2"
Example:
for "S1" + "S2"

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
2:20:29 AM Page 280


 After shims "S1" and "S2" have been installed, rotate differential 5 turns in each direction so that tapered
roller bearings slip into place.
 Measure torsional side clearance 4 times at circumference.
 Specification: 0.12 to 0.22 mm
NOTE:  If torsional side clearance is outside tolerance, repeat adjustments. But do

not change total shim thickness "Stotal".
 Individual measured values may only differ from one another by max. 0.06
mm.
2:20:29 AM Page 281


Shift mechanism, servicing


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Shift mechanism, installation position
2:22:32 AM
2:22:38 Page 1
Fig. 67: Installation Position Of Gear Selector Mechanism

1 - Selector rod
2 - Front push rod
3 - Selector lever on transmission
2:22:32 AM Page 2
Fig. 68: Shift Lever Knob And Protective Boot Remove/Install Components, Shift Lever And - Rear Push
Rod And Shift Lever And - Front Push Rod
I - Removing and installing gear shift knob and cover. Refer to Gear shift knob and cover, removing and
installing
II - Servicing gear shift and rear push rod. Refer to Gear shift and rear push rod, servicing
III - Servicing selector rod and front push rod. Refer to Selector rod and front push rod, servicing
Removing and installing shift mechanism. Refer to Shift mechanism, removing and installing
Adjusting shift mechanism. Refer to Shift mechanism, adjusting
See Caution for disconnecting Telematics battery. Refer to Shift mechanism, servicing
2:22:32 AM Page 3
NOTE:  Disconnect Ground strap from battery in engine compartment before

working on shift mechanism.
 Heed radio code on vehicles with encoded radio.
Gear shift knob and cover, removing and installing
1 - Gear shift knob
 Detach and install together with cover

2 - Cover
2:22:32 AM Page 4
 Detach and install together with gear shift knob

3 - Connection piece
 For locking gear shift knob onto gear shift

 Opening catch. Refer to Fig. 78
 Connects cover to gear shift knob
4 - Cover for center console
 Removing and installing. Refer to Removing
2:22:32 AM Page 5
5 - Damping washer
 Installation position: Convex side face up
 Installation position: Arrow on noise insulation points in direction of travel
7 - Hex nut, 10 Nm
8 - Anti-noise cover
9 - Hex nut, 10 Nm
10 - Gear shift
 Removing and installing. Refer to Shift mechanism, removing and installing
Gear shift and rear push rod, servicing
2:22:32 AM Page 6
NOTE: Lubricate bearing and contact surfaces with polycarbamide grease, part no. G
052 142 A2.
1 - Gear shift
 Lubricate area around hole at bottom with polycarbamide grease G 052 142 A2
 Lubricate ball with polycarbamide grease G 052 142 A2
2 - Spacer tube
3 - Circlip
2:22:32 AM Page 7
 Always replace
4 - Washer
 Collar faces ball guide (item 6)
5 - Rubber ring
6 - Ball guide
7 - Rubber ring
2:22:32 AM Page 8
8 - Rear push rod
 With ball housing

9 - Bolt, 6 Nm
 Qty. 4
Selector rod and front push rod, servicing

1 - Rear push rod
2:22:32 AM Page 9
2 - Bolt, 6 Nm
 Qty. 4
4 - Washer
6 - Clamp
7 - Hex nut, 10 Nm
 Qty. 4
 For fixing gear shift housing to body
2:22:32 AM Page 10

8 - Hex nut, 10 Nm
 Self-locking
 Always replace
9 - Gear shift
10 - Spacer tube
11 - Selector fork
2:22:32 AM Page 11
12 - Bolt
13 - Gear shift housing
15 - Boot
 Remove catalytic converter and front heat shield before removal and assembly
NOTE:  Carefully pull boot over selector rod

 Position boot on markings of selector rod and push rod

2:22:32 AM Page 12
16 - Selector rod
 With gearshift linkage
17 - Bolt, 23 Nm
 Self-locking
 Always replace
 Cannot be removed from mounting bushing of front push rod
19 - Front push rod
Gear shift and rear push rod, removing and installing
Removing
Remove gear shift knob together with gear shift cover and cover of center console.

2:22:32 AM Page 13

upward to remove.
 Remove bolts (arrows C) and then remove ashtray -2- from center console.
2:22:32 AM Page 14


2:22:32 AM Page 15
 Remove securing nuts (arrows) for gear shift housing.
This lowers the gear shift housing.
Fig. 82: Shift Mechanism Housing Fasteners

 Disconnect push rod by unscrewing hex socket-head bolt -2-.

 Disconnect selector rod by unscrewing hex socket-head bolt -3-.
 Disconnect rear push rod assembly from gear shift housing (arrows).
 Remove gear shift and rear push rod from gear shift housing.
Installing
 Adjusting shift mechanism. Refer to Shift mechanism, adjusting.

2:22:32 AM Page 16
Tightening torques
Rear push rod to gear shift housing 6 Nm

Selector rod to selector fork/gear shift 25 Nm
Front push rod to rear push rod 25 Nm
Gear shift housing to body 10 Nm
Cover to rear push rod 10 Nm
Removing
console.

2:22:32 AM Page 17

upward to remove.
 Unscrew bolts (arrows C) and then remove ashtray -2- from center console.
2:22:32 AM Page 18

 Unscrew noise insulation for gear shift housing (arrows).

2:22:33 AM Page 19
 Unscrew securing nuts (arrows) for gear shift housing.

 Disconnect exhaust system from clamp(s) -1- onward.

 Disconnect driveshaft -2- from transmission and secure at side with wire. Refer to Fig. 92.
 Remove heat shield -3- above exhaust system (arrows).
2:22:33 AM Page 20
 Re-insert speed nut which was previously removed (arrow) and attach drive shaft to it with a wire.

 Remove gearshift linkage (arrow -A-).

 Unscrew hex socket head bolt of push rod (arrow -B-).
 Swivel gear shift housing with selector rod and push rod down and remove.
Installing
Install in reverse order.
 Push on gearshift linkage until bolt is located in counterbore of selector shaft.
2:22:33 AM Page 21

 Bolt selector rod firmly in place (arrow -A-).

 Secure push rod to transmission (arrow -B-).
 Install heat shield -3- above exhaust system (arrows).

 Bolt driveshaft -2- to transmission.
 Secure clamp(s) -1-.
2:22:33 AM Page 22

 Secure heat shield for drive shaft to Torsen differential housing (arrows).
 Adjust shift mechanism. Refer to Shift mechanism, adjusting.

Tightening torques
Component Nm
Gear shift housing to body 10
Heat shield for drive shaft to Torsen differential housing 25
Noise insulation for gear shift housing to rear push rod 10
2:22:33 AM Page 23
1) Replace bolt
NOTE: The following points are essential to ensure proper adjustment:
 Moving parts of shift mechanism and transmission elements are in perfect

condition
 Shift mechanism moves freely
 Transmission, clutch and shift mechanism are in perfect condition.
Removing
console.

2:22:33 AM Page 24

upward to remove.
 Remove bolts (arrows -C-) and then remove ashtray -2- from center console.
2:22:33 AM Page 25


 Measure distance -a- between two studs in shift mechanism
NOTE: Measure from center of stud to center of stud.
2:22:33 AM Page 26

 Specification: Dimension a = 85 mm
 If specification is not obtained, produce distance -a- as follows:

 Loosen bolt (arrow) for push rod.
 Rear push rod (in shift mechanism) must move easily backward and forward on slider
 Adjust dimension -a- by moving rear push rod (in shift mechanism).
 Tighten bolt for push rod (arrow) to 25 Nm.

 Loosen bolt for selector rod (arrow).
 Selector rod/shift mechanism connection must move freely
Aligning gear shift
2:22:33 AM Page 27

 Center bottom of gear shift in ball socket.
 Bottom of gear shift must be at same distance from all points of ball socket (arrows).
 Gear shift is vertical in direction of travel.
 Secure gear shift in this position.

 Tighten bolt for selector rod (arrow) to 25 Nm.
NOTE: Take care not to alter position of gear shift when tightening the bolt.
 Install covers and gear shift knob.
Shift adjustment, checking
 Gear shift must be in 3rd/4th gear gate with transmission in neutral.
2:22:33 AM Page 28
 Press clutch.
 Check shifting to all gears.
 Gear shift must not come into contact with cover of center console when shifting.
 Gear shift must automatically return from 5th/reverse gear gate to 3rd/4th gear gate.
 Reverse gear can only be selected when gear shift is in 3rd/4th gear gate with transmission in neutral
beforehand.
 It is not possible to shift from 5th gear directly to reverse gear.
NOTE: If gear shift can be shifted directly from 5th gear to reverse, or if only 5th gear
and reverse gear cannot be engaged, check locking unit for 5th and reverse
gear and replace if necessary. Refer to Removing and installing locking unit for
5th gear and reverse gear.


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2:22:33 AM Page 29

 3282 Transmission support

 3282/10 Adjustment plate
2:22:33 AM Page 30
Fig. 108: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine
 10-222A Support bar
Transmission, removing

2:22:33 AM Page 31
Fig. 110: Support Bar 10-222 A With Supports 10-222 A/1 Installed On Engine
 Set up support bar 10-222 A with supports 10-222 A/1.

 Pre-tension engine slightly using spindle of support bar.

 Remove sound insulation (arrows).
2:22:33 AM Page 32
 Remove heat shield for driveshaft from Torsen differential housing (arrows).

 Release clamp -1- and remove front part of exhaust pipe -2-.
 Disconnect driveshaft -3- from transmission and secure at side with wire (see following illustration).
 Re-insert speed nut (arrow) slightly and secure drive shaft with wire.
2:22:33 AM Page 33

 Remove bracket for sound insulation (arrow).

 Remove three engine/transmission connecting bolts underneath (arrow).

2:22:33 AM Page 34
 Remove heat shields (arrow -1- and arrow -2-) above right drive axle.

 Disconnect drive axles -1- from drive flanges and tie up out of way.
NOTE: Take care not to damage surface protection of drive axles.


 Lower engine/transmission lifter V.A.G 1383 A and place to one side.
2:22:33 AM Page 35

 Disconnect selector rod (arrow A-).

 Remove hex socket head bolt of push rod (arrow -B-).
Fig. 121: Identifying Connectors For Vehicle Speed Sensor (VSS) And Back-Up Lights
 Disconnect connector from speedometer vehicle speed sensor (arrow -A-).

 Disconnect connector from back-up light switch (multi-function sensor, arrow B-).
 Disconnect all other electrical connections and Ground wires from transmission and from
engine/transmission connecting bolts.
2:22:33 AM Page 36
 If installed, remove Engine speed (RPM) sensor -G28- from left of transmission (arrow) and place to one
side.
Fig. 123: Removing Starter Bolt

 Disconnect engine/transmission starter and secure against inadvertent operation if necessary.
NOTE: There is no need to disconnect starter cables.
2:22:33 AM Page 37
 Remove engine/transmission connecting bolts underneath with exception of bolts (arrow -A- and arrow -
B-).
Fig. 125: Transmission Support 3282 Attachment Plate

 To remove manual transmission 012, align transmission support 3282 using adjustment plate 3282/10 and
position on transmission lifter V.A.G 1383 A.
A - Support elements
NOTE:  Drawing shows only symbolic representation of support elements -A-.

Arrow -B- points in direction of travel.
 Adjustment plate 3282/10 only fits in one position.
2:22:33 AM Page 38
Fig. 126: Setting Transmission Jack Under Vehicle

 Position transmission jack under vehicle with arrow symbol -B- (Refer to Fig. 125) on adjustment plate
pointing in direction of travel/vehicle.
Fig. 127: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Support On
Transmission
2:22:33 AM Page 39
 Remove remaining engine/transmission connecting bolts (arrows -A- and -B-).

 Press transmission out of dowel sleeves and carefully lower slightly using transmission lifter V.A.G 1383
A until slave cylinder is just about accessible.
NOTE: When lowering transmission take care not to damage hydraulic pipe to slave
cylinder.

 Remove clutch slave cylinder (arrow) and secure with wire, do not open hydraulic circuit.
NOTE: Do not press clutch pedal once slave cylinder has been removed.
NOTE: When lowering ensure clearance from drive axles.
2:22:33 AM Page 40
 If removed transmission is to be replaced, first modify transmission mount to suit replacement

transmission (arrows).
For repairs, secure transmission to repair stand by means of transmission support VW 353 and retaining plate
VW 309.
Lifting tackle 2024 A in conjunction with auxiliary hook 10-222 A can be used for transporting the
transmission.
Fig. 131: Lifting Engine With 2024A Engine Sling

 Bolt on two brackets of lifting tackle 2024 A using bolts -A- M10 x 50.
 Attach lifting tackle 2024 A and raise slightly with workshop crane.
 Hook 4th hole of each hole rail into position -3- and position -6- of lifting tackle 2024 A.
CAUTION: Use locking pins for hooks and setting pins.
Transmission, installing
 Clean splines of input shaft and apply a little lubricating grease G000 100.
2:22:33 AM Page 41
Clutch plate must slide easily back and forth on input shaft.
 Apply a thin coat of copper grease, e.g. Z 381 351 TE, to contact surface for plunger on clutch release
lever.

 If plastic ring of release bearing is loose, stick back onto bearing ring with adhesive AMV 195 KD1 01.
Three rectangular lugs (arrows) on plastic ring engage in recesses in bearing ring.
If scores deeper than 0.5 mm are present, replace release bearing.
 Check whether dowel sleeves for centering engine/transmission in cylinder block have been installed and
install if necessary.
 Make sure intermediate plate, if installed, is correctly positioned at engine.
 Using a thread tap, remove residual locking fluid from all threaded holes bearing self-locking bolts.
 Replace all self-locking nuts.

2:22:33 AM Page 42
 Raise transmission until clutch slave cylinder can be installed together with holder for hose/pipe assembly
(arrow).
 Install bolts for lower engine/transmission connection and for starter; to do so, insert starter.

 Bolt tunnel crossmember onto transmission mount -4-.

 Lift transmission using engine/transmission lifter V.A.G 1383 A and firmly bolt tunnel crossmember to
body.
 Bolt driveshaft to transmission:
 Align exhaust system free of stress:
 Check oil level in manual transmission. Refer to Transmission oil level, checking.
 Check shift adjustment, re-adjust if necessary. Refer to Shift mechanism, adjusting.
See Caution for connecting Telematics battery. Refer to Transmission, removing and installing
NOTE: On re-connecting the battery, remember to check and activate vehicle

equipment (radio, clock, convenience electronics etc.).
2:22:33 AM Page 43
Refer to
Tightening torques
Fig. 135: 4Identifying Engine/Transmission Mountings (Automatic/Manual Transmission)

1.8 Liter engine to transmission
Item Bolt Nm
1, 3, 4 M12 x 67 65
2, 6 M12 x 90 65
5, 11 M12 x 110 65
7 through 10 M10 x 45 45
A: Dowel sleeves for centering
1 - Drive axle to drive flange M8 40 Nm

M10 70 Nm
+ 90 °
1) Always replace bolt and washer
Component Nm
2:22:33 AM Page 44
Engine speed (RPM) sensor -G28- 10

Clutch slave cylinder to transmission1) 23
1) Replace bolt
TORSEN DIFFERENTIAL HOUSING, REMOVING AND INSTALLING
Torsen differential housing, removing and installing


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2:22:33 AM Page 45


Removing
 Obtain (if necessary) radio code for vehicles with encoded radio.
 Place drip tray V.A.G 1306 underneath and drain gear oil.
Vehicles with 4-cylinder engine
2:22:33 AM Page 46


2:22:33 AM Page 47
 Re-insert speed nut (arrow) slightly and secure drive shaft to stud with wire.


 Lower engine/transmission lifter V.A.G 1383 A
2:22:33 AM Page 48

 Remove transmission mount (arrows).

 Remove Torsen differential housing -A- from transmission cover -B-.
NOTE: Shown in illustration with transmission removed.
 Remove spring -C- from pinion.
Removing and installing Torsen differential. Refer to Torsen differential housing, servicing, and Torsen
differential, removing and installing.
Servicing housing. Refer to Torsen differential housing, servicing, and Torsen differential, removing and
installing
Installing
2:22:33 AM Page 49
 Clean sealing surface and coat with AMV 188 001 02.

 Place spring -C- over pinion on hollow shaft.
 Lift transmission with engine/transmission lifter V.A.G 1383 A.
 Install transmission mount.

 Install tunnel crossmember onto transmission mount -4- and body -2- and -3-.
 Top up gear oil and check oil level in transmission. Refer to Transmission oil level, checking.
 Align exhaust system stress-free
2:22:33 AM Page 50
See Caution for connecting Telematics battery. Refer to Torsen differential housing, removing and installing
NOTE: On re-connecting battery, remember to check and activate vehicle equipment

Refer to

Tightening torque
Component Nm

+ 90 °
1) Always replace bolt including washer
2:22:33 AM Page 51
Torsen differential housing to transmission 25

Heat shield for driveshaft to Torsen differential housing 25
1) Replace bolt


NOTE:  The vehicle must be level for checking the oil level. An inspection pit or 4-
2:22:33 AM Page 52
pillar lifting platform are the most suitable methods.

 The oil filler plug is situated on the left of the transmission below the
speedometer vehicle speed sensor and may be concealed by the heat
shield for the drive axle.
 Use special tool 3357 to loosen oil drain plug.
Fig. 149: Checking Oil Level At Oil Filler Hole

 Remove oil filler plug to check gear oil level (arrow).
 Specification: Oil level up to lower edge of filler hole
 Top up gear oil if necessary. Specification. Refer to Code letters, assignment of mechanical units,
transmission ratios and capacities onward.
Tightening torque
Component Nm
Oil filler plug 25
2:22:33 AM Page 53

Assembly sequence. Refer to Ball bearing for input shaft, multi-function sensor, pinion, selector rods,
transmission cover and Torsen differential housing, removing and installing.
Transmission, assembly overview
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
2:22:33 AM Page 54
5 - 5th gear
6 - Reverse gear
 Removing and installing reverse idler gear. Refer to Reverse idler gear, removing and installing
7 - Tapered roller bearing

 Only repaired at factory
2:22:33 AM Page 55
 Removing and installing with housing. Refer to Torsen differential housing, removing and installing
9 - Ball bearing
10 - Ball bearing
11 - Drive flange
12 - Torsen differential Housing
13 - Spring
 Between Torsen differential and hollow shaft
14 - Input shaft
2:22:33 AM Page 56

17 - Ball bearing
18 - Differential

19 - Pinion
2:22:33 AM Page 57
20 - Radial-tapered roller bearing
21 - Hollow shaft
Transmission, sub-assembly overviews
Fig. 153: Transmission, Assembly Overview

2:22:33 AM Page 58
I - Removing and installing ball bearing for input shaft and multi-function sensor. Refer to Ball bearing
for input shaft and multi-function sensor, removing and installing
II - Removing and installing input shaft, pinion, hollow shaft, selector rods, transmission cover and
Torsen differential housing. Refer to Input shaft, pinion, hollow shaft, selector rods, transmission cover
Ball bearing for input shaft and multi-function sensor, removing and installing
 With differential and drive flanges

 Removing and installing drive flanges. Refer to Oil seal for drive flange, replacing
2:22:33 AM Page 59

 Removing and installing sensor and driving gear for speedometer. Refer to Speedometer vehicle speed
sensor and drive-wheel, removing and installing
 Installation position of bleeder valve. See Installation position of bleeder valve
2 - Internal TORX screw, 35 Nm
 Self-locking
 Replace
3 - Guide bushing
 With O-ring and oil seal for input shaft. Refer to Clutch release mechanism components (on
transmission), servicing
2:22:33 AM Page 60
4 - Dished washer
 Small diameter (convex side) facing guide bushing
5 - Circlip
6 - Ball bearing
7 - Circlip
8 - Input shaft
 Removing and installing. Refer to Input shaft, pinion, hollow shaft, selector rods, transmission cover
2:22:34 AM Page 61
9 - Bolt, 25 Nm
10 - Locking plate
 For multi-function sensor
11 - Multi-function switch
12 - Connector
 For multi-function switch
13 - Bolt, 10 Nm
2:22:34 AM Page 62
 Removing and installing. Refer to Transmission shift mechanism, disassembling and assembling
Installation position of bleeder valve
Fig. 157: Identifying Installed Position Of Breather

When pressed in, bleeder valve must protrude 21 mm out of housing.
Input shaft, pinion, hollow shaft, selector rods, transmission cover and Torsen differential housing, removing and
installing
2:22:34 AM Page 63
2 - Input shaft

3 - Selector rod with 3rd and 4th gear selector fork

assembling
2:22:34 AM Page 64
 Replacing mounting bushings. Refer to Transmission shift mechanism, disassembling and assembling
5 - Damping washer
6 - Guide shaft
7 - Damping washer
2:22:34 AM Page 65
9 - Selector shaft

 Replacing oil seal for selector shaft. Refer to Torsen differential housing, servicing, and Torsen
differential, removing and installing
10 - Detent segment
2:22:34 AM Page 66
 With collar for securing spring of detent segment
12 - Selector rod with selector fork for 1st/2nd/5th and reverse gears

assembling
 Removing and installing ball sleeves. Refer to Removing and installing ball sleeve
13 - Pinion with hollow shaft
 Disassembling and assembling. Refer to Pinion and hollow shaft, disassembling and assembling
 Adjusting. Refer to General
 Servicing mounting for pinion and hollow shaft. Refer to Pinion and hollow shaft, disassembling and
assembling
 Removing and installing oil drain plug. See Removing and installing oil drain plug
2:22:34 AM Page 67
16 - Spring
 Removing and installing with transmission installed. Refer to Torsen differential housing, removing
and installing
 Removing Torsen differential from housing, installing. Refer to Torsen differential housing, servicing,
and Torsen differential, removing and installing
 Servicing housing. Refer to Torsen differential housing, servicing, and Torsen differential, removing
and installing
2:22:34 AM Page 68
Removing and installing oil drain plug
Fig. 162: Identifying Oil Collector Tray

Removing
 Turn oil drain plug (arrow) and pull out.
Installing
 Push oil drain plug into transmission cover until catch engages.
 Installation position: Oil drain plug faces upward in transmission cover
Ball bearing for input shaft, multi-function sensor, pinion, selector rods, transmission cover and Torsen differential
housing, removing and installing
NOTE:  The differential does not have to be removed in order to remove the above-
mentioned components.
 Removal is only necessary when adjustment work must be performed.
Refer to Adjustment table.
2:22:34 AM Page 69

 Allen key extension 3357
2:22:34 AM Page 70
Fig. 164: Identifying Special Tools - Disassembly And Assembly

 VW 309 Holding plate

 VW 353 Transmission support
 3235 Pressing-in tool
 V.A.G 1582 Tapered roller bearing puller

 V.A.G 1582/2 Gripper

 V.A.G 1306 Drip tray

2:22:34 AM Page 71

 Sealant AMV 188 001 02
Removing

 Drain oil using Allen key extension 3357.
Fig. 167: Securing Transmission In Assembly Stand

 Clamp transmission in repair stand.
pulling off guide sleeve.
2:22:34 AM Page 72

 Remove clutch release lever -A- with release bearing.

 Remove guide sleeve -B-.
 Remove washer -C-.
 Remove circlip -D- in front of input shaft ball bearing.
Fig. 169: Pulling Input Shaft Ball Bearing Out Of Transmission Housing
 Pull ball bearing of input shaft out of transmission housing.
 Remove circlip (arrow) behind input shaft ball bearing.

2:22:34 AM Page 73
Fig. 171: Identifying Cover, Transmission Cover , and Transmission Housing

 Disconnect Torsen differential housing -A- from transmission cover -B-.

 Remove spring from pinion.
 Remove transmission cover -B- from transmission housing -C-.

 Remove bolts (arrows) and pull out multi-function switch.
2:22:34 AM Page 74

 Remove bolts for guide shaft (arrows).

 Remove screw for detent segment (arrow) and remove segment by swivelling out.
Fig. 175: Identifying Input Shaft, Pinion Shaft , Relay Shaft , Shift Rods and Shift Forks
2:22:34 AM Page 75
 Carefully pull out input shaft -A-, pinion -B-, guide shaft -C-, selector rods -D- and selector shaft and
selector forks -E- altogether.
Installing
NOTE: If the input shaft ball bearing, the input shaft or the transmission housing have
been replaced, first define the thickness of the circlips for the input shaft. Refer
to Input shaft, adjusting.
Fig. 176: Swing Transmission Housing Into Position Shown

 Swivel transmission housing into position as illustrated. It is then easier to insert components mentioned
below.
Fig. 177: Identifying Input Shaft, Pinion Shaft , Relay Shaft , Selector Rods and Selector Forks
2:22:34 AM Page 76
 Assemble input shaft -A-, pinion -B-, guide shaft -C-, selector rods -D- and selector shaft and selector
forks -E-.
 Insert these components in transmission housing altogether.
NOTE: Guide shaft -C- and selector shaft can also be inserted afterward if necessary.
Refer to Fig. 178 and Fig. 180.

Position of shift mechanism in transmission
4 - Guide shaft
5 - Shifting catch
6 - Selector shaft
NOTE: Shown in illustration without input shaft and pinion.
2:22:34 AM Page 77
Fig. 179: Move Transmission To Engage 3rd Gear

 Swivel transmission housing and then engage 3rd gear (direction of arrow).
Fig. 180: Installing Relay Shaft And Shift Rod

 Insert guide shaft -A-.
 Place selector shaft -B- sideways in hole in transmission housing and join to retaining eyelet.
 Swivel selector shaft carefully in direction of arrow.
2:22:34 AM Page 78

 Insert detent segment and tighten screw (arrow).

 Install bolts for guide shaft (arrows)

 Replace O-ring for multi-function switch.
2:22:34 AM Page 79
 Carefully insert multi-function switch and tighten screws (arrows).
Fig. 184: Identifying Cover and Transmission Cover

 Check whether dowel sleeves for transmission cover -A- (arrows) are present in transmission housing -B-
.
 Install transmission cover on transmission housing.

 Install spring -C-.
 Install Torsen differential housing -A- on transmission cover -B-.
2:22:34 AM Page 80
 Remove rear circlip (arrow) for input shaft ball bearing.

 Installation position: Solid side of ball cage faces transmission housing

 Press in ball bearing:
 Push thrust pad -A- of pressing-in tool onto input shaft.

 Position pressing-in tool behind splines for clutch plate.
 Pre-load bolts -B-.
 Bolts are supported in counterbores of thrust pad -A-
 Press ball bearing in as far as it will go by tightening bolts alternately (1/2 turn).
2:22:34 AM Page 81

 Install front circlip -D- for input shaft ball bearing.

 Mount dished washer -C-.
 Installation position: Convex side faces guide sleeve -B-
pushing on guide sleeve.
 Replace guide sleeve together with oil seal and O-ring.
 Install new guide sleeve -B- for release bearing.

 Install clutch release lever -A- and release bearing.
TORSEN DIFFERENTIAL HOUSING, SERVICING, AND TORSEN DIFFERENTIAL, REMOVING

AND INSTALLING
Torsen differential housing, servicing, and Torsen differential, removing and installing
2:22:34 AM Page 82


2:22:34 AM Page 83
 VW 439 Guide section

 40-21 Sleeve

2:22:34 AM Page 84

 VW 771/15 from universal tools VW 771
 Separating tool Kukko 17/2

 Internal puller Kukko 21/4
2:22:34 AM Page 85

2 - Spring
3 - Front needle bearing

 Installation position. See Installation position of front needle bearing
2:22:34 AM Page 86
 Press out after removing flange shaft. See Pressing out Torsen differential
 Pressing in. See Pressing in Torsen differential
5 - Rear needle bearing

 Installation position. See Installation position of rear needle bearing

6 - Ball bearing
2:22:34 AM Page 87

 Pressing off. See Pressing off ball bearing of Torsen differential
7 - Circlip
8 - Circlip
 Remove and install together with drive flange. See Removing and installing drive flange
9 - Ball bearing
 For drive flange

 Pressing out. See Pressing out ball bearing for drive flange
 Pressing in. See Pressing in ball bearing for drive flange
11 - Circlip
12 - Sealing cap
 Removing. See Removing sealing cap
2:22:34 AM Page 88

13 - O-ring
 Always replace
 Install with grease
15 - Oil seal
 Extract with extractor lever VW 681

 Driving in. See Driving in oil seal
16 - Dampener
2:22:34 AM Page 89
17 - Circlip
 Self-locking
 Always replace
19 - Drive flange
 Removing and installing. See Removing and installing drive flange
Removing sealing cap


 Install an M8 bolt into threaded hole of sealing cap -B-.
 Pull out sealing cap -B- with bolt.
Removing and installing drive flange
2:22:34 AM Page 90
NOTE:  When installing drive flange circlip must be installed at same time.
Pressing out Torsen differential
Fig. 198: Pressing Out Torsen Differential

 Place pressure piece 3002 through hole (arrow) directly onto Torsen differential.
Pressing off ball bearing of Torsen differential
Fig. 199: Pressing Off Ball Bearing From Torsen Differential

2:22:34 AM Page 91
Fig. 200: Pressing On Ball Bearing On Torsen Differential

 Press on ball bearing as far as it will go.
Pressing out ball bearing for drive flange

Pressing in ball bearing for drive flange
2:22:34 AM Page 92

 Install circlip after pressing in.

Both needle bearings in Torsen differential are extracted using the same internal puller.
Installation position of front needle bearing
2:22:34 AM Page 93
Fig. 204: Installation Position Of Front Needle Bearing

 Dimension a = 32.5 mm
Installation position of rear needle bearing
Fig. 205: Installation Position Of Rear Needle Bearing, Dimension

2:22:34 AM Page 94

Both needle bearings in Torsen differential are pressed in using the same special tool.
Pressing in Torsen differential
Fig. 207: Pressing In Torsen Differential

Driving in oil seal
Fig. 208: Driving In Sealing Ring
2:22:34 AM Page 95
 Installation position: 2 mm below surface of housing
TRANSMISSION SHIFT MECHANISM, DISASSEMBLING AND ASSEMBLING
Transmission shift mechanism, disassembling and assembling
Fig. 209: Identifying Special Tools - Shift Mechanism On Transmission Side, Disassembling And
Assembling
2:22:34 AM Page 96
 VW 295 Mandrel


NOTE: Installation position of shift mechanism assembly in transmission. See

2:22:34 AM Page 97

3 - O-ring
 Always replace
5 - Damping washer
2:22:34 AM Page 98
6 - Guide shaft
7 - Damping washer
9 - Detent segment

11 - Spring pin
2:22:34 AM Page 99
selector rod
13 - Selector rod for 1st and 2nd gear and for 5th and reverse gear
14 - Ball sleeve
 Removing and installing. See Removing and installing ball sleeve
16 - Driver
selector rod
17 - Mounting bushing for 3rd and 4th gear
 Extracting. See Pulling out mounting bushing for 3rd and 4th gear selector rod
 Driving in. See Driving in mounting bushing for 3rd and 4th gear selector rod as far as it will go
2:22:34 AM Page 100


18 - Ball sleeve
 Pry away from selector rod using a screwdriver

 Press onto selector rod
19 - Selector rod for 3rd. and 4th gear
21 - Spring pin
22 - Cover
2:22:34 AM Page 101

24 - Selector shaft
25 - Oil seal
 Pry out with screwdriver

 Installation position. See Installation position of oil seal
Installation position of 5th and reverse gear selector fork and of driver for selector rod
Fig. 215: Identifying Installed Position For 5th/Reverse Gear Shift Fork And Coupling Plate For Shift
Rod
Removing and installing ball sleeve
Fig. 216: Removing/Installing Ball Sleeve
2:22:35 AM Page 102

Pulling out mounting bushing for 3rd and 4th gear selector rod
Fig. 217: Removing Bushing For 3rd And 4th Gear Shift Rod
A - Internal puller 22 to 28 mm, e.g. Kukko 21/4 in conjunction with multi-purpose tool VW 771
Driving in mounting bushing for 3rd and 4th gear selector rod as far as it will go
Fig. 218: Driving In Bushing For 3rd And 4th Gear Shift Rod
Installation position of oil seal
2:22:35 AM Page 103

Fig. 219: Identifying Installed Position Of Sealing Washer

 Half-fill space between sealing lip and dust lip with sealing grease G 052 128 A1.
 Slightly oil circumference of sealing ring.
 Insert oil seal with tubular section VW 420

4 - Guide shaft
5 - Shifting catch
2:22:35 AM Page 104

6 - Selector shaft
Removing and installing locking unit for 5th gear and reverse gear

 Detach heat shield (arrow -2-) above right drive axle.

 Loosen heat shield (arrow -1-) above right drive axle and swivel downward.
Fig. 222: Identifying Gear Lock

 Remove locking unit (arrow).
Assembling locking unit
2:22:35 AM Page 105


 Insert spring -1- in housing -2- and turn counter-clockwise with slight pressure until spring engages in
base of housing.
 Position bushing -3- on spring in such a way that bent end of spring is located in the groove intended for
this purpose.
 With bushing -3-, compress spring and rotate approx. 1 turn counter-clockwise until lug of bushing is
located above groove in housing -2-.
 Press lug of bushing -3- into groove of housing -2- as far as it will go.
 Turn bushing -3- clockwise and release, bushing -3- jumps into installation position.

Installation position of bushing:
Lug (arrow -A-) of bushing must always be positioned opposite groove (arrow -B-) of housing.
Checking installation position:
 Turn bushing counter-clockwise and release.
2:22:35 AM Page 106

 Bushing must always spring back into position, lug must be pushed on as far as it will go -direction of
arrow A-
Fig. 225: Installed Position Of Complete Gear Lock In Transmission

Installation position of locking unit assembly in transmission:
Recess (arrow -A-) faces bolt (arrow -B-)
2:22:35 AM Page 107


 VW 295 Mandrel
2:23:35 AM
2:23:44 Page 1

 VW 447 i Thrust pad

2:23:36 AM Page 2
 VW 222 A Mandrel
 30-24 Mandrel
 40-202 Pressing-out element
NOTE:
2:23:36 AM Page 3

 Observe technical data when installing new gear wheels or the input shaft.
and capacities.
 Replacing components -items 2, 4 and 6 --> Input shaft, disassembling and
assembling influences the position of the ball bearing. In this case, input
shaft must be re-adjusted. Refer to Input shaft, adjusting.
1 - Circlip
 Mark
2:23:36 AM Page 4
2 - Ball bearing
3 - Circlip
 Mark

2:23:36 AM Page 5
5 - Needle bearing
 Secured with bolt. See Locking bolt for needle bearing

 Installation position. See Installation position of needle bearing
6 - Input shaft
 With oiling sleeve

 Driving in oiling sleeve. See Driving oiling sleeve into input shaft
7 - Needle bearing for 3rd gear
8 - Sliding gear for 3rd gear
2:23:36 AM Page 6

9 - Spring
 Inserting in 3rd gear sliding gear. See Inserting spring into sliding gear
11 - Circlip
 Mark
2:23:36 AM Page 7
12 - 3rd and 4th gear synchro-hub
 High collar faces 3rd gear

 Pressing off. See Pressing out 3rd and 4th gear synchro-hub
 Pressing on. See Pressing on 3rd and 4th gear synchro-hub
13 - Circlip
 Mark
 Re-determine when replacing synchro-hub. See Determining circlip

2:23:36 AM Page 8
14 - 3rd and 4th gear locking collar
 Installation position. See Installation position of locking collar
16 - Spring
18 - 4th gear needle bearing
19 - 5th gear wheel
 Pressing off. See Pressing out 5th gear wheel

20 - Circlip
 Mark
 Re-determine when replacing 5th gear wheel. See Determining circlip
2:23:36 AM Page 9

21 - Roller sleeve
 Replace
 Is damaged on removal
 Extracting. See Extracting roller sleeve
 Installation position. See Installation position of roller sleeve
 Driving in. See Driving in roller sleeve
22 - Sleeve
 Plastic
2:23:36 AM Page 10

 Remove locking bolt (arrow).
NOTE: Bolt is not always installed.
Fig. 235: Driving Out Needle Bearing

Installation position of needle bearing
2:23:36 AM Page 11
Fig. 236: Installation Position Of Needle Bearing

Dimension -a- from bottom edge of rule to top edge of needle bearing = 39.5 mm
NOTE: Measure from top edge of rule and subtract height of rule from measured value.

2:23:36 AM Page 12

 If installed, screw in locking bolt and tighten to 25 Nm.
Driving oiling sleeve into input shaft
Fig. 239: Driving In Oiling Sleeve Into Input Shaft

Item Oiling sleeve diameter Driving-in tool

A 14 mm VW 222 A
B 16 mm 30-24
Flared edge of oiling sleeve faces driving-in tool
 Drive-in depth:
3.5 mm below top edge
Extracting roller sleeve
2:23:36 AM Page 13
Fig. 240: Removing Roller Sleeve

 Before installing internal puller, destroy plastic bushing inside roller sleeve.
Installation position of roller sleeve
Fig. 241: Installed Position Of Roller Sleeve

Driving in roller sleeve
2:23:36 AM Page 14
Fig. 242: Driving In Roller Sleeve

Pressing out 5th gear wheel
Fig. 243: Pressing Off 5th Gear

Pressing out 3rd and 4th gear synchro-hub
2:23:36 AM Page 15
Fig. 244: Pressing Off Synchro-Hub For 3rd And 4th Gear

 Push 3rd gear synchro-ring (arrow) toward sliding gear for 3rd gear, then install separating tool -A-.

2:23:36 AM Page 16

C-.
Fig. 247: Identifying Installed Positions Of Circlips

 Circlips -1- and -2- secure ball bearing of input shaft.
Determining thickness. Refer to Input shaft, adjusting.
2:23:36 AM Page 17
Thickness 2.00 mm. Identifiable by: Color brown.
Determining thickness. Refer to Available circlips for 3rd and 4th gear synchro-hub. Identifiable by: Color
blue.
Determining thickness. Refer to Available circlips for 5th gear wheel.
Determining circlip


Available circlips for 3rd and 4th gear synchro-hub

1.90 1.96 2.02
1.93 1.99 2.05
Available circlips for 5th gear wheel
2:23:36 AM Page 18

1.90 1.96 2.02
1.93 1.99
Pressing on 3rd and 4th gear synchro-hub
Installation position of locking collar
3
2:23:36 AM Page 19
Chamfer (arrow -1-) faces 4th gear
Low shoulder (arrow -2-) faces 3rd gear
High shoulder (arrow -3-) faces 4th gear
Fig. 251: Pressing On 5th Gear

 Heat 5th gear wheel to approx. 100 ° C before pressing on.
High collar faces reverse gear
Input shaft, adjusting
(Determining input shaft circlips)
2:23:36 AM Page 20
Fig. 253: Spacer Gauge 3167

 3167 Distance gauge

 Depth slide gauge
Input shaft must be re-adjusted if
 Input shaft
or
 Ball bearing
is/are replaced.
2:23:36 AM Page 21
Fig. 254: Placing Transmission Housing Over Input Shaft Onto Spacer Gauge
 Clamp input shaft with soft jaws -A- in vice.

 Position distance gauge 3167 on 3rd gear sliding gear.
 Position transmission housing over input shaft onto distance gauge.
Fig. 255: Determining Circlip Thickness, Measuring Value "a"

 Position depth slide gauge on transmission housing and measure up to lower groove for circlip in input
shaft.
 Measured value in following example: -a- = 28.50 mm
2:23:36 AM Page 22
Fig. 256: Determining Circlip Thickness, Measuring Value "b"

 Position depth slide gauge on transmission housing and measure up to contact surface of ball bearing.
 Measured value in following example: -b- = 26.80 mm
Determining circlip behind ball bearing for input shaft
Formula:
"x" = dimension "a" - dimension "b"
Example:
Dimension "a" 28.50 mm
- Dimension "b" 26.80 mm
= Dimension "x" (circlip thickness) 1.70 mm
 Determine circlip using chart. Part numbers
Available circlips
Dimension "x" Thickness (mm)

1.48 to 1.56 1.54
1.57 to 1.65 1.63
1.66 to 1.74 1.72
1.75 to 1.83 1.81
1.84 to 1.92 1.90
1.93 to 2.01 1.99
2.02 to 2.10 2.08
2.11 to 2.20 2.17
2.21 to 2.27 2.25
2.28 to 2.35 2.33
2:23:36 AM Page 23
Determining circlip in front of ball bearing for input shaft
 Drive determined rear circlip and ball bearing onto input shaft using Press tube 30-100.

Available circlips

1.45 1.72 1.99
1.54 1.81 2.08
1.63 1.90 2.17
PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING
Pinion and hollow shaft, disassembling and assembling
2:23:36 AM Page 24


2:23:36 AM Page 25

 VW 429 Thrust collar
 VW 454 Pressure piece

2:23:36 AM Page 26

 40-103 Base
 3062 Thrust pad
 3128 Puller
 Kukko 17/2 Separating tool
 Kukko 21/1 Internal puller
NOTE:
2:23:36 AM Page 27

 Observe technical data when installing new gear wheels or drive unit.
and capacities.
Adjustment table.
2 - Shim "S3"
3 - Outer race for double tapered roller bearing 1)
2:23:36 AM Page 28
 Replace together with -item 5

 Extracting. See Extracting outer race for double tapered roller bearing
 Pressing in. See Pressing in outer race for double tapered roller bearing

4 - Pinion1)
 Paired with ring gear, replace as assembly

 Adjusting pinion and ring gear. Refer to General
5 - Inner race for double tapered roller bearing 1)
 Replace
2:23:36 AM Page 29
 Gets damaged on removal

 Pressing off. See Pressing off inner race for double tapered roller bearing
 Pressing on. See Pressing on inner race for double tapered roller bearing
6 - Circlip
 Determine thickness when replacing double tapered roller bearing. See Determining circlip
7 - Needle bearing
 For pinion in hollow shaft


2:23:36 AM Page 30
8 - Hollow shaft 1)
11 - 1st gear sliding gear
12 - Spring
 Inserting in 1st gear sliding gear. See Inserting spring into sliding gear
14 - 1st and 2nd gear synchro-hub
 Pressing off. See Pressing off 1st and 2nd gear synchro-hub
 Pressing on. See Pressing on synchro-hub for 1st and 2nd gear
2:23:36 AM Page 31

15 - Circlip
 Mark
16 - Needle bearing for 2nd gear
17 - 1st and 2nd gear locking collar
 Installation position. See Installation position of locking collar for 1st and 2nd gear
2:23:36 AM Page 32
19 - Spring
 Inserting in 2nd gear sliding gear. See Inserting spring into sliding gear
20 - 2nd gear sliding gear

21 - Circlip
 Mark
2:23:36 AM Page 33
22 - 3rd gear wheel
 Pressing off. See Pressing off 3rd gear wheel

 Pressing on. See Pressing on 3rd gear wheel
23 - Circlip
 Mark
 Re-determining when replacing 3rd gear wheel. See Determining circlip
24 - 4th gear wheel
 Pressing off. See Pressing off 4th gear wheel

25 - Circlip
 Mark
 Re-determining when replacing 4th gear wheel. See Determining circlip
2:23:36 AM Page 34

26 - Needle bearing
28 - Spring
2:23:36 AM Page 35
30 - Circlip
 Mark
31 - Synchro-hub 5th gear and reverse gear
 Pressing off. See Pressing off 5th gear and reverse gear synchro-hub
 Pressing on. See Pressing on synchro-hub for 5th gear and reverse gear

32 - Circlip
 Mark
2:23:36 AM Page 36

33 - Needle bearing
34 - Locking collar for 5th gear and reverse gear
 Installation position. See Installation position of locking collar for 5th gear and reverse gear
36 - Spring
 Inserting in reverse gear sliding gear. See Inserting spring into sliding gear
2:23:36 AM Page 37

37 - Reverse gear sliding gear
38 - Circlip
 Mark
 Installation position Installation position of circlips item 7
39 - Inner race for tapered roller bearing 1)
 Pressing off. See Pressing off inner race for tapered roller bearing
 Pressing on. See Pressing on inner race for tapered roller bearing
40 - Bushing
2:23:36 AM Page 38
 For securing outer race of small tapered roller bearing

 Extracting. See Pulling out locking bushing for outer race of small tapered roller bearing
 Does not need to be installed after small tapered roller bearing has been replaced

41 - Outer race for tapered roller bearing1)
 Pressing out. See Pressing out outer race for tapered roller bearing
 Pressing in. See Pressing in outer race for tapered roller bearing
42 - Shim "S4"
2:23:37 AM Page 39
43 - Ring
 For holding rubber washer

 Assignment
44 - Rubber washer
 For length compensation

 Assignment
Extracting outer race for double tapered roller bearing
Fig. 270: Pulling Out Outer Race For Double Tapered Roller Bearing
Removing differential. Refer to Differential, removing and installing.
 Position pressure piece of puller 3128 beneath outer race.

 Install threaded section of puller 3128 together with pressure plate VW 401 onto transmission housing.
When bolt is tightened, outer race is pulled out of housing.
Pressing off inner race for double tapered roller bearing
2:23:37 AM Page 40
Fig. 271: Pressing Off Inner Race For Double Tapered Roller Bearing
NOTE:  Outer race -A- must be mounted before inner race can be removed.
 Inner race of double tapered roller bearing will be destroyed during
pressing off.
Pressing in outer race for double tapered roller bearing
Smaller diameter of thrust pad 3062 faces outer race.
Pressing on inner race for double tapered roller bearing
2:23:37 AM Page 41
Fig. 273: Pressing On Inner Race For Double Tapered Roller Bearing
Determining circlip
Fig. 274: Determining Circlip To Be Installed


 Determine circlips for synchro-hubs, needle bearings and gear wheels of individual gears as shown for
double tapered roller bearing.
Available circlips and their part numbers:
Pulling out locking bushing for outer race of small tapered roller bearing
2:23:37 AM Page 42
Fig. 275: Pulling Off Securing Bushing For Small Tapered Roller Bearing Outer Race
Pressing out outer race for tapered roller bearing
Fig. 276: Pressing Out Outer Race For Tapered Roller Bearing
 Press outer race out together with ring -item 43: Refer to Pinion and hollow shaft, disassembling and
assembling, shim "S4" -item 42: Refer to Pinion and hollow shaft, disassembling and assembling and
rubber washer for length compensation -item 44: Refer to Pinion and hollow shaft, disassembling and
assembling.
Pressing in outer race for tapered roller bearing
2:23:37 AM Page 43

Pressing off inner race for tapered roller bearing
Fig. 278: Pressing Off Inner Race For Tapered Roller Bearing
 Press off inner race together with reverse gear sliding gear.
Pressing on inner race for tapered roller bearing
2:23:37 AM Page 44

 Install circlip before pressing on inner race.
Pressing off 5th gear and reverse gear synchro-hub
Fig. 280: Pressing Off Synchronizer Hub For 5th Gear And Reverse Gear

 Press off synchro-hub together with 5th gear sliding gear.
Pressing off 4th gear wheel
2:23:37 AM Page 45

Pressing off 3rd gear wheel
Fig. 282: Pressing Off 3Rd-Gear Gear Wheel


 Press off 3rd gear wheel together with 2nd gear sliding gear.
Pressing off 1st and 2nd gear synchro-hub
2:23:37 AM Page 46
Fig. 283: Pressing Off 1st And 2nd Gear Synchro-Hub


 Press off synchro-hub together with 1st gear sliding gear.

 Determine circlips for synchro-hubs, needle bearings and gear wheels of individual gears as shown in.
See Determining circlip.
 Circlip -1- secures synchro-hub for 1st and 2nd gear.
2:23:37 AM Page 47
1.90 1.96 2.02

1.93 1.99
 Circlip -2- secures 2nd gear needle bearing/sliding gear.

2.50

 Circlip -3- secures 3rd gear wheel.

1.90 1.98 2.06
1.94 2.02

1.86 1.94
1.90 1.98
2:23:37 AM Page 48
 Circlip -5- secures 5th gear needle bearing/sliding gear.
Identifiable by color: brown

2.00

 Circlip -6- secures synchro-hub for 5th gear and reverse gear.

1.90 1.96 2.02
1.93 1.99 2.05
 Circlip -7- secures needle bearing for reverse gear sliding gear.

2.50
 If necessary determine circlips using chart. Part numbers
2:23:37 AM Page 49


C-.
Pressing on synchro-hub for 1st and 2nd gear
2:23:37 AM Page 50
Fig. 289: Pressing On Synchronizer Hub For 1st And 2nd Gears
High collar on inside faces 2nd gear
Installation position of locking collar for 1st and 2nd gear
Fig. 290: Identifying Installed Position Of Operating Sleeve For 1st And 2nd Gear
Chamfer (arrow -1-) faces 2nd gear
Shoulder (arrow -2-) faces 1st gear
Pressing on 3rd gear wheel
2:23:37 AM Page 51
Fig. 291: Pressing On 3rd-Gear Gear Wheel

Groove on gear wheel faces 4th gear

Pressing on synchro-hub for 5th gear and reverse gear
2:23:37 AM Page 52
Fig. 293: Pressing On Synchronizer Hub For 5th Gear And Reverse Gear
High collar on inside faces 5th gear
Installation position of locking collar for 5th gear and reverse gear
3
 Note locking collar assignment to reverse idler gear. See Locking collar assignment to reverse idler
gear
2:23:37 AM Page 53
Chamfer (arrow -1-) faces reverse gear
Low shoulder (arrow -2-) faces 5th gear
High shoulder (arrow -3-) faces reverse gear
Locking collar assignment to reverse idler gear
Fig. 295: Allocation Of Operating Sleeve To Reverse Idler Gear

A Reverse idler gear with Either locking collar type (with chamfer or high shoulder) can be used for
chamfer assembly
B Reverse idler gear without Only locking collars with high shoulder can be used for assembly. Do not
chamfer use locking collars with chamfer.
REVERSE IDLER GEAR, REMOVING AND INSTALLING
Reverse idler gear, removing and installing
2:23:37 AM Page 54

1 - Circlip
2 - Support plate
 Different versions, Assignment. See Locking collar assignment to reverse idler gear
4 - Needle bearing
5 - Thrust washer
2:23:37 AM Page 55

 With axle for reverse idler gear (arrow)

 Axle for reverse idler gear does not have to be removed in order to remove reverse idler gear
 Axle for reverse idler gear is not available as replacement part
 For additional fastening of axle for reverse idler gear
2:23:37 AM Page 56

OIL SEAL FOR DRIVE FLANGE, REPLACING

 VW 295 Mandrel
2:24:27 AM
2:24:33 Page 1
 T10037 Puller


NOTE:  Use the same procedure for removing both left and right oil seals.
 It is not necessary to remove the exhaust system.
Removing

2:24:27 AM Page 2
 Remove cover plates above drive axle (arrows 1 + 2).

 Disconnect drive axle from transmission flange:
 Tie drive axle up as far out of the way as possible. Take care not to damage paintwork on drive axle.
 Place drip tray VAG 1306 under transmission.
Replacing left oil seal

Replacing right oil seal
Fig. 302: Removing Drive Flange (Right Side)
2:24:27 AM Page 3
 Remove drive flange by firmly screwing puller T10037 to transmission housing (arrow).

 Always replace circlip of drive flange.

Drive flange assembly with mounted polygonal bearing
2:24:27 AM Page 4
1 - Drive flange
3 - Spacer ring
4 - Circlip
NOTE:  Polygonal bearings run roughly when drive flange is not installed. This
 Look out for damages to polygonal bearings (e.g. cracks in outer race of
bearing)
 Drive flanges with a splined shaft diameter of 30 mm have a spacer ring -5-
installed between polygonal bearing and planet pinion.
Installing
NOTE: Repair rim offset 6.5 mm if employing used drive flange.
Fig. 305: Installing Right-Hand Drive Flange Seal

 Drive in new oil seal for right drive flange 5.5 mm below surface of housing, taking care not to tilt it.
2:24:27 AM Page 5
Fig. 306: Installing Left-Hand Drive Flange Seal

 Drive in new oil seal for left drive flange 5.5 mm below surface of cover, taking care not to tilt it.
 Screw drive axle to drive flange.
 Screw on cover plates for drive axle, if installed.
 Checking oil level in manual transmission. Refer to Transmission oil level, checking.
Tightening torques
Component Nm
M10 70
Heat shields for drive axles 23
SPEEDOMETER VEHICLE SPEED SENSOR AND DRIVE-WHEEL, REMOVING AND

INSTALLING
Speedometer vehicle speed sensor and drive-wheel, removing and installing
Removing
2:24:28 AM Page 6
Fig. 307: Identifying Speedometer Vehicle Speed Sensor (VSS) and O-ring
 Unplug connector of sender -A-.

 Press down retainer, swivel sensor to one side and pull upward and out.
Installing
 Replace O-ring -B- during installation.

 Insert sensor and engage.
NOTE: Handle sender with care. If damaged, speed values can no longer be precise.
Speedometer drive wheel, removing and installing
2:24:28 AM Page 7

 VW 295 Mandrel
 T10037 Puller

2:24:28 AM Page 8

Removing

 If installed, remove cover plate above left drive axle.
 Disconnect drive axle from drive flange.

2:24:28 AM Page 9
Removing speedometer driving gear:
Fig. 311: Press Drive Gear Retaining Clips In Direction Of Arrows Using Screwdriver
 Press clips in direction of arrow using a screwdriver.

 Remove driving gear by prying out on all sides.
Installing
NOTE: Install the driving gear carefully ensuring it is not crooked on the differential. Do
not use force or the driving gear could break.
2:24:28 AM Page 10
Fig. 312: Identifying Installed Position Of Drive Gear, Retaining Clip And Seal
Driving tab of driving gear -A- faces oil seal -B- and locks in place in groove of differential.
The clips (arrows) engage in circumferential groove of differential.
 Always replace oil seal -B- and circlip -C-.

Tightening torques
Component Nm
M10 70
OIL SEAL FOR DRIVE FLANGE/DRIVE SHAFT, REPLACING
Oil seal for drive flange/drive shaft, replacing
2:24:28 AM Page 11
Fig. 313: Identifying Special Tools - Oil Seal For Drive Flange/Drive Shaft, Replacing

 30-505 Insertion mandrel
 30-506 B Press tool
Removing
2:24:28 AM Page 12
 Place drip tray VAG 1306 underneath and drain gear oil.


 Unscrew heat shield for driveshaft from cover of Torsen differential (arrows).
2:24:28 AM Page 13
 Re-insert speed nut (arrow) slightly and secure driveshaft to stud with wire.
 Place drip tray VAG 1306 below cap.
NOTE:

Oil escapes when cap -B- is taken off.

 Install an M8 bolt into threaded hole of cap.
 Remove cap by means of bolt.
2:24:28 AM Page 14

Fig. 319: Pulling Out Oil Seal For Drive Flange Using VW 681
 Pull out oil seal for drive flange using VW 681.
Installing
2:24:28 AM Page 15
Fig. 320: Driving In New Flange Shaft Seal

 Drive in new oil seal for drive flange 2 mm below surface of housing, taking care not to tilt it.
 Insert drive flange.

 Insert drive flange circlip at same time as shaft.
 Insert cap with a new O-ring and secure.

 Align exhaust system stress-free:
2:24:28 AM Page 16
Tightening torques
Component Nm
Drive shaft to manual transmission 1) 55
1) Replace bolt

2:24:28 AM Page 17

 3257 6 mm Allen key extension
NOTE:  The differential can also be removed and installed with the transmission
installed.
 The differential can be removed and installed without disassembling the
transmission, input shaft, pinion or transmission housing. The above-
mentioned parts must be disassembled if the differential is to be adjusted.
 Watch out for visible damages to the polygonal bearings.
 Polygonal bearings run roughly when drive flange is not installed. This
 Drive flanges with a splined shaft diameter of 30 mm have a spacer ring
installed between polygonal bearing and bevel gear. See Drive flange
assembly with polygonal bearings, -item 5-.
Adjustment table.
2:24:28 AM Page 18

2 - Oil seal
 Replacing. Refer to Oil seal for drive flange, replacing
3 - Circlip
 Replace
 Removing and installing. See Removing and installing circlip
4 - Spacer ring
2:24:28 AM Page 19
 Only installed on drive flanges with polygonal bearings and splined diameter 30 mm
 Removing. See Removing spacer ring
 Installing. See Installing spacer ring
5 - Drive flange
 Removing and installing. Refer to Oil seal for drive flange, replacing
 Drive flange assembly: See Drive flange assembly with polygonal bearings

 Can also be removed without removing manual transmission
2:24:28 AM Page 20

Removing spacer ring
2:24:28 AM Page 21
Fig. 326: Removing Spacer Ring

 If difficult to move, pull out spacer ring using multi-purpose tool VW 771.

 Push spacer ring in as far as it will go, ensuring it is not crooked.
Drive flange assembly with polygonal bearings
2:24:28 AM Page 22

1 - Drive flange
3 - Spacer ring
5 - Circlip
NOTE: Needle bearings (polygonal bearings) do not move freely when drive flange is
removed. This does not indicate faulty bearings.
2:24:28 AM Page 23



2:24:28 AM Page 24

 VW 472/1 Pressure piece

 3138 Punch-out tool
 3144 Sleeve
 3296 Pipe
2:24:28 AM Page 25

 VW 459 Pressing-out and pressing in tool

 3 - Kukko 204/2 Puller
 4 - Kukko 22/2 Counter-support
 Kukko 44-2 Two-arm puller
NOTE:
2:24:28 AM Page 26

 Removing and installing differential. Refer to Differential, removing and

installing.
 Replace both tapered roller bearings together.
Adjustment table.
2 - Shim "S2"

2:24:28 AM Page 27
 Extracting. See Extracting tapered roller bearing outer race from transmission housing
 Pressing in. See Pressing tapered roller bearing outer race into transmission housing

 Pulling off. See Extracting inner race for right tapered roller bearing
 Pressing on. See Pressing on inner race for right tapered roller bearing
5 - Ring gear 1)
 Paired with pinion (drive unit)
2:24:28 AM Page 28
 Driving out of housing using mandrel. See Driving ring gear out of housing
 Installing to differential housing HEATING RING GEAR TO APPROX. 100 ° C and installing 10
 Assignment

7 - Bolt, 60 Nm plus 1/8 turn (45)
2:24:28 AM Page 29
 Always replace
 Screw in bolts evenly and tighten to torque in diagonal sequence
 Pulling off. See Extracting inner race for left tapered roller bearing
 Pressing on. See Mounting inner race for left tapered roller bearing
 Assignment
2:24:28 AM Page 30
 Driving out. See Driving outer race of left tapered roller bearing out of cover
 Pressing in. See Driving outer race of left tapered roller bearing into cover
 Assignment
11 - Shim "S1"

 Assignment
 Assignment
2:24:28 AM Page 31

14 - Differential bevel gear shaft
 Drive out with mandrel after removing spring pin
15 - Spring pin
 For securing bevel gear shaft

 With circumferential groove: Removing and installing. See Removing and installing spring pin
 Without circumferential groove: Drive out with mandrel
2:24:28 AM Page 32
 Apply gear oil on insertion
Extracting tapered roller bearing outer race from transmission housing
Fig. 337: Pulling Outer Race/Tapered Roller Bearing Out Of Transmission Housing
2:24:28 AM Page 33
 Insert tapered section of pressure piece VW 472/1 into outer race.
Extracting inner race for right tapered roller bearing
Fig. 339: Pulling Off Right Tapered Roller Bearing Inner Race
A - Two-arm puller, e.g. Kukko 20/10 or Kukko 44/2
A-.
Pressing on inner race for right tapered roller bearing

2:24:28 AM Page 34
Extracting inner race for left tapered roller bearing
Fig. 341: Pulling Off Left Tapered Roller Bearing Inner Race
A-.
Mounting inner race for left tapered roller bearing
Fig. 342: Installing Left Tapered Roller Bearing Inner Race

2:24:28 AM Page 35
Driving outer race of left tapered roller bearing out of cover
Fig. 343: Driving Out Outer Race Of Left Tapered Roller Bearing From Cover
 Screw out webs -A- and -B- until they are positioned on outer race inside recess in housing.
Driving outer race of left tapered roller bearing into cover
 Press outer race of left tapered roller bearing into cover using pressure piece 2050.
 Insert tapered section of pressure piece 2050 into outer race.
Driving ring gear out of housing
2:24:28 AM Page 36

Heating ring gear to approx. 100 ° C and installing

 Use locating pins -A- (self-made) to guide ring gear when installing.
 Allow to cool somewhat before screwing in bolts. Then tighten to torque.
2:24:28 AM Page 37

 Lubricate one-piece thrust washer with gear oil and insert.

 Insert large bevel gears.
 Insert small bevel gears offset by 180 ° and swivel into place (arrow).
 Drive bevel gear shaft into final position and secure.
Removing and installing spring pin
Fig. 348: Pulling Out Spring Pin With Side Cutting Pliers
Removing
 Extract spring pin with circumferential groove using side-cutting pliers.

 Knock out spring pin without circumferential groove from behind with mandrel.
Installing
 Drive in spring pin as far as it will go.
2:24:28 AM Page 38
General
 Careful adjustment of the pinion and ring gear is a decisive factor as regards the service life and smooth
running of the final drive. Even during production, the pinion and ring gear are checked together to
ensure a good seating position and low noise in both directions of rotation. The position which achieves
the smoothest running is determined by moving the pinion axially, so that the ring gear is never
absolutely tight against the pinion but remains within the specified tolerance for torsional side clearance.
 The objective of adjustment is to once more achieve the position for smoothest running, which was
originally ascertained on the testing machine during production.
 The dimension "r" referenced to controller "Ro" is written on the circumference of the ring gear. Only
replace drive unit components (pinion and ring gear) together.
Drive units, adjusting and marking

2:24:28 AM Page 39
1 - Code "0937" stands for Oerlikon drive unit with transmission ratio 37 : 9.
2 - Pair number (312) of drive set
3 - Dimension "r" referenced to controller of testing machine used in production. Dimension "r" is
always stated in 1/100 mm. Example: "25" stands for r = 0.25 mm
Ro - Length of testing machine controller used.

R - Actual dimension between ring gear axis and end face of pinion at the point of smoothest running for
this one drive set
2:24:28 AM Page 40
Vo - Hypoid offset
Position of shims
Fig. 351: Identifying Shim Locations

NOTE: Adjustment table for replacing individual transmission components. Refer to

Adjustment table.
S1 - Shim for ring gear in final drive cover
S3 - Shim for pinion in transmission housing
2:24:28 AM Page 41
S4 - Shim for pinion in transmission cover
Adjustment table
NOTE: When performing transmission repair work, the pinion, ring gear or drive unit
must only be re-adjusted if you are replacing components which directly
influence the setting of the final drive. Refer to the following table so as to avoid
unnecessary adjustment.
To be adjusted:
Ring gear Pinion Pinion Torsional side
Replaced component: "S1"+"S2" 1) "S3"+"S4" 1) "S4" 1) clearance
Refer to Ring over Refer to Shim "S4", re- Checking
gear, dimension "r" determining when Refer to
adjusting Refer to replacing transmission Measuring
Pinion, cover torsional side
adjusting clearance
3)
Transmission cover X
Double tapered roller X X
bearing for pinion and
hollow shaft
Differential tapered X X
roller bearing
Drive unit 2) X X X
1) Shims, installation position. Refer to Position of shims
2) Pinion and ring gear, only replace together
3) If transmission housing is replaced, input shaft must also be adjusted. Refer to Input shaft, adjusting.
Drive unit, re-adjustment sequence
2:24:28 AM Page 42
Fig. 352: Adjusting Gear Set, Sequence

If the pinion and ring gear require re-adjustment, please follow the sequence described below in the interest of
rationalized work procedure:
3.) Distribute total shim thickness "Stotal" of "S3" + "S4" in such a way that dimension from center of
ring gear to end face of pinion corresponds to mounting dimension "R" as defined during production.
Refer to Defining thickness of shim "S3" onward.
4.) Distribute total shim thickness "Stotal" of "S1" + "S2" in such a way that the specified torsional side
clearance is present between ring gear and pinion. Refer to Defining thickness of shim "S2" onward.
NOTE: List of components and shims. Refer to Position of shims.
Pinion, adjusting
2:24:28 AM Page 43

(Adjusting pinion and hollow shaft)
Work after which pinion must be adjusted see Table. Refer to Adjustment table.

 VW 385 Universal measuring device
2:24:28 AM Page 44


 VW 792 Assembly device
 3062 Thrust pad
 3182 Insertion sleeve
(Adjusting pre-load of tapered roller bearing for pinion and hollow shaft)
2:24:28 AM Page 45
Fig. 355: Pinion Shaft Component, Overview

 Press inner race -1- of double tapered roller bearing onto pinion and secure. Refer to Pinion and hollow
shaft, disassembling and assembling onward.
 Install needle bearing -2-.

 Position circlip -3- on hollow shaft and press on inner race of tapered roller bearing -4-. Refer to Pinion
and hollow shaft, disassembling and assembling onward.
 Insert pinion shaft in hollow shaft.
NOTE: In the illustration the hollow wheel is shown without gears. The pinion can be
set either with or without gears.
2:24:28 AM Page 46
 Insert outer race of double tapered roller bearing for pinion in transmission housing without shims.
Smaller diameter of pressure plate 3062 faces outer race.

 Insert outer race of pinion tapered roller bearing together with shim "S4*" (1.0 mm thick) in transmission
cover.
NOTE:  A shim "S4" 1.0 mm thick is used provisionally as a reference value. It is

referred to below as "S4*". Once measured value "e" has been determined,
"S4*" will be replaced by actual shim "S4".
 For measurement, always insert rubber washer together with ring for
rubber washer. Refer to item 44 Pinion and hollow shaft, disassembling
and assembling.
 Insert fully assembled pinion and hollow shaft in transmission housing.

 Turn transmission so that transmission cover faces downward.
2:24:28 AM Page 47
 Press head of pinion with lever VW 296 until outer race of tapered roller bearing makes contact with
 Maintaining same pressure, rotate pinion in opposite direction to hollow shaft 5 turns in both directions,
so that double tapered roller bearing slips into place.
 Next, rotate pinion and hollow shaft together 5 turns in both directions, so that tapered roller bearing slips
into place.
 Install dial indicator and set to "0" with 1 mm pre-load.
NOTE: Dial indicator extension must be situated on ground surface of pinion head.
 Turn transmission 180 ° so that transmission cover faces upward.

place. Otherwise, measurement results will be incorrect.
2:24:28 AM Page 48
 Read off and note down clearance indicated on dial indicator.
 Example measured value: 0.45 mm
NOTE: If the measurement is repeated, first rotate the pinion and hollow shaft once
more 5 turns in each direction. Set dial indicator to "0" with 1 mm pre-load once
again.
Formula:
Example:
+ measured value (example) 0.45 mm
of "S3" + "S4"
Formula:
"S3*" = "Stotal" - "S4*"
Example:
of "S3" + "S4"
- inserted shim "S4*" 1.00 mm
 Remove outer race of tapered roller bearing, insert shim "S3*" in transmission housing and re-install
outer race. See Pressing in outer race for double tapered roller bearing
2:24:28 AM Page 49

 Install measuring tools and secure with bolt (arrow) to transmission housing.
 0.05 to 0.15 mm
 Tighten bolts of transmission cover to 22 Nm.

 Remove measuring tools.
Defining dimension "e"
NOTE: Dimension "e" is required to determine the definitive shim thickness of "S3"
and "S4".
2:24:29 AM Page 50
 Adjust set rings of multi-purpose measuring mandrel VW 385/1 to following values:
Fig. 363: Assembling Measuring Bar VW 385/1

 Assemble multi-purpose measuring mandrel VW 385/1 as shown in illustration:
 Dial indicator extension -A-, 6.5 mm long
 Adjust controller VW 385/30 to Ro in line with ring gear diameter and place on measuring mandrel.
Ring gear diameter 170 mm = 54.95 mm
Fig. 364: Placing End Gauge On Drive Pinion Face

2:24:29 AM Page 51
 Place gauge block plate on pinion head.
NOTE: Make sure plate fits exactly and contact area is oil free.

 Remove controller and insert measuring mandrel in housing.
 Dial indicator extension -A- = 6.5 mm long must be screwed in

 Dial indicator faces cover of final drive
 Position cover of final drive and tighten 4 bolts to 22 Nm.

 Pull 2nd centering disc outward using moveable set ring until measuring mandrel can only just be turned
by hand.
2:24:29 AM Page 52
 Turn measuring mandrel until tip of dial indicator runs into gauge block plate on pinion head and gauge
displays maximum deflection (point of return).
 Measured value in following example: "e" = 0.26 mm (red zone)
NOTE: After removing multi-purpose measuring mandrel, check again whether dial
indicator with controller VW 385/30 in position is still set to "0" with 2 mm pre-
load.
 The dimension "r" referenced to controller "Ro" is measured for the drive units which are delivered as
replacement parts and written on the circumference of the ring gear.
 If measurement is performed in red zone measured value "e" must be deducted.
 If measurement is performed in black zone measured value "e" must be added on.
Formula:
"S3" = "S3*" + "r" + "e"
("e" in black zone)
"S3" = "S3*" + "r" - "e"
("e" in red zone)
Example:
+ dimension "r" 0.38 mm
- obtained value "e" (red zone) 0.26 mm

0.40 0.55 0.70
0.45 0.60 0.75
0.50 0.65
2:24:29 AM Page 53
Formula:
"S4" = "Stotal" - "S3"
Example:
of "S3" + "S4"

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Checking dimension "r"
 Install pinion/hollow shaft with defined shims "S3" and "S4".

 Rotate hollow shaft against pinion 5 turns in both directions, so that tapered roller bearing slips into place.
place.
2:24:29 AM Page 54
 Insert multi-purpose measuring mandrel. Refer to Defining dimension "e", and check measurement.
 Read off dial indicator counter-clockwise (red zone).
 If correct shims were selected, dimension "r" (written on circumference of ring gear) must be displayed
showing a tolerance of ± 0.04 mm
Shim "S4", re-determining when replacing transmission cover
 2 x centering disc VW 385/3

 Measuring plate VW 385/17
 Universal dial indicator holder VW 387
 Assembly device VW 792
 Dial indicator
 Dial indicator extension
 Depth caliper gauge with minimum measuring accuracy of 5/100 mm
 Clean joint surfaces of cover.
Fig. 368: Measuring Difference In Depth On Old And New Transmission Cover
 Measure difference in depth "a" on old and new transmission covers.
Example:
2:24:29 AM Page 55
Depth "a" of old transmission cover 257.40 mm

Depth "a" of new transmission cover 257.55 mm
 Install thicker shim "S4" if new transmission cover is deeper.

 Install thinner shim "S4" if old transmission cover is deeper.
Example:
Old shim "S4" 0.95 mm

= New shim "S4" 1.10 mm
Available shims. Refer to Available shims for "S4".
 Insert outer race for tapered roller bearing together with shim "S4" in transmission cover. See Pressing in
outer race for tapered roller bearing

 Install measuring tools and secure with bolt (arrow) to transmission cover.
 0.05 to 0.15 mm
2:24:29 AM Page 56
If this value is not obtained, the setting must be corrected.

 VW 382/10 Dial indicator extension

 VW 385/17 Gauge block plate
 VW 386 A Clamp for pinion
2:24:29 AM Page 57
 VW 388 Measuring lever



 VW 521 Adjusting device for ring gear

 Dial indicator
The ring gear must be re-adjusted if:
2:24:29 AM Page 58
transmission housing, final drive cover, differential tapered roller bearing, differential housing or drive unit are
replaced.
Adjustment table. Refer to Adjustment table
(Adjusting pre-load of differential tapered roller bearing)
 Pinion removed
 If only differential tapered roller bearings are replaced, the ring gear can be removed from the differential
housing. In this case, the pinion does not have to be removed.
 Pull out oil seals for drive flanges using extractor lever VW 681.
 Remove outer races of differential tapered roller bearings and take out shims. Refer to Differential,
 Drive outer race of small tapered roller bearing and shim "S2" into transmission housing. For
measurement purposes, a shim "S2*" 1.20 mm thick is used (2 shims of 0.60 mm).
NOTE: A shim "S2" 1.20 mm thick is used provisionally as a reference value. It is

referred to below as "S2*". Once torsional side clearance is determined, "S2*" is
replaced by the definitive "S2".
2:24:29 AM Page 59
 Press outer race of tapered roller bearing into cover of differential without shim "S1".
 Insert differential without driving gear for sender of speedometer -G22 in transmission housing.
 Install cover of differential using 4 bolts (25 Nm).
 Position transmission so that cover of differential faces upward.
 Rotate differential 5 turns in both directions, so that tapered roller bearing slips into place.
 Lay measuring plate VW 385/17 on differential.
 Set up measuring tools using a 30 mm dial indicator extension.

 Set dial indicator (3 mm measuring range) -A- to "0" with 2 mm pre-load.
2:24:29 AM Page 60
NOTE: Measuring tip of dial indicator must be positioned on center of differential.
 Lift differential without turning; read and note clearance indicated on dial indicator.
NOTE:
Fig. 375: Securing Special Tools VW 521/4 And VW 521/12 At Right On

Differential (Housing Side)
 To raise differential, fasten special tools VW 521/4 and VW 521/12 to right

of differential (housing side).
 If the measurement is repeated, first rotate the pinion and hollow shaft
once more 5 turns in each direction, so that the tapered roller bearing slips
into place.
Formula:
Example:
Inserted shim(s) "S2*" 1.20 mm
+ measured value 0.62 mm
for "S1" + "S2"
NOTE:  Provisional shim "S1*" is replaced by definitive "S1" after torsional side
clearance has been determined.
 Total shim thickness "Stotal" remains unchanged.
2:24:29 AM Page 61
Formula:
"S1*" = "Stotal" - "S2*"
Example:
for "S1" + "S2"
- inserted shim(s) "S2*" 1.20 mm
Assigning shims
Measuring torsional side clearance
 Pinion installed with shims "S3*" and "S4*"
 Install differential with ring gear: S1* is installed on cover side, S2* in transmission housing.
 Mount final drive cover and tighten bolts to 25 Nm.
 Insert adjustment tool for ring gear VW 521/4 and VW 521/12.
 Rotate differential 5 turns in both directions, so that tapered roller bearings slip into place.

 Secure dial indicator holder VW 387 to housing.

 Insert dial indicator together with dial indicator extension VW 382/10 (6 mm plane).
 Set measuring lever VW 388 to dimension "a" = 67 mm (for ring gear diameter 170 mm).
 Determine clearance between flanks of teeth as follows:
2:24:29 AM Page 62
 Rotate ring gear until it makes contact with one tooth flank (end of clearance).
 Set dial indicator to "0" with 2 mm pre-load.
 Turn ring gear back until it makes contact with opposite tooth flank (torsional side clearance).
 Read off torsional side clearance and note down measured value.
 Turn ring gear additional 90 ° turn in each direction and repeat measurement 3 times.
NOTE:
Fig. 377: Installing Clamping Piece VW 386 A

 If pinion turns when differential is rotated, install VW 386 A to ensure that

exact torsional side clearance can be measured.
 Release clamp for turning ring gear.
Determining mean torsional side clearance
 Add up 4 measured values and divide total by 4.
Example:
= Sum total of measured values 1.16 mm
 Result: The mean torsional side clearance equals 1.16 mm : 4 = 0.29 mm
NOTE: If during measurement the individual values differ from one another by more
than 0.06 mm, the ring gear or drive unit itself have not been correctly installed.
Check repair work and replace drive unit if necessary.
2:24:29 AM Page 63
Formula:
"S2" = "S2*" - torsional side clearance + lift
Example:
- mean torsional side clearance 0.29 mm
+ lift (constant value) 0.15 mm

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Formula:
"S1" = "Stotal" - "S2"
Example:
for "S1" + "S2"

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
2:24:29 AM Page 64

 After shims "S1" and "S2" have been installed, rotate differential 5 turns in each direction so that tapered
roller bearings slip into place.
 Measure torsional side clearance 4 times at circumference.
 Specification: 0.12 to 0.22 mm
NOTE:  If torsional side clearance is outside tolerance, repeat adjustments. But do

not change total shim thickness "Stotal".
 Individual measured values may only differ from one another by max. 0.06
mm.
2:24:29 AM Page 65
TRANSMISSION
6 Spd. Manual Transmission 01E All Wheel Drive
00 GENERAL, TECHNICAL DATA

The 6-speed manual transmission 01E all wheel drive is installed in the Audi A4 2002 > in conjunction with the
V6 gasoline engine.
Fig. 1: Locations On Transmission Identification

 Code letters and serial number -arrow 1-

 Manual transmission 01E -arrow 2-
Fig. 2: Code Letters And Transmission Consecutive Serial Number

2:25:49 AM
2:26:01 Page 1
Code letters and transmission consecutive serial number -arrow 1-
Example: ENV 321549

I I
Code letters Transmission consecutive serial number
Additional data is production-related
NOTE: The code letters for the transmission are also given on the vehicle data stickers.
Fig. 3: Manual Transmission 01E

Manual transmission 01E -arrow 2-
Code letters, mechanical unit assignment, transmission ratios, capacities
Manual transmission 6-speed 01E, all wheel drive

Code letters FRE
Production from 04.01
to
Allocation Model Audi A4 2001 >
Engine 3.0 l - 162 kW
Ratio Final drive 35 : 8 = 4.375
Z2 : Z1 =i 1st gear 28 : 8 = 3.500
2nd gear 34 : 18 = 1.889
3rd gear 33 : 25 = 1.320
4th gear 30 : 29 = 1.034
5th gear 30 : 35 = 0.857
6th gear 27 : 37 = 0.730
Reverse gear 38 : 11 = 3.455
2:25:49 AM Page 2
Code letters FRE

Speedometer electronic
Capacity 2.5 liters
Clutch mechanism hydraulic
Clutch plate Ø 240 mm
Drive axle flange Ø 75.5 mm
Overall ratio iov. in top gear 3.193
Assignment of rear final drive FUB
Code letters
Final drive 01R is assigned to manual transmission 01E, all wheel drive.
Mechanical unit assignment:
Refer to 00 - GENERAL, TECHNICAL DATA

2:25:49 AM Page 3

Fig. 6: Code Letters And Manufacturing Data For The Final Drive
Code letters and manufacturing data for the final drive
Example: ETS 26 04 00
I I I I
I I I I
Code letters Day Month Year (2000) of manufacture
Additional data is production-related
Code letters, transmission ratios, capacities
Refer to 00 - GENERAL, TECHNICAL DATA
TRANSMISSION LAYOUT
2:25:49 AM Page 4
Transmission layout

1 - Engine
2 - Clutch
6 - Front drive pinion (output shaft)
2:25:49 AM Page 5
7 - Hollow shaft
9 - Driveshaft
10 - Rear drive pinion
NOTE: Arrows face in direction of travel.

I - 1st gear
2:25:49 AM Page 6
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
T - Speedometer drive, electronic
NOTE: Arrows face in direction of travel.
CALCULATING OVERALL RATIO (I)
Calculating overall ratio (i)
Transmission ratio
Ratios Formula
iG = gear ratio ZG2 : ZG1
iA = Final drive ratio ZA2 : ZA1
iov = overall ratio iG x iA
Example:
6. gear Final drive
Calculations:
iG = 23 : 41 = 0.561
iA = 35 : 9 = 3.889
iov = 0.561 x 3.889 = 2.182
2:25:49 AM Page 7
transmission repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned
Special tools
For a complete list of special tools used in this article
Transmission
 When installing a new transmission, the oil level must be checked and oil added if necessary. Refer to
Transmission oil level, checking.
 Capacities and specifications. Refer to Code letters, mechanical unit assignment, transmission ratios,
capacities onward.
 When exchanging the rear final drive the oil level in rear final drive must be checked and, if necessary,
corrected.
Refer to 39 - FINAL DRIVE, DIFFERENTIAL
 Thoroughly clean all unions and the adjacent areas before disconnecting.
 When installing transmission, ensure that the dowel sleeves are installed correctly.
 Always replace O-rings, seals and gaskets.

2:25:49 AM Page 8
 Before installing radial shaft seals, lightly oil outer circumference and pack space between sealing lips -
arrow- half-full with sealing grease G 052 128 A1.
 The open side of the seals faces toward the side with fluid filling.
 When replacing seals, always vary the point at which the sealing lips make contact (use insertion depth
tolerances).
 Lightly oil O-rings before installing to prevent them being trapped and damaged when assembling.
 After replacing seals and gaskets check oil level in transmission. Refer to Transmission oil level,
checking.
Sealants
 Thoroughly clean housing joint surfaces before applying sealing paste.

 Apply sealing paste AMV 188 001 02 evenly and not too thick.
Locking elements


2:25:49 AM Page 9
 Replace spring pins. Installation position: Slot -A- longitudinal to line of force -arrow-.
Nuts, bolts
 Slacken the nuts and bolts in reverse sequence to the specified tightening sequence.
 Nuts and bolts which secure covers and housings should be slackened and tightened diagonally.
 Parts which are particularly sensitive (e.g. clutch pressure plates) must be kept straight and slackened and
tightened diagonally in stages.

 The threads of bolts which are secured by a locking fluid should be cleaned with a wire brush. Then apply
AMV 185 101 A1 when inserting.
 Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be
cleaned (e.g. with a tap). Otherwise there is a danger of bolts shearing when subsequently being removed.
Mount
 Attach the needle bearing with the written side (greater plate thickness) to the installing tool.
 Grease needle bearing for transmission rear input shaft in flywheel.
 Lubricate all bearings in transmission housing with gear oil before installing.
 Heat inner races of taper roller bearings to approx. 100 ° C before installing. Press in onto stop when
installing so there is no axial play.
 Do not interchange inner or outer races of bearings of the same size.

 Always replace the taper roller bearings on one shaft together and use new bearings from a single
manufacturer.
 The taper roller bearings for the output shaft and the differential in the transmission are low-friction
bearings. Do not additionally oil new taper roller bearings when measuring friction torque. The bearings
are pre-treated at the factory with a special type of oil for this purpose.
Adjustment shims
 Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain
exact shim thickness required.
 Only install perfect, undamaged shims.
Gears, synchros, inner races for sliding gears
 Heat gears and synchros to approx. 100 ° C before installing. Press in onto stop when installing so there is
no axial play.
 Heat inner races for sliding gears to approx. 100 ° C when installing.
2:25:49 AM Page 10
 Temperature can be checked with temperature tester V.A.G 1558.

Sliding gears
 After installing, check 1st to 6th sliding gears and reverse sliding gear for axial play of 0.15 to 0.35 mm
and check that they rotate freely.
Synchronizer rings
 Do not interchange synchronizer rings. When reusing always reinstall to the same gear.
 Check for wear; replace if necessary.
 Coat with gear oil when installing
Clutch mechanism
 When removing transmission, remove clutch slave cylinder without disconnecting pipes.
 Do not depress the clutch pedal after removing the slave cylinder if the hydraulic pipe is still connected.
Otherwise the piston will be pressed out of the slave cylinder.
 Do not tilt clutch pressure plate, loosen and tighten diagonally in small steps.
transmission in order to reduce the smell.
30 CLUTCH


Cabriolet
.
2:25:49 AM Page 11



Cabriolet
.
Refer to

NOTE:  Disconnect battery Ground strap with the ignition switched off.
052 142 A 2.
 Before working on pedal cluster, remove cover below dash panel:
Refer to
 Ensure that no brake fluid escapes into the footwell, plenum chamber or
thoroughly.
Pedal cluster assembly, overview
2:25:49 AM Page 12

1 - Bracket
3 - Securing clip
5 - Brake pedal
2:25:49 AM Page 13
 Maintenance-free mount, do not grease
6 - Clutch Vacuum Vent Valve Switch -F36-

8 - Clutch pedal
2:25:49 AM Page 14
9 - Securing clip
10 - Mount
 Removing and installing. Refer to Hydraulic system, exploded view


2:25:50 AM Page 15
 Black side faces clutch pedal

 Removing and installing. Refer to Over center spring, removing and installing
 Allocation
14 - Clutch Pedal Position (CPP) Switch -F194- (Interlock switch)
15 - TORX-screw - 25 Nm
 For fastening brake master cylinder/brake servo to mounting bracket
Over center spring, removing and installing

 T40025 retaining clamp
Removing
 Remove driver's side tray:
Refer to
2:25:50 AM Page 16

 Tension over-center spring with clutch pedal and press on retaining clamp T40025.
 Bring clutch pedal to rest position and remove over-center spring downward together with retaining
clamp T40025.
Installing

 Install over-center spring with retaining clamp T40025, operate clutch pedal and remove retaining clamp.
Hydraulic system, exploded view
2:25:50 AM Page 17

2 - Supply hose
3 - Hose assembly
 For plug connections on master/slave cylinders

 Detaching from master cylinder and installing. Refer to Master cylinder, removing and installing
 Detaching from slave cylinder. See Detaching slave cylinder from hose/pipe assembly
4 - Grommet
2:25:50 AM Page 18
5 - Bracket

6 - Clutch pedal
7 - Master cylinder

 Clips (arrow A) and seal (arrow B) must not be removed
 To remove the hose/pipe assembly, pull out the clip (arrow A) up to the stop. Refer to Fig. 34
9 - Mount
2:25:50 AM Page 19

 Prying off. See Lever off mount
 Pressing on. See Press master cylinder operating rod into mount

10 - Transmission
11 - Slave cylinder

installing
2:25:50 AM Page 20
12 - Bleeder valve
 A broken bleeder valve can be screwed out with a 3mm hex socket wrench

13 - Dust cap
14 - Clamp
2:25:50 AM Page 21
 To remove the line, pull out the clamp to the stop. See Detaching slave cylinder from hose/pipe
assembly
15 - Bracket

 Fastened together with slave cylinder to transmission

 Self-locking
 Always replace
17 - Retaining clip
18 - Gasket
19 - Bolt
Lever off mount

Press master cylinder operating rod into mount
2:25:50 AM Page 22


Removing
 To remove the hose/pipe assembly, lever out the clip -A- up to the stop using a screwdriver. Only then
can the hose/pipe assembly be pulled out.
Installing

2:25:50 AM Page 23

 3094 Hose clip

 V.A.G 1922 Pliers
Removing
Refer to

Cabriolet
 With the ignition switched off disconnect the battery Ground strap.
2:25:50 AM Page 24
 Pull the rubber gasket off plenum chamber in direction of arrow.
 Remove cover -1- above plenum chamber.

 Lever off both trim caps -3- with a screwdriver.

 Unscrew nuts -4- and remove both wiper arms -2-.
 Pull off clips -1- and remove cowl grille -5-.
2:25:50 AM Page 25
 Unscrew the bolts -arrows- and pull off the sealing cap.
 Carefully lever off the retainer bar with a screwdriver -arrow-.
2:25:50 AM Page 26
 Release the connector catches -arrows- and detach connectors -1- and -2- of engine control unit.

 Detach connectors -2- on connector console.

 Unscrew the electrical wiring connection -1-.

 Release catch -arrow- and detach additional relay carrier in electronics box upward.
 Pull engine wiring harness together with rubber grommet through opening in electronics box.
2:25:50 AM Page 27

clean the affected areas thoroughly.

 Remove rubber grommet from cross panel above connection pipe for supply hose.
 Pry out retaining clip -C- with a screwdriver and then pull out pipe -B- slightly.
2:25:50 AM Page 28

 Unscrew bolt for brake fluid reservoir -1- and detach fluid level connector downward.
NOTE: The brake fluid reservoir is not removed.
NOTE:  For the sake of clarity, the brake fluid reservoir is not shown here.
 To remove the upper Torx bolt, the brake fluid reservoir must be swivelled
slightly to one side.


 Detach vacuum pipe from brake servo -1-.
Refer to
2:25:50 AM Page 29

 Detach steering column from steering box -arrow A-.
Refer to 48 - STEERING .
 Detach connectors from clutch pedal switch -1-, brake pedal switch -2- and from accelerator pedal
module -3-.
2:25:50 AM Page 30
 Unscrew retaining bolts for mounting bracket -arrow B- and remove the complete pedal cluster.
Separate master cylinder operating rod from clutch pedal as follows:
 Removing over-center spring. Refer to Over center spring, removing and installing.
NOTE:  In order to assure sufficiently secure installations of Clutch Vacuum Vent

Valve Switch -F36- -Item 6-: Refer to Pedal cluster assembly, overview and
of Clutch Pedal Position (CPP) Switch -F194- -Item 14-: Refer to Pedal
cluster assembly, overview (Interlock switch) in the pedal assembly, these
switches must not be installed more than once.
Fig. 39: Pressing Retainer Together And Detaching Clutch Pedal From
Master Cylinder Using VAG 1922
 When releasing, make sure that the clutch pedal does not knock against
the mount for the clutch pedal switch -arrow-. The mount could break off.
 Position pliers VAG 1922 in the clutch pedal recesses, press the mount together -arrow- and detach clutch
2:25:50 AM Page 31
 Release securing clip -1- and remove clutch pedal -2-.

 Screw out bolts -3- and remove master cylinder -4-.
Installing
Installation is carried out in the reverse order, when doing this note the following:
Clutch Pedal
 Install mount -1- in clutch pedal.

 Press the clutch pedal in direction of arrow until it engages; ensure correct locking of the mount -1- in the
clutch pedal.
 Installing over-center spring. Refer to Over center spring, removing and installing.
2:25:50 AM Page 32
 Insert complete pedal cluster and tighten bolt -1- finger tight. The second mechanic should guide the pipe
into the master cylinder starting from the plenum chamber.

 Tighten the retaining bolts for the brake servo -arrows- to 25 Nm.
2:25:50 AM Page 33

 Press retaining clip -C- home.

 Push pipe -B- into master cylinder until it audibly locks in place.
 Insert rubber grommet -D- over connection pipe/supply hose -A- into the cross panel.
 Slide supply hose -A- for the brake fluid reservoir on as far as its stop.

 Screw in securing bolt for brake fluid reservoir.
 Tighten the hex socket head bolt -arrow B- for securing pedal cluster to dash panel crossmember to 25
2:25:50 AM Page 34
Nm.
 Plug in connectors -1-, -2- and -3-.
 Attach steering column to steering box -arrow A-.
 Install storage compartment for driver's side:
Refer to
 Bleed the clutch system. Refer to Clutch system, bleeding.

 Insert the electronics box and tighten nuts -arrows- to 4 Nm.

 Route the engine wiring harness and join the connector in the connector station.
 Install the engine control unit and, if removed, also the auxiliary relay carrier and the auxiliary fuse box.
Refer to
 97 WIRING
 Press on sealing cap hand-tight and tighten bolts in diagonal sequence - 4 Nm.
See Caution for disconnecting Telematics battery. Refer to Clutch mechanism, servicing
2:25:50 AM Page 35
Refer to

 VAS 5234 Brake filler and bleeder unit
 Brake fluid specification.
NOTE:  Open the bleeder valve before switching on the bleeder unit.
clutch mechanism.
 Before bleeding, pull out clutch pedal and fill brake fluid reservoir with
brake fluid up to "max." marking.
 Connect VAS 5234 Brake filler and bleeder unit, but do not switch on at this stage.
2:25:50 AM Page 36

 Switch on the bleeder appliance and allow about 100 cm3 of brake fluid to drain out.
NOTE: Ensure bleeder hose is correctly installed during bleeding operation.
 Close bleeder valve and tighten to 4.5 Nm.

 Depress clutch pedal several times after completion of bleeding process.
2:25:50 AM Page 37

1 - Transmission
3 - Shaft seal
 For input shaft

 Removing. See Removing shaft seal for input shaft
 Installing. See Installing shaft seal for input shaft
 Standard insertion depth: 3.5 mm, insertion depth for repairs: 4.5 mm
2:25:50 AM Page 38
4 - Locating sleeve
5 - Bolt -15 Nm
 3 pieces

 Removing. See Removing clutch release lever

 Must engage in lugs in intermediate piece when installed. See Installing clutch release lever
 Before installing, coat contact surface of clutch slave cylinder push rod with copper grease, e.g. Z 381
351 TE.
2:25:50 AM Page 39
7 - Leaf spring
8 - Release and tighten bolt - 25 Nm
 Self-locking
 Always replace
9 - Release bearing
 With or without plastic ring, depending on version. See Repairing release bearing with plastic ring
 Cement detached plastic ring. See Repairing release bearing with plastic ring
 Do not wash out, wipe clean only
 Engage retaining latches at the release bearing in contact release lever
2:25:50 AM Page 40


installing
 When installing, push on until the securing bolt can be fitted
2:25:50 AM Page 41

 Self-locking
 Always replace

12 - Bracket

 Fastened together to transmission with slave cylinder
 Bolt onto transmission with clutch slave cylinder
2:25:50 AM Page 42
13 - Push rod
Removing shaft seal for input shaft

Installing shaft seal for input shaft


 Fill space between sealing and dust lips with sealing grease G 052 128 A1.
2:25:50 AM Page 43

Removing clutch release lever
Fig. 56: Removing Clutch Release Lever

 Release bolt -1-, remove leaf spring - 2- and press back the detent -arrow-.
 Remove clutch release lever -4- together with release bearing -3-.
 Disengage the retaining latches of the release bearing at release lever.
Installing clutch release lever
Fig. 57: Installing Clutch Release Lever

 Before installing the clutch release lever, the contact surface of clutch slave cylinder push rod must be
coated with a thin layer of copper paste.
 Insert clutch release lever -A- into the intermediate piece -C- and allow it to engage (detent -B- becomes
visible).
2:25:50 AM Page 44
 Insert leaf spring -Item 7: Refer to Clutch release mechanism, servicing, tighten retaining bolt -Item :
Refer to 8 Clutch release mechanism, servicing to 25 Nm.

Removing
 To remove the hose/pipe assembly, lever out clip -A- to the stop using a screwdriver. Only then can the
Installing

Removing clutch slave cylinder

2:25:50 AM Page 45
 Remove bolt -arrow-, remove clutch slave cylinder rearward.
NOTE: Do not depress clutch pedal after removing slave cylinder.

 Coat clutch slave cylinder with lithium grease G 052 150 A2. See Coat clutch slave cylinder with
grease before installing.
 Engage bracket for hose/pipe assembly -3- at the slave cylinder -4-.
 When inserting the clutch slave cylinder into the mounting hole of the transmission housing, keep it as far
as possible in line with the direction of operation of the push rod.
NOTE:  If the clutch slave cylinder -4- is inserted off-line there is a danger that the
push rod will be guided past the clutch release lever.
 When installing, press in the clutch slave cylinder far enough so that the
securing bolt can be fitted easily.
 Tighten bracket for hose/line assembly together with slave cylinder on transmission.
Coat clutch slave cylinder with grease before installing
2:25:50 AM Page 46
TE.
 Before installing slave cylinder into transmission housing, lubricate area -a- on boot with lithium grease
G 052 150 A2.
Repairing release bearing with plastic ring

In the case of release bearings with plastic ring it is possible that the plastic ring detaches from the
release bearing during removal of the transmission. This does not signify that replacement of the release
bearing is necessary.
 Cement the loose plastic ring to the bearing ring the with adhesive AMV 195 KD1 01 before installing
the transmission.
Three rectangular lugs -arrows- on the plastic ring engage into recesses in the bearing ring.
NOTE: If the plastic ring has become embedded deeper than 0.5 mm in the bearing
2:25:50 AM Page 47
surface, the bearing ring must be replaced.
CLUTCH, SERVICING
Clutch, servicing

 Retainer 10-201
 Thrust pad 3062
 Grease G 000 100
2:25:50 AM Page 48

instructions.
 The adjuster ring for the SAC-clutch pressure plate (self-adjusting clutch
pressure plate) must be reset before assembly when the clutch ring is
replaced exclusively. Refer to SAC clutch pressure plate adjuster ring,
resetting onward.
code.
splines. Remove corrosion and apply only a very thin coating of grease G
000 100 to the splines. Then move clutch plate to and for on input shaft
 Pressure plates are protected against corrosion and greased. Only the
 If the clutch has burnt out, thoroughly clean the bell housing, flywheel and
parts of the engine facing the transmission in order to reduce the smell.
Clutch with SAC pressure plate
2:25:50 AM Page 49

 Make sure that centering pins are a tight fit.

Refer to
2:25:50 AM Page 50

2 - Needle bearing
 Driving off and on
Refer to
2:25:50 AM Page 51

 Always replace
 Screw length 43 mm 60 Nm plus additional 180 ° turn
 Screw length 22.5 mm 60 Nm plus additional 90 ° turn
4 - Clutch plate

2:25:50 AM Page 52
 Centering. See Removing and installing clutch with SAC pressure plate
 Do not grease
 Clutch plate diameter. Refer to Code letters, mechanical unit assignment, transmission ratios,
capacitiesonward
Fig. 66: Identifying Clutch Components (SAC Pressure Plate)

 Resetting adjuster ring. Refer to SAC clutch pressure plate adjuster ring, resetting
 Removing and installing. See Removing and installing clutch with SAC pressure plate
 Check ends of diaphragm spring. See Checking ends of the diaphragm spring
2:25:50 AM Page 53
 Check spring connection and riveted fastenings
6 - Bolt, 25 Nm
 Tighten in small stages and in diagonal sequence
Removing and installing clutch with SAC pressure plate
Fig. 67: Removing And Installing Of Clutch With SAC Pressure Plate
NOTE:  The SAC pressure plate adjuster ring must be turned back prior to
installation when the clutch plate is replaced exclusively. Refer to SAC
clutch pressure plate adjuster ring, resetting onward.
 The clutch plate lining and the contact surface of the pressure plate must
make full contact with the flywheel before the securing bolts are inserted.
 Tighten securing bolts evenly and in diagonal sequence in small steps to
avoid damaging centering holes in pressure plate and centering pins on
flywheel.
 Installation position of clutch plate: spring pack (coil springs) or marking "Getriebeseite" toward pressure
 Loosen and tighten bolts gradually in several stages working diagonally. Tightening torque: 25 Nm.
 Re-position Retainer 10-201 when removing.
Checking ends of the diaphragm spring
2:25:50 AM Page 54

SAC clutch pressure plate adjuster ring, resetting
"SAC" stands for self-adjusting clutch.
When installing a new clutch plate with a used SAC pressure plate, the pressure plate adjuster ring must
be turned back to the limit stop. If the pressure plate adjuster ring is not turned back, the SAC pressure
plate functions at a reduced pressure, resulting in increased wear of the clutch and in particular of the
clutch plate (clutch slips).
If the clutch plate is not replaced, the adjuster ring does not require resetting.
New SAC pressure plates are pre-set and consequently do not require resetting.
2:25:50 AM Page 55
 Insert 3 pressure plate securing bolts -A- in the fixing holes of the pressure plate at a 120 ° offset (1/3
turn) as indicated in the illustration.
 Screw 3 nuts -B- (M8) onto bolts -A-and tighten slightly.

 Position SAC pressure plate on the pressing tool in such a way that only the 3 bolt heads rest upon it.
 Center special tool 3062 on the center of the pressure plate.
2:25:50 AM Page 56
 Position two screwdrivers at the adjuster ring. Press against the pressure plate with the pressing tool until
the adjuster ring can just be moved.
 Turn the adjuster ring evenly using both screwdrivers in direction of arrow until it reaches the limit stop -
arrow A-.
 Hold the adjuster ring at the stop while reducing the pressure of the pressing tool so that the adjuster ring
remains in position.

Gear shift lever mechanism, installation position
2:25:50 AM Page 57
Fig. 72: Gear Shift Lever Mechanism, Installation Position

1 - Selector rod
2 - Front push rod
3 - Connecting rod
4 - Gear selector lever
Component overview
2:25:51 AM Page 58
Fig. 73: Shift Mechanism Remove/Install Components - Part 1

Part 1
NOTE: Lubricate bearing areas and slide surfaces with polycarbamide grease, Part No.
G 052 142 A2.
1 - Ball
2 - Rubber ring
3 - Ball guide
4 - Rubber ring
2:25:51 AM Page 59
5 - Washer
 Shoulder faces ball guide (Item 3 Component overview)
6 - Snap ring
 Remove to remove the ball

7 - Compression spring
8 - Spacer bushing
9 - Washer
2:25:51 AM Page 60
10 - Snap ring
11 - Noise insulation cover
12 - Shift knob
 with cover
 Removing and installing. Refer to Shift knob and cover, removing and installing
13 - Nut - 10 Nm
14 - Ball housing
15 - Inner Torx bolt
2:25:51 AM Page 61
16 - Shift lever
 Angled area faces rear
17 - Bolt
18 - Nut - 10 Nm
19 - Shift mechanism housing
20 - Shift fork
21 - Nut - 10 Nm
 Self-locking
 Always replace
22 - Bushing
2:25:51 AM Page 62

Part 2
1 - Ball socket
 To remove, bend back peenings on shift rod -Item 19 Component overview
2 - Washer
3 - Ball socket
 To remove, remove locking clips -Item 9- Component overview
4 - Boot
2:25:51 AM Page 63
5 - Transmission shift lever
6 - Nut - 23 Nm
7 - Bolt - 23 Nm
8 - Operating rod

9 - Locking clamp
10 - Bolt - 40 Nm
2:25:51 AM Page 64
11 - Pivot rod
 with bushing, bolt and washers
13 - Washer
14 - Ball housing
16 - Boot
 Carefully pull over shift rods when removing

 When installing, place on markings of shift rod and pivot rod
2:25:51 AM Page 65

18 - Clamping piece
19 - Shift rod
20 - Shift fork
21 - Nut - 10 Nm
22 - Nipple
Shift knob and cover, removing and installing
2:25:51 AM Page 66
Removing
NOTE: Remove shift knob together with shift lever cover and cover for center console.

 Unclip cover for center console and lift this out upward -arrows-.

 Detach connecting part -1- in direction of arrow and pull off shift knob together with shift lever cover
upward.
Installing
2:25:51 AM Page 67
Special Tools and Equipment

 VAG1383A engine/transmission hoist
Removing
 Remove shift knob with cover. Refer to Shift knob and cover, removing and installing.
Vehicles with large radio compartment:
 Remove A/C Control Head.
Refer to 87 AIR CONDITIONING
Vehicles with small radio compartment:
2:25:51 AM Page 68
 Lift up panel -1- first in direction of arrow -A- and pull it out in the direction of arrow -B-.
All:
 Remove bolts -arrows C- and then remove ashtray -2- from center console.
 Disconnect electrical harness connector for ashtray lighting.
 Lift out noise insulation upward.
 Remove noise insulation cover for shift mechanism housing (arrows).

NOTE: The flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise
2:25:51 AM Page 69
it may be damaged.
Fig. 85: Exhaust System At Double Clamps

 Disconnect exhaust system at double clamps -arrows-.

 Detach rear part of exhaust system on retaining loops and remove it.
NOTE: A second technician is required to remove the rear part of exhaust system.

 Remove heat shield for drive axle -arrows-.
2:25:51 AM Page 70

 Remove bolts at flange of transmission/drive axle.

 Remove heat shield -1- -arrows-.
 Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially.
 Remove heat shield.
 Tie up the drive axle -2- on transmission to the side.
 Disconnect connecting rod -2- of shift rod.

 Remove pivot rod -1-, to do this unbolt socket-head bolts.
2:25:51 AM Page 71

 Remove nut -1- and pull transmission shift lever -2- from shift rod of transmission.
Wood
 Remove VAG1359/2 universal mount from VAG1383A engine/transmission jack and place a piece of
wood -arrow- onto punch instead.
 Support tunnel cross member using VAG1383A engine/transmission lift.
 First remove bolts -1- and -2-, then bolts -3- and -4-.
 Remove shift mechanism toward rear.
Installing
NOTE: Always replace gaskets and self-locking nuts.
 Install tunnel cross member.
2:25:51 AM Page 72
Refer to 40 - FRONT SUSPENSION
 Secure driveshaft to transmission.
 Install and adjust exhaust system free of stress.
Refer to
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL,
ENGINE CODE(S): BHF
 Adjust shift mechanism. Refer to Shift lever mechanism, adjusting.
Tightening torques
Component Nm
Pivot rod to transmission 40
Transmission shift lever to transmission 23
Transmission shift lever to shift rod 23
Shift lever mechanism, adjusting
NOTE: The following are prerequisites for correct gear linkage adjustment:
 Perfect gear linkage operating and transfer elements.

 Gear shift lever mechanism moves smoothly.
Work sequence
 Remove A/C control head.
2:25:51 AM Page 73
 Lift panel -1- first in direction of arrow -A- and pull out in direction of arrow -B-.
All:
 Unscrew the bolts -arrows C- and pull out the ashtray -2- from the center console.
 Lift out the noise insulation upward.
 Unscrew noise insulation cover for shift lever housing -arrows-.
2:25:51 AM Page 74

 Measure distance -a- between the two threaded studs in the shift lever mechanism
 Specified value: Distance a = 85 mm
NOTE: Measure from the centers of the two threaded studs.
 If this is not the case, adjust distance -a- as follows:

 Loosen push rod bolt (arrow).
 Rear push rod (in shift lever mechanism) should move freely in both directions on slide.
 Set distance -a- by moving rear push rod (in shift lever mechanism).
 Tighten push rod bolt -arrow- to 23 Nm.

 Loosen bolt for selector rod -arrow-.
 Connection between selector rod and shift lever mechanism should move freely.
2:25:51 AM Page 75
Align the shift lever as follows:

 Center the bottom of the gear lever in the center of the ball housing.
 The distance between the ball housing and the bottom of the gear lever -arrows- must be equal at all
points.
 Shift lever in vertical position to direction of travel.
 Shift lever held in this position.

 Tighten selector rod bolt -arrow- to 23 Nm.
NOTE: The shift lever must remain in the same position while the bolt is being
tightened.
Shift lever alignment, checking
2:25:51 AM Page 76
 The shift lever must rest in the 3rd/4th gear gate when the transmission is in neutral.
 Depress clutch.
 Check that all gears can be engaged.
 It should only be possible to engage the R gear after releasing the block.
 The gear lever must return automatically from the R gear gate to the 3rd/4th gear gate.
If after repeated selection of a gear it fails to engage smoothly, shift lever alignment must be repeated.
 Install covers and shift lever knob


Cabriolet
.


Cabriolet
.
2:25:51 AM Page 77

 10-222A Engine support bridge

 2024A Engine Sling
 3282 transmission support
 3282/12 adjustment plate
 VAG 1383 A Engine/transmission hoist
Removing
2:25:51 AM Page 78
Refer to

Cabriolet
Fig. 98: Removing Battery Cover

 Slide cover over the battery to the right (arrow 1) and pull it off upward (arrow 2).

 Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.
2:25:51 AM Page 79

 Remove rear engine cover (arrows).

 Remove front engine cover (arrows).

2:25:51 AM Page 80
 Remove cover -1- in engine compartment (right side).
 Remove bolts for holding plate -3- for solenoid valves (arrows).
 Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
 Remove hose -4- of crankshaft housing ventilation from air duct -2-.
 Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
 Disconnect hose -1- from air duct.
NOTE: Illustration depicts air guide with the removed engine from rear.
 Remove engine/transmission connecting bolts accessible from above.
2:25:51 AM Page 81
Fig. 105: Positioning 10-222A Engine Support Bridge On Bolted Flanges Of Fenders
 Position 10-222A engine support bridge on bolted flanges of fenders.
Fig. 106: Removing Eyelet For 2024A Engine Sling

 Remove eyelet for 2024A engine sling.

 Insert bolt -1- in the center bore of 2024A Engine Sling and secure with a cotter pin.
 Attach bolt for 2024A engine sling at 10-222A engine support bridge spindle.
 Attach 2024A Engine Sling to sling clamps at front and rear of engine.
WARNING: Take-up hooks and pins at engine sling must be secured using securing
pins (arrows) as shown in illustration.
 Slightly pre-tension engine using engine support bridge spindle.
Vehicles with auxiliary heater:
2:25:51 AM Page 82
Fig. 107: Fasteners

 Remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
All:

 Remove the sound-proofing material (arrows).
2:25:51 AM Page 83

 Unbolt bracket for noise insulation panel (arrow).
it may be damaged.




2:25:51 AM Page 84
Fig. 112: Driveshaft Secured With Wire To Heat Shield

 Secure driveshaft -1- with wire (arrow) to heat shield.
Wood
2:25:51 AM Page 85
Wood
 Release slowly the tunnel cross member using VAG1383A engine/transmission hoist.

 Remove nuts -1- and -2-.

 Remove bolts (arrows) and remove tunnel cross member downward using transmission mount.
2:25:51 AM Page 86

 Remove left and right heat shields for drive axles (arrows).
 Remove drive axles from transmission drive flange.
NOTE: Take care not to damage protective coating on drive axles.
Between
 Raise transmission using punch of VAG 1383 A engine/transmission hoist high enough, so that a piece of
wood (arrow) can be placed in between.
2:25:51 AM Page 87

 Remove the three bottom engine/transmission connecting bolts (arrows).

 Lower transmission again.

 Unbolt starter -1- (arrows) and remove it from transmission bell housing.
 Remove remaining mounting bolts for engine/transmission. One bolt remains tightened by hand.
2:25:51 AM Page 88
 Disconnect harness connector for back-up light switch at right of transmission and set aside electrical
wire.
Fig. 121: Disconnecting Harness Connector From Speedometer Vehicle Speed Sensor (VSS) -G22- At
 Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of
transmission.
 Unbolt heat shield for engine speed (RPM) sensor.
 Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.
2:25:51 AM Page 89


Fig. 125: 3282 Transmission Support, 3282/12 Adjustment Plate And VAG1383A Engine/Transmission
2:25:51 AM Page 90
Hoist
 Set up 3282 transmission support for removing manual transmission 01E all wheel drive using 3282/12
adjustment plate and VAG1383A engine/transmission hoist.
A - Attachments
NOTE:
Fig. 126: Identifying Attachments Symbols On Adjustment Plate

 Attachments -A- are shown in schematic form, arrow -B- points in the
direction of travel.
 3282/12 adjustment plate only fits in one position.
Fig. 127: Place Transmission Jack And Adjustment Plate 3282/12 Under Transmission
 Roll VAG 1383 A engine/transmission hoist underneath transmission. Arrow B (Refer to Illustration Fig.
126) on adjustment plate 3282/12 points in the direction of travel.
2:25:51 AM Page 91
Fig. 128: Align Adjustment Plate 3282/12 Parallel To Transmission And Lock Safety Supports On
Transmission
 Remove last mounting bolts for engine/transmission.
 Press transmission off dowel sleeves and lower carefully using VAG 1383 A engine/transmission hoist
just enough for access to slave cylinder.
NOTE: When lowering the transmission, make sure the hydraulic line/hose to clutch
slave cylinder is not damaged.

 Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect line.
NOTE: Ensure freedom of movement of drive axles when lowering.
Installing
2:25:51 AM Page 92
NOTE: Always replace seals, gaskets and self-locking nuts.
 Clean input shaft splines and (in case of used clutch plates) clean hub splines. remove corrosion and apply
only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
 Coat contact surface of clutch release lever plunger with a thin layer of copper grease, e.g. Z 381 351 TE.

 If the plastic ring of the release bearing is loose, adhere it to the bearing ring again using adhesive AMV-
195-KD1-01.
 3 rectangular tabs (arrows) of the plastic ring reach into the cutouts of the bearing ring.
 If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.
 All threaded bores in which self-locking bolts are threaded must be cleaned of remaining locking fluid
using a tap.
 Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or
replace if necessary.
 Place intermediate plate onto the dowel sleeves on engine flange.
 Tie electrical wires off to the side before installing, so that they are not pinched between engine and
transmission.
 Lift transmission until clutch slave cylinder with mounting bracket for line/hose can be installed (arrow).
2:25:51 AM Page 93

 Secure slave cylinder with a new bolt (arrow).

 Install starter and secure connecting bolts for engine/transmission on left and right side.
 Install connecting rods and pivot rods for shift mechanism.
Between
 Place a piece of wood (arrow) onto punch of VAG 1383 A engine/transmission hoist and raise
transmission slightly.
2:25:51 AM Page 94

 Tighten the three bottom engine/transmission connecting bolts (arrows).

 Guide the tunnel cross member with loosely inserted transmission mount over front exhaust pipes.
it may be damaged.
Wood
 Place a piece of wood (arrow) onto punch of VAG 1383 A engine/transmission hoist and raise tunnel
cross member and transmission slightly.
 Next, tighten bolts -1- to -4- hand-tight.
 Release slowly the VAG 1383 A engine/transmission hoist.
 Tighten bolts for tunnel cross member.
2:25:51 AM Page 95
Fig. 135: Identifying Transmission Raised Using Punch Of VAG 1383 A, A Piece Of Wood And
Transmission Mount Bolts
 For tension-free installation, raise transmission using punch of VAG 1383 A engine/transmission hoist
high enough so that a piece of wood -1- can be placed in between.
 Tighten bolts (arrows) for transmission mount.
 Slowly lower transmission again.
 Tighten nuts -2- and -3-.
 Bolt drive axles on drive flange.
 Check adjustment of shift mechanism and adjust if necessary. Refer to Shift lever mechanism,
adjusting.
Refer to
ENGINE CODE(S): BHF
 Check transmission oil level in manual transmission. Refer to Transmission oil level, checking.
See Caution for disconnecting Telematics battery. Refer to Transmission, removing and installing
2:25:51 AM Page 96
Refer to

Tightening torques

Securing engine/transmission for manual transmission with All Wheel Drive (with intermediate plate)
Item no. Bolt Nm

1, 10, 11 M10 x 60 45
2 M12 x 130 65
3 M10 x 150 45
4 M12 x 80 65
5, 6, 8 M12 x 80 65
7 M12 x 105 65
9 M10 x 59 45
A: Alignment bushing
Component Nm
Clutch slave cylinder to transmission 23 1)
Connecting rod for shift rod to transmission 23
Engine Speed (RPM) sensor -G28- 10
Transmission mount with console to transmission 23
2:25:51 AM Page 97

Heat shield for drive axle to cover for Torsen differential 25
Air duct to throttle valve supports 10
1) Always replace bolt
NOTE:  The vehicle should be absolutely horizontal when checking transmission

oil level. This work is best performed over an inspection pit or using a 4 -
column lifting platform.
 The prescribed oil level is to be adhered to exactly; the transmission
reacts very sensitively to overfilling.
Fig. 137: Location Of Sealing Plug For Gear Oil Inspection

 Remove oil filler plug -B- to check final drive oil level.
 Check oil level using a shop-built tool, e.g. a piece of angled wire.
 Specification: Oil level 4 mm ± 1 below bottom edge of oil filler hole
 Top up with gear oil, if necessary: Specification. Refer to Code letters, mechanical unit assignment,
Tightening torque
Component Nm
Oil filler plug 40
2:25:52 AM Page 98
Fig. 138: Transmission, Disassembling And Assembling, Sequence

Assembly sequence. Refer to Assembly sequence
1 - Bearing housing, Torsen differential and end cover
 Removing and installing. Refer to Bearing housing, Torsen differential and end cover, removing and
installing
2 - Manual transmission and selector shaft
2:25:52 AM Page 99
 Removing and installing. Refer to Manual transmission and selector shaft, removing and installing
3 - Transmission housing and differential

 Servicing transmission housing. Refer to Transmission housing, servicing
Bearing housing, Torsen differential and end cover, removing and installing
Fig. 139: Bearing Housing, Torsen Differential And End Cover, Overview
1 - Bearing housing
 Disassembling and assembling. Refer to Bearing housing, disassembling and assembling
2:25:52 AM Page 100

2 - Bolt, 25 Nm
 6 pieces
3 - Dished washer
 Installation position: Large diameter (concave side) facing shims
4 - Washer
 Qty. 2 or 3
 Re-determining thickness. Refer to Fig. 213
2:25:52 AM Page 101

5 - Oil collector
 Disassembling and assembling. Refer to Fig. 208

 Removing. Refer to Fig. 163
 Installing. Refer to Fig. 209
6 - Multi-point socket head bolt, 150 Nm
 Loosening. Refer to Fig. 166

 Tightening. Refer to Fig. 207
7 - 2nd inner race for four-point bearing
 Roller bearing side

 Pulling off. Refer to Fig. 168
 Driving on. Refer to Fig. 206
8 - Spring
 Servicing only possible at manufacturer

 Servicing mount for Torsen differential. Refer to Mount for Torsen differential, servicing
2:25:52 AM Page 102

10 - Bolt, 25 Nm
 5 pieces
11 - End cover
 Servicing. Refer to End cover, servicing
12 - Gasket
 Always replace
13 - Dowel sleeve
2:25:52 AM Page 103

 2 pieces
 Removing and installing 5th and 6th gear. Refer to 5th and 6th gear, removing and installing
 Removing and installing input shaft, drive pinion, hollow shaft and shift mechanism in transmission.
Refer to Input shaft, drive pinion, hollow shaft and shift lever mechanism in transmission, removing
and installing
15 - Oil drain plug, 40 Nm
16 - Solenoid
2:25:52 AM Page 104

 2 pieces
 Clean
17 - Supporting plate
 Installation position: Lug faces magnet
18 - Bolt, 25 Nm
 2 pieces
Manual transmission and selector shaft, removing and installing
Fig. 143: Manual Transmission And Selector Shaft, Overview

2:25:52 AM Page 105

1 - 5th and 6th gear
 Transmission remains flanged to transmission housing

 Removing and installing. Refer to 5th and 6th gear, removing and installing
and installing
3 - Bolt, 25 Nm
 3 pieces
 Inserted with sealing paste AMV 188 001 02

2:25:52 AM Page 106



 Disassembling and assembling. Refer to Selector shaft, disassembling and assembling
6 - Locking bolt, 50 Nm
 4 pieces
 Insert with sealing paste AMV 188 001 02
2:25:52 AM Page 107

 Servicing. Refer to Transmission housing, servicing
8 - Oil filler plug, 40 Nm
9 - Differential
 Covered by final drive cover.


11 - Dowel sleeve
2:25:52 AM Page 108

 2 pieces
12 - Bolt, 25 Nm
 12 pieces
5th and 6th gear, removing and installing
Fig. 146: 5Th And 6Th Gear, Removing And Installing, Overview
1 - 1st inner race for four-point bearing

2:25:52 AM Page 109

2 - Needle bearing for 5th gear
3 - Inner race for 5th sliding gear

4 - 5th sliding gear

5 - Spring pin
 Pressing out. Refer to Fig. 171

 Pressing in. Refer to Fig. 198
6 - Follower for 5th and 6th gear
 Only replace complete with selector rod for 5th and 6th gear -Item 8- 5th and 6th gear, removing and
installing
7 - Selector fork, 5th and 6th gear
 Can be replaced separately
8 - Selector rod for 5th and 6th gear
 Only replace complete with follower for 5th and 6th gear
9 - Locking collar/synchro-hub for 5th and 6th gear

10 - Circlip
11 - 5th gear wheel
2:25:52 AM Page 110

 Pull off together with synchro-hub and inner race for 5th gear. Refer to Fig. 174
13 - Needle bearing
 For 6th gear
14 - Thrust washer
 For needle bearing for 6th sliding gear
2:25:52 AM Page 111

 Installation position: Grooves face circlip, smooth face contact surface toward needle bearing
15 - Circlip
16 - Inner race
 For cylinder roller bearing

 Remove by hand. Refer to Fig. 178
17 - Washer
2:25:52 AM Page 112

18 - Spacer sleeve
 Length 39.6 mm
19 - 6th gear wheel
 To press off, remove bearing plate. Refer to Fig. 176

 Pressing off. Refer to Fig. 182
 Pressing on. Refer to Assembling
Input shaft, drive pinion, hollow shaft and shift lever mechanism in transmission, removing and installing
Fig. 149: Input Shaft, Pinion, Hollow Shaft And Selector Mechanism (Transmission Side), Removing And
Installing, Overview
2:25:52 AM Page 113

1 - Bearing plate
 Servicing. Refer to Bearing plate, servicing
 Only replace complete with follower for 5th and 6th gear. Refer to 5th and 6th gear, removing and
installing, Item 6
3 - Follower for reverse gear
 Pulling out ball housing. Refer to Pulling ball sleeve out of follower for reverse gear
 Driving in ball housing. Refer to Driving ball sleeve flush into follower for reverse gear
4 - Selector fork, 3rd and 4th gear
 Can be replaced separately.

 Installation position: Rib toward follower
2:25:52 AM Page 114

5 - Selector rod for 3rd and 4th gear
 Only replace complete with follower for 3rd and 4th gear
6 - Input shaft
7 - Follower for 1st and 2nd gear
2:25:52 AM Page 115

8 - Circlip
 2 pieces
9 - Selector rod for 1st and 2nd gear
 Only replace complete with pinned selector fork for 1st and 2nd gear
10 - Hollow shaft
 Disassembling and assembling. Refer to Drive pinion and hollow shaft, disassembling and assembling
2:25:52 AM Page 116

11 - Pinion shaft
 4 pieces
Assembly sequence
Fig. 152: Identifying Special Tools - Bearing Housing, Torsen Differential, End Cover, Selector
Mechanism, Assembly Sequence
Removing and installing bearing housing, Torsen differential, end cover, shift lever mechanism in
2:25:52 AM Page 117

transmission, input shaft, drive pinion and hollow shaft
 VW 402 Thrust plate

 VW 407 Thrust tool
 VW 415 A Tube
 VW 447 H Thrust plate

 VW 454 Thrust pad
2:25:52 AM Page 118

 VW 540 Engine and transmission support

 VW 681 Seal extractor
 30-23 Extension
 30-100 Thrust sleeve

 30-211 A Support bridge

 2064 Setting pin
 3116 Spring pin
2:25:52 AM Page 119

 3118 Thrust piece
 3121 Drift
 3275 Internal puller
Fig. 155: Pressure Device 3276

 Pressure device 3276
Fig. 156: Identifying Special Tools - Kukko 20/10 Puller Set

 1 - 2-Arm puller Kukko 20/10

 2 - Puller hooks V/170
 Container
 Depth gauge
Disassembling
2:25:52 AM Page 120

Fig. 157: Transmission In Assembly Fixture

 Clamp transmission in VW 540 holding fixture.

 Place container under the transmission.
 Drain gear oil.

 Screw out bolts -1- and detach leaf spring -2-.

 Remove clutch release lever -4- together with release bearing -3- and intermediate piece -5-.
 Unbolt guide sleeve.
2:25:52 AM Page 121

Fig. 159: Unbolt Bearing Housing And Pull Off

 Unscrew bearing housing -arrow- and pull off.
Fig. 160: Bearing Housing

Bearing housing is pushed away slightly from end cover by coil spring -A- when it is being pulled off.
 When detaching bearing housing, observe installation position of dished washer -C-.
 Installation position: Outside diameter (concave side) facing shims -B-
 Remove shims -B-, note thickness and re-determine if necessary. Refer to Fig. 213.
2:25:52 AM Page 122

Fig. 161: Identifying Torsen Differential

 Pull Torsen differential out of end cover.
Fig. 162: Identifying Oil Diverter At End Cover

 Pull oil collector sufficiently far out of end cover -arrow- until it moves freely.
Fig. 163: Removing Oil Diverter Out End Cover Hole

2:25:52 AM Page 123

 Swivel oil collector -arrow- down and guide it out through hole of end cover.
 Remove oil collector.
Fig. 164: Identifying Locking Bolts And Selector Shaft Cover & Fasteners
 Remove locking bolts -A- for selector shaft from transmission housing.
 Remove 3 bolts -B- for cover for selector shaft, remove cover.
Fig. 165: Lock Input Shaft By Engaging 2 Gears (E.G. Reverse And 2nd Gear) By Moving 2 Selector
Rails
 Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do this by moving 2 selector plates -
arrows-.
2:25:52 AM Page 124

Fig. 166: Remove Support Plate For Needle Bearing

 Slacken multi-point socket head bolt -arrow B- in input shaft through hole -arrow A- in end cover and
unscrew.
 Remove supporting plate.
 Remove supporting plate for needle bearing.
Fig. 167: Identifying Magnets -A - And End Cover Fasteners

 Remove 2 magnets -arrows A- and clean.

 Slacken 5 bolts -arrows B- for attaching end cover to manual transmission and remove.
2:25:52 AM Page 125

Fig. 168: Pull 2nd Inner Race For 4-Point Bearing (Roller Bearing Side) Off From Input Shaft
 Pull off 2nd inner race of four-point bearing (roller bearing side) for input shaft.
NOTE: Internal puller 3275 engages in a circular groove in the inner race when pulling
off -arrow-.
 Remove end cover together with end cover/bearing plate gasket.

 Pull dowel sleeves out of bearing plate.
Fig. 169: Pulling Off Selector Gear For 5th Gear With Spring Together With 1st Inner Race For 4-Point
Bearing (Ball Bearing Side) For Input Shaft
 Pull off 5th sliding gear and spring together with 1st inner race -A- of four-point bearing (ball bearing
side) for input shaft.
B - Two-arm puller, e.g. Kukko 20/10
 Remove 5th gear synchro-ring.

 Remove circlip for 5th gear wheel.
 Lock hollow shaft in position by engaging two gears. Refer to Fig. 165
2:25:52 AM Page 126

Fig. 170: Pull Off Drive Gear For 5th Gear

 Pull off 5th gear wheel.
NOTE: Only use hexagon bolt of spring sleeve 3116, length 50 mm
C - Two arm puller, e.g. Kukko 20/10 with 200 mm hooks
 Remove shim -B- for 5th gear wheel, note thickness and re-determine if necessary. Refer to Fig. 199.
 Remove spacer sleeve -A-.
Fig. 171: Pressing Out Spring Pin For Selector Fork For 5th and 6th Gear
 Press out spring pin -A- for selector fork for 5th and 6th gear.
NOTE:  Do not damage synchro-ring for 6th gear when pressing out spring pin.
 Do not drive out spring pin, otherwise selector rod bearing will be
damaged.
 Pull selector rod on follower together with selector fork for 5th and 6th gear and locking collar as far as
2:25:52 AM Page 127

possible away from bearing plate (until stop is felt).
Fig. 172: Alignment Marks On, Locking Collar For 5th and 6th Gear And Synchronizer Hub
 Mark relative positions -arrow 3- of locking collar for 5th and 6th gears -arrow 1- and synchro-hub -A-
(paired) -arrow 1-.
Fig. 173: Pulling Off Yoke Together With Selector Fork And Locking Collar From Selector Rod
 Pull follower together with selector fork and locking collar off selector rod.
2:25:52 AM Page 128

Fig. 174: Pull Off 6th Gear Selector Gear, 6th Gear Synchronizer Ring, 5th And 6th Gear Synchronizer
Hub And Needle Bearing Inner Race For 5th Gear Selector Gear
 Pull off 6th sliding gear, synchro-ring for 6th gear, synchro-hub for 5th and 6th gears and inner race for
5th sliding gear needle bearing.
A - Two-arm puller, e.g. Kukko 20/10 with 200 mm hooks
Fig. 175: Identifying Locking Bolts For Selector Rods

 Unscrew selector rod locking bolts.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
 Drive out dowel sleeves on bearing plate and remove bearing plate from transmission housing.
2:25:52 AM Page 129

 Secure drive pinion opposite hollow shaft e.g. with hose strap, to prevent it slipping out.
 Detach bearing plate with input shaft, drive pinion and hollow shaft and with shift lever mechanism in
transmission from transmission housing.
Fig. 176: Identifying Yoke, 5th and 6th Gear Selector Rod , and Reverse Gear Yoke
 Remove circlip from selector rod for 1st and 2nd gear and remove follower -A-.
 Pull out selector rod -B- for 5th and 6th gear.
 Remove follower -C- for reverse gear.
Fig. 177: Removing/Installing Inner Race For Roller Bearing

 Pull thrust washer -arrow A- for needle bearing for 6th gear off shaft.
 Remove circlip -arrow B- for cylinder roller bearing inner race with pliers.
 Take out inner race -arrow C- for cylinder roller bearing (not a press fit).
2:25:52 AM Page 130

Fig. 178: Removing/Installing Input Shaft With 3rd and 4th Gear Selector Rod And Selector Fork
 Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out at an angle from bearing
plate.
Fig. 179: Removing/Installing Reverse Gear Relay Lever

 Unscrew hexagon bolt -D-, remove spring clasp -B- and retaining plate -A-, pull out shaft -C- for reverse
idler gear.
 Take out spring, synchro-ring and reverse idler gear.
 Remove relay lever for reverse gear.
NOTE:  Drive pinion and hollow shaft can be removed complete if it is possible to
easily lever off 6th gear wheel.
 If, however, it is necessary to press off 6th gear wheel, the drive pinion
must be pulled out from hollow shaft.
 Remove temporary locking element preventing drive pinion from slipping out.
2:25:52 AM Page 131

Fig. 180: Identifying Pinion, Hollow Shaft , Taper Rollers, Waved Washer And Needle Bearing Cage
 Pull drive pinion out of hollow shaft -D- collect taper rollers -A- (23 off) when carrying out this step.
 Remove corrugated spring -B- and needle roller assembly -C-.
NOTE: Carefully protect mount from contamination, clean if necessary.
Fig. 181: Checking Pinion/Hollow Shaft Bearing

 Check drive pinion/hollow shaft bearing.
1 - Flange ring (conical contact surface facing taper rollers)
2 - Taper rollers (23 off) with large diameter facing drive pinion head
2:25:52 AM Page 132

3 - Supporting ring (conical contact surface facing taper rollers)
4 - Corrugated spring
5 - Circlip for taper roller bearings for drive pinion
Fig. 182: Pressing Off Drive Gear For 6th Gear

 Pressing off 6th gear wheel
NOTE: Because of the type of fit, it may be possible to press gear off easily.
 Remove hollow shaft or drive pinion and hollow shaft from bearing plate together with selector rod and
selector fork for 1st and 2nd gears.
Assembling
 Install hollow shaft with selector fork and selector rod for 1st and 2nd gear (without follower) into
bearing plate.
2:25:52 AM Page 133

Fig. 183: Press On To Stop So That There Is No Play

 Heat 6th gear to approx. 100 ° C and install.
 Installation position: Shoulder toward taper roller bearing
WARNING: Wear protective gloves!
 Press fully in until zero play.

 Insert taper roller bearing of drive pinion/hollow shaft with multi-purpose grease.
 Arrangement: Refer to Fig. 181
2:25:52 AM Page 134

A - Flange ring, taper roller (23 off) and supporting ring
B - Corrugated spring
C - Needle roller assembly
D - Hollow shaft
 Oil needle bearing well.

 Insert drive pinion into hollow shaft and secure with hose strap, to prevent it from slipping down.
Fig. 185: Install Synchronizer Ring

 Install relay lever -A- for reverse gear over relay lever bolt. paying attention to pin (for limiting
movement of relay lever relevant to synchro-ring).
 Insert reverse idler gear -B- and engage relay lever with groove on reverse idler gear.
 Insert synchro-ring -C-.
 Installation position: Position flat on synchro-ring circumference to face input shaft (not as yet installed) -
arrow 1-.
 Insert spring.
 Installation position: Hook single angled end into recess on synchro-ring -arrow 2-. Turn double angled
end anti-clockwise and insert into opening on bearing plate -arrow 3-.
2:25:53 AM Page 135


 Insert shaft for reverse idler gear -C-.

 Install retaining plate -A-.
 Installation position: Chamfers of holes for locking pins of synchro-ring face bearing plate
 Insert spring clasp -B- into locking pins of synchro-ring.

 Replace self-locking nut -D- and tighten to 25 Nm.
 Slide input shaft -A- with selector rod and selector fork for 3rd and 4th gear at an angle into bearing plate.
 Selector fork installation position: Rib toward follower. Refer to Input shaft, drive pinion, hollow shaft
and shift lever mechanism in transmission, removing and installing, Item 4-
2:25:53 AM Page 136


 Press inner race -arrow C- for cylinder roller bearing onto input shaft.
 Install circlip -arrow B- using pliers.
Fig. 189: Engage Free End Of Relay Lever Into Notch In Reverse Gear Yoke
 Engage recess in follower for reverse gear with the free end of relay lever -arrow A-.
 Slide selector rod for 5th and 6th through follower for reverse gear in direction of -arrow B-.
2:25:53 AM Page 137

 Slide follower -A- for 1st and 2nd gear onto selector rod and secure with circlips.
 Lubricate selector rods and all bearings of input shaft and drive pinion in transmission housing and
bearing plate with gear oil.
Fig. 191: Prying Input Shaft Seal Out Of Disassembled Transmission

 Lever used input shaft seal carefully out of transmission housing with VW 681.
 Coat sealing surfaces between bearing plate and transmission housing with sealing paste AMV 188 001
02.
 Insert complete bearing plate into transmission housing.
NOTE: When inserting the complete bearing plate, ensure that the selector rods align
with their mounting points.
 Drive in 2 dowel sleeves for bearing plate/transmission housing.

 Tighten bolts in diagonal sequence to 25 Nm.
2:25:53 AM Page 138

 Insert locking bolts for selector rods with sealing paste AMV 188 001 02 and tighten to 50 Nm.
D - Reverse gear
Fig. 193: Identifying Thrust Washer

 Install thrust washer -arrow A- for needle bearing for 6th gear.
 Installation position: Shoulder toward circlip -arrow B-, smooth contact surface to shaft end
 Lubricate needle bearing for 6th sliding gear with gear oil and install.
 Slide on 6th sliding gear with spring and synchro-ring.
 Installation position: The lugs of synchro-ring engage into recesses below in sliding gear.
2:25:53 AM Page 139

Fig. 194: Supporting Input Shaft With Bracket 30-211 A

 Support input shaft with support bridge 30-211 A.
Fig. 195: Installation Location Of Synchronizer Hub For 5th and 6th Gear
Installation position of 5th and 6th gear synchro-hubs:
 Side with projecting face -arrow 1- faces shaft end.

 The input shaft oil bore -arrow 2- and the synchro-hub oil groove -arrow 3- are aligned.
2:25:53 AM Page 140

Fig. 196: Driving On 5th and 6th Gear Synchronizer Hub

 Heat synchro-hub for 5th and 6th gears to approx. 100 ° C, install and drive on up to stop.
 Check 6th sliding gear for axial play.
 Permissible axial play: 0.15 to 0.35 mm
 Align markings -arrow 3- on paired synchro -hub -A- and locking collar for 5th and 6th gears -arrow 1-.
 Install locking collar -arrow 1- with selector fork -arrow 2- onto synchro-hub -A-, and at the same time
install follower for 5th and 6th gears -B- onto selector rod -C-.
NOTE:  Selector fork rib -arrow 2- must face toward shaft end.
 When sliding follower onto selector rod for 5th and 6th gear, note holes for
spring pin.
2:25:53 AM Page 141

Fig. 198: Pressing In Spring Pin

 Press in spring pin -A- flush.
NOTE:  Do not drive in spring pin, otherwise selector rod bearing will be damaged.
 Mount spring pin groove in direction of force as shown in illustration.
Fig. 199: Determine Shim For 5th Gear Drive Gear

 Re-determine shim for 5th gear wheel:
 Install spacer sleeve -A- (length 39.6 mm) onto hollow shaft.
 When installing circlip, press indirection of arrow until fully home.
 Measure size between sleeve and installed circlip using depth gauge -B-.
The following shims are available
Measured range (mm) Shim thickness (mm)

31.01 to 31.11 1.05
31.11 to 31.21 1.15
2:25:53 AM Page 142

31.21 to 31.31 1.25

31.31 to 31.41 1.35
Fig. 200: Set Selected Shim Onto Hollow Shaft

 Install selected size of shim -arrow- onto hollow shaft.
Fig. 201: Driving On 5th Gear

 Heat 5th gear to approx. 100 ° C, install and drive on up to stop.
 Installation position: Shoulder toward spacer sleeve
2:25:53 AM Page 143

Fig. 202: Redetermine Shim For 5th Gear Drive Gear

 Re-determine circlip for 5th gear wheel:
 Determine and attach the thickest 2nd circlip that will still just fit.
Available circlips

2.32 2.40 2.48
2.34 2.42 2.50
2.36 2.44
2.38 2.46
 Install circlip.
Fig. 203: Drive On Inner Race Of Needle Bearing For 5th Gear Selector Gear
 Drive on inner race for 5th sliding gear free of axial play.
 Oil needle bearing with gear oil and install.
2:25:53 AM Page 144

 Place synchro-ring for 5th gear in locking collar.

 Slide on 5th sliding gear with spring.
Fig. 204: Installing 1st Inner Race For Four-Point Bearing For Input Shaft Onto Input Shaft And Drive
On Up To Stop
 Heat 1st inner race for four-point bearing (ball bearing side) for input shaft to approx. 100 ° C, install
onto input shaft and drive on up to stop.
 Insert dowel sleeves into bearing plate.

 Install new gasket for end cover.

2:25:53 AM Page 145

 Install end cover and insert securing bolts -arrows B-.
NOTE: Do not tighten bolts at this stage.
 Clean 2 magnets -arrow A- and insert.

 Insert supporting plate. Refer to Fig. 166 and tighten by hand.
 Installation position: Lugs face magnets.
 Tighten bolts for end cover in diagonal sequence.
Fig. 206: Installing 2nd Inner Race Of The 4-Point Bearing (Roller Bearing Side)
 Lubricate 2nd inner race for four-point bearing (roller bearing side) and insert onto input shaft with track
for ball facing four-point bearing of input shaft and drive over hole in end cover.
 Remove support bridge 30-211 A.
Rails
2:25:53 AM Page 146

arrows-.
 Tighten multi-point socket head bolt to 150 Nm.
 Check neutral position of followers.
 Gear gates must align.
Fig. 208: Identifying Oil Diverter

 Use screwdriver to unclip cover for oil collector -3- from oil collector -1- at long end and remove magnet
-2-.
4 - O-ring
5 - Positioning segment
 Clean oil collector.

 Assemble oil collector.

2:25:53 AM Page 147

 Guide oil collector, with supporting arm ahead, from interior of end cover through hole of end cover
sufficiently far -arrow-, so that the new O-ring can be installed onto oil collector from outside.
 Lightly oil new O-ring and insert.

 Insert oil pipe of oil collector in input shaft.
Fig. 210: Turning Oil Diverter Until Positioning Segment Lies In The Recess Of End Cover
 Rotate oil collector until positioning segment is positioned in milled recess of end cover -arrow-.
 Press in oil collector onto stop.
 Slide assembly sleeve -A-, Part No. 01E 311 120, onto selector shaft -B-.
 Installation position: Flat of selector shaft faces downward
2:25:53 AM Page 148

 Insert locking bolts -A- for selector rod with sealing paste AMV 188 001 02 and tighten to 50 Nm.
 Lightly oil new O-ring for selector shaft cover and install.
 Install cover for selector shaft.

 Install bolts -B- (x 3) with sealing paste AMV 188 001 02 and tighten to 25 Nm.
 Push Torsen differential onto splines of hollow shaft.
Fig. 213: Determine Required Shim(s), Press Torsen Differential In Direction Of Arrow
 Press Torsen differential in direction of arrow; measure distance between top edge of bolted end cover
and front edge of outer race of ball bearing for Torsen differential.
 Determine shim(s) required according to table.
The following adjustment shims are available:
Measured range mm Qty. Shim thickness (mm)

7.05 to 7.30 1 1.65
2:25:53 AM Page 149

1 1.45
1 1.20
7.30 to 7.55 1 1.65
1 1.45
1 0.95
7.55 to 7.80 1 1.65
1 1.45
1 0.70
7.80 to 8.05 1 1.65
1 1.45
1 0.45
8.05 to 8.25 2 1.65
8.25 to 8.50 1 1.65
1 1.45
8.50 to 8.75 1 1.65
1 1.20

8.75 to 9.00 1 1.65
1 0.95
9.00 to 9.25 1 1.65
1 0.70
9.25 to 9.50 1 1.65
1 0.45

 Insert dished washer -C- into bearing housing.
 Install shims determined from table -B-.
2:25:53 AM Page 150

 Install spring -A- onto end of flanged shaft.

 Lightly oil new O-ring for bearing housing and insert.
 Oil small needle bearing in drive pinion.
 Insert complete bearing housing and pre-tighten evenly.

 Tighten bolts in diagonal sequence.
 Pack space between sealing lip and dust lip of new seal for input shaft with sealing grease.

 Tap in input shaft seal.
 Insertion depth: 3.5 mm
NOTE: Insertion depth for repairs is 4.5 mm when a used input shaft is employed.

 Install release bearing, clutch release lever and guide sleeve. Refer to Clutch release mechanism,
servicing.
 Select all gears.
 Install connecting rod.
 Top off manual transmission with gear oil and check oil level. Refer to Transmission oil level, checking.
BEARING HOUSING, DISASSEMBLING AND ASSEMBLING
Bearing housing, disassembling and assembling
2:25:53 AM Page 151

Fig. 216: Identifying Special Tools - Bearing Housing, Disassembling And Assembling
 VW 295a Adapter

 VW 415 A Tube
2:25:53 AM Page 152

 VW 416 B Tube
 VW 457 Mounting rail

 2005 Drift
2:25:53 AM Page 153

Fig. 218: Thrust Pad 2007

 Thrust pad 2007

 Adjustment shim Part No. 016 311 391 B
2:25:53 AM Page 154

Fig. 219: Bearing housing, Overview

1 - Flanged shaft
 Pressing out. See Pressing out flanged shaft

 Pressing in. See Pressing cylinder roller bearing for input shaft into end cover
 Pressing off. See Pressing off vibration damper

 Pressing on. See Pressing on vibration damper
3 - Seal
 Pulling out. See Removing seal
2:25:53 AM Page 155

 Preparing for installation. See Preparing seal for installing

 Tapping in. See Inserting seal
4 - Bearing housing
5 - O-ring
 Replace
 Coat lightly with gear oil when installing
6 - Ball bearing
 For flanged shaft

 Pressing out. See Pressing out ball bearing for flanged shaft
 Pressing in. See Pressing in ball bearing for flanged shaft
7 - Circlip
Pressing out flanged shaft
Fig. 220: Pressing Out Flange Shaft

 Remove circlip before pressing out flanged shaft.
Pressing in flanged shaft
2:25:53 AM Page 156


 Press on vibration damper before pressing in flanged shaft. See Pressing on vibration damper.
Pressing off vibration damper
Fig. 222: Pressing Off Vibration Damper

Pressing on vibration damper
2:25:53 AM Page 157

Fig. 223: Pressing On Vibration Damper

NOTE: Observe position of holes.
Removing seal
Fig. 224: Pulling Out Seal

Preparing seal for installing
2:25:53 AM Page 158


A - Washer
Part no. 016 311 391 B (1.7 mm thick)
B - Seal
 Pack space between sealing and dust lips half full with sealing grease.
 Install washer and seal onto tool as illustrated.
 Installation position: Open side of seal faces toward bearing housing
Inserting seal
Fig. 226: Driving In Flange Shaft Seal

 Remove washer.
Pressing out ball bearing for flanged shaft
2:25:53 AM Page 159

Fig. 227: Pressing On Grooved Ball Bearing For Flange Shaft

Pressing in ball bearing for flanged shaft
Fig. 228: Pressing In Grooved Ball Bearing For Flange Shaft

MOUNT FOR TORSEN DIFFERENTIAL, SERVICING
Mount for Torsen differential, servicing
2:25:53 AM Page 160

Fig. 229: Identifying Special Tools - Mount For Torsen Differential, Servicing (1 Of 2)


2:25:53 AM Page 161

 3116 Spring pin

 4 - Kukko 22/1 Counter support
NOTE: The shims for Torsen differential have to be re-determined after replacing
following components. Refer to Fig. 213:
2:25:53 AM Page 162

Fig. 231: Torsen Differential Bearing, Overview

 End cover
 Inner race for needle bearing
 Torsen differential
 Torsen differential ball bearing
1 - Ball bearing

 Pressing off. See Pressing off ball bearing from Torsen differential
2:25:53 AM Page 163

 Servicing only at manufacturer

3 - Inner race
 For Torsen differential needle bearing

 Pulling off. See Pulling off inner race for Torsen differential needle bearing
 Pressing on. See Pressing on inner race for Torsen differential needle bearing
4 - Needle bearing
2:25:53 AM Page 164

 For drive pinion/Torsen differential

 Pulling out. See Removing needle bearing for drive pinion/Torsen differential
 Pressing in. See Inserting needle bearing for drive pinion/Torsen differential
Pressing off ball bearing from Torsen differential
A - Separating device 22 to 115 mm, e.g. Kukko 17/2

Installation position: Thrust pad 3118 with shoulder facing press tool VW 412
Pulling off inner race for Torsen differential needle bearing
2:25:53 AM Page 165

Fig. 235: Pulling Off Inner Race Of Torsen Differential Needle Bearing
A - Inner race
B - Separating tool 22 to 115 mm, e.g. Kukko 17/2
Pressing on inner race for Torsen differential needle bearing
Fig. 236: Pressing On Inner Race Of Torsen Differential Needle Bearing

Removing needle bearing for drive pinion/Torsen differential
2:25:53 AM Page 166

Fig. 237: Pulling Out Needle Bearing For Pinion/Torsen Differential

B - Counter support, e.g. Kukko 22/1
Inserting needle bearing for drive pinion/Torsen differential
Fig. 238: Pressing In Needle Bearing For Pinion/Torsen Differential

 Pressing in needle bearing flush with inner edge.
END COVER, SERVICING
End cover, servicing
2:25:53 AM Page 167

Fig. 239: Identifying Special Tools - End Cover, Servicing


 VW 415 A Tube

 2006 A Supporting ring
2:25:53 AM Page 168

 1 - Kukko 21/6 Internal puller and Kukko 21/7 Internal puller

2:25:53 AM Page 169

Fig. 241: End Cover, Overview

1 - End cover
 If replaced, the thickness of the circlip - End cover, servicing must be re-determined
 Re-determine shims for Torsen differential. Refer to Fig. 213
3 - Cylinder roller bearing for input shaft
 Pressing out. See Pressing cylinder roller bearing for input shaft out of end cover
 Pressing in flush. See Pressing cylinder roller bearing for input shaft into end cover
4 - Four-point bearing for input shaft
2:25:54 AM Page 170

 Removing. See Removing ball bearing for input shaft out of end cover
 Installing. See Installing ball bearing for input shaft in end cover
5 - Circlip
 Re-determining thickness. Refer to Available circlips

6 - Baffle plate
 Replace
 Installing and peening in position when replacing four-point bearing for input shaft. See Peening baffle
plate in position when replacing ball bearing for input shaft
 Installing and peening in position when replacing end cover. See Peening baffle plate in position when
replacing end cover
7 - Needle bearing

 Pulling out. See Removing needle bearing for Torsen differential from end cover
 Tapping in. See Insert needle bearing of Torsen differential flush in end cover.
Pressing cylinder roller bearing for input shaft out of end cover
Fig. 242: Pressing Roller Bearing For Input Shaft Out Of End Cover
A - Internal extractor 37 to 46 mm, e.g. Kukko 21/6
B - Counter support spindle, e.g. Kukko 22/2
2:25:54 AM Page 171

Pressing cylinder roller bearing for input shaft into end cover
Fig. 243: Pressing Roller Bearing For Input Shaft Into End Cover
Shoulder of pipe section VW 415 A faces toward press tool VW 412.
Removing ball bearing for input shaft out of end cover
Fig. 244: Set Screwdriver In Place As Shown, Drive It Into Baffle Ring And Pry It Out
 Position screwdriver as illustrated, drive into baffle plate -arrow- and lever out.
 Remove circlip.
 Take out bearing, remove peening indentations if necessary.
Installing ball bearing for input shaft in end cover
2:25:54 AM Page 172

Fig. 245: Installation Position Of Circlip

Installation position of circlip:
 Ends of circlip -arrows- face toward roller sleeve for drive pinion.
NOTE: The thickness of the circlip must be re-determined if the bearing or the end
cover are replaced.
 Determining thickness of circlip for four-point bearing for input shaft:
 Press outer race of four-point bearing onto stop.

 Determine the thickest circlip that will just fit and install it.
 Axial play: no more than 0.08 mm
Available circlips
2.55 2.65
2.60 2.70
Peening baffle plate in position when replacing ball bearing for input shaft
2:25:54 AM Page 173

Fig. 246: Peening Baffle Ring When Replacing 4-Point Bearing For Input Shaft
 Use a blunt punch with a ball-shaped end (ball-diameter 5 mm) to peen in position.
 Insert baffle plate.
 First peen at points marked with -arrows 1-.
 Then peen at points marked with -arrows 2- at distance -a- from first position.
 Distance a = 5 mm
 Observe position and diameter of peening positions:
 Distance b = 2 mm
 Dimension c = 3 mm
Peening baffle plate in position when replacing end cover
2:25:54 AM Page 174

Fig. 247: Peening Baffle Ring When Replacing End Cover

 Use a blunt punch with a ball shaped end (ball-diameter 5 mm) to peen in position.
 Peen in first peening point -arrow- at distance -d- from the center line of the two shafts.
 Dimension d = 10 mm
 Peen in second and third peening points in same manner at distance -a-.
Removing needle bearing for Torsen differential from end cover
2:25:54 AM Page 175

Fig. 248: Pulling Torsen Differential Needle Bearing Out Of End Cover
B - Spindle from counter support, e.g. Kukko 22/2
Insert needle bearing of Torsen differential flush in end cover.
Fig. 249: Driving Torsen Differential Needle Bearing Flush Into End Cover
 Install pressure plate VW 412 onto bearing with shoulder facing up.
BEARING PLATE, SERVICING
Bearing plate, servicing
2:25:54 AM Page 176

Fig. 250: Identifying Special Tools - Gear Carrier, Servicing


 10-15 Guide pins
 30-504 Press tool

 Depth gauge
2:25:54 AM Page 177

Fig. 251: Gear Carrier, Overview

1 - Bearing plate
 Re-determine shim S4 when replacing
2 - Outer race/small taper roller bearing for drive pinion
 Driving out. Refer to Driving out outer race for small taper roller bearing
 Pressing in. Refer to Pressing in outer race/small taper roller bearing
3 - Shim S4
 Adjustment overview. Refer to Adjustment overview
2:25:54 AM Page 178

 Re-determining thickness. Refer to Re-determining shim S4
 Pressing out. See Pressing cylinder roller bearing for input shaft out of bearing plate
 Pressing in. See Pressing cylinder roller bearing for input shaft into bearing plate
 Measuring insertion depth. See Measuring insertion depth of cylinder roller bearing for input shaft

5 - Ball sleeves
 4 pieces
 Removing and driving in. See Driving out and driving in ball sleeves for selector rods
2:25:54 AM Page 179

For follower for reverse gear:
 Pulling out. See Pulling ball sleeve out of follower for reverse gear
 Tapping in. See Driving ball sleeve flush into follower for reverse gear
6 - Bolt, 35 Nm
 For relay lever
7 - Dowel pin (7 x 28)
 Drive in and drive out with drift
 With locking pins

 Installation position: Position flat on synchro-ring circumference to face input shaft. Refer to Fig. 185
2:25:54 AM Page 180


10 - Spring
 Installation position: Hook single angled end into recess on synchro-ring. Turn double angled end anti-
clockwise and insert into opening on bearing plate
11 - Reverse idler gear axle
12 - Retaining plate
 Installation position: Chamfers of holes for locking pins of synchro-ring face bearing plate. Refer to Fig.
186
13 - Spring clasp
2:25:54 AM Page 181

14 - Bolt, 25 Nm
 Self-locking
 Always replace

15 - Relay lever for reverse gear
 Pulling out ball sleeve. See Pulling ball sleeve out of follower for reverse gear
 Driving in ball sleeve. See Driving ball sleeve flush into follower for reverse gear
2:25:54 AM Page 182

 Replace only together with follower. Refer to 5th and 6th gear, removing and installing, Item 6
Driving out and driving in ball sleeves for selector rods
Fig. 255: Driving Selector Rod Ball Sleeves Out And In

Install ball sleeve with the inscribed side (thicker metal) facing the drift.
 Insertion depth a = 2.5 mm

 Press synchro-ring onto reverse idler gear cone and measure gap "a" with feeler gauge.
 Dimension, new: 0.75 to 2.3 mm

 Wear limit: 0.2 mm
Pulling ball sleeve out of follower for reverse gear
2:25:54 AM Page 183

Fig. 257: Pulling Reverse Gear Ball Sleeve Out Of Yoke

A - Counter support, e.g. Kukko 22/1
B - Internal extractor 14.5 to 18.5 mm, e.g. Kukko 21/2
Driving ball sleeve flush into follower for reverse gear
Fig. 258: Driving Ball Sleeve Flush Into Reverse Gear Yoke
2:25:54 AM Page 184

Pressing cylinder roller bearing for input shaft out of bearing plate
Fig. 259: Pressing Roller Bearing For Input Shaft Out Of/Into Gear Carrier
Pressing cylinder roller bearing for input shaft into bearing plate
 Measuring insertion depth. See Measuring insertion depth of cylinder roller bearing for input shaft
Measuring insertion depth of cylinder roller bearing for input shaft
2:25:54 AM Page 185

Fig. 261: Measuring Press-In Depth Of Input Shaft Roller Bearing

Dimension a = 7 mm
Re-determining shim S4
Fig. 262: VW 385/32 End Measuring Plate

 VW 385/32 End measuring plate
2:25:54 AM Page 186

Fig. 263: 3116 Spring Pin

 3116 Spring pin

 Digital depth gauge accurate to within at least 5/100 mm.
Determining New Shim S 4, Overview
2:25:54 AM Page 187

Fig. 264: Determining New Shim S 4, Overview

This procedure must be carried out when replacing the following components:
 Bearing plate. Refer to Determining thickness of shim when replacing bearing plate
 Hollow shaft. Refer to Determining thickness of shim when replacing hollow shaft
The procedure restores the required preload of the taper roller bearings for the drive pinion and hollow shaft.
1 - Shim S4
2 - Bearing plate
2:25:54 AM Page 188

4 - Hollow shaft
5 - Taper roller bearing of drive pinion/hollow shaft
6 - Pinion shaft

a - Bearing plate housing depth
b - Dimension from drive pinion head to shoulder of taper roller bearing on hollow shaft
 Taper roller bearing (drive pinion/hollow shaft) pre-tensioned to 10 Nm
S4 - Thickness of shim S4
2:25:54 AM Page 189

NOTE: When replacing the drive pinion (final drive set), observe adjustment overview.
Refer to Adjustment overview.
Determining thickness of shim when replacing bearing plate
Fig. 266: Measuring Difference In Depths Between Old And New Gear Carriers
 Measure difference of depth "a" on old and new bearing plates.
Example:
Depth "a" of old bearing plate 124.40 mm

Depth "a" of new bearing plate 124.65 mm
Difference = 0.25 mm
 If new bearing plate is deeper, install a thicker S4 shim.

 If old bearing plate was deeper, install a thinner S4 shim.
Example:
Previous shim S4 0.95 mm

Difference +0.25 mm
New shim S4 = 1.20 mm
Available shims. Refer to table. Refer to Available shims for S4.
Determining thickness of shim when replacing hollow shaft
 Use a caliper gauge accurate to within at least 5/100 mm.
2:25:54 AM Page 190

Fig. 267: Tighten Clamping Sleeve To Exactly 10 Nm

 Tighten spring pin to exactly 10 Nm.
A - Vice clamps
Fig. 268: Setting End Gauge VW 385/32 Onto Pinion Face

 Place end measuring plate VW 385/32 onto drive pinion head and measure dimension "d".
 Top measuring point is shoulder for inner race of small taper roller bearing.
 Example: 248.50 mm
 Install new hollow shaft and once again measure dimension "d".
2:25:54 AM Page 191


 Determine the difference:
Dimension "d" of old hollow shaft 248.50 mm

Dimension "d" of new hollow shaft 248.70 mm
 Install appropriately thinner shim S4 if dimension "d" of new hollow shaft is larger.
 Install appropriately thicker shim S4 if dimension "d" of new hollow shaft is smaller.
Available shims for S4
Shim thickness (mm)

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Different tolerances make it possible to obtain the exact shim thickness required, if necessary, install 2 shims.
2:25:54 AM Page 192

Fig. 270: Identifying Special Tools - Transmission Housing, Servicing


 VW 423 Tube

2:25:54 AM Page 193



 30-505 Fitting mandrel
 40-503 Inserting drift
 2062 Fitting drift

 VAG 1331 Torque wrench (5 to 50 Nm)
 Depth gauge
 Assembly sleeve Part No. 01E 311 120
1) Adjustments are required if these components are replaced. Refer to Adjustment overview: Refer to
2:25:54 AM Page 194


1 - Seal for flanged shaft
 Pulling out. See Pulling out seal for flanged shaft

 Tapping in. See Driving in seal for flanged shaft
 Pack space between sealing lips with sealing grease
 Replacing with transmission installed. Refer to Removing input shaft seal when transmission is not
disassembled
2 - Cover1)
 For final drive
3 - O-ring
2:25:54 AM Page 195

 For cover for final drive

 Always replace
4 - Shim S1
 Note thickness

5 - Taper roller bearing outer race, large1)
 Removing and installing. Refer to Driving outer race for large taper roller bearing out of coverand
2:25:54 AM Page 196

Driving outer race for large taper roller bearing into cover
6 - Taper roller bearing outer race, small1)
 Removing and installing. Refer to Driving outer race for small taper roller bearing out of
transmission housing and Pressing outer race for small taper roller bearing into transmission
housing
7 - Shim S2
 Note thickness
8 - Seal
 For input shaft

 Levering out. See Levering out input shaft seal when transmission is disassembled
 Tapping in. See Drive in input shaft seal flush
 Always replace when removing input shaft
 Replacing when transmission is not disassembled. See Removing input shaft seal when transmission is
not disassembled and Drive in input shaft seal flush
10 - Ball sleeve for selector shaft
 Pulling out. See Pulling out ball sleeve

 Tapping in. See Driving in ball sleeve
11 - Ball sleeves for selector rods
 Pulling out as -Item 10 Transmission housing, servicing. See Pulling out ball sleeve
 Driving in as -Item 10 Transmission housing, servicing. See Driving in ball sleeve
12 - Circlip
 Installation position: Eyes facing up
13 - Switch for reversing light, 20 Nm
 Removing and installing. See Removing and installing reversing light switch
14 - O-ring
2:25:54 AM Page 197


 Always replace


16 - Ball stud, 20 Nm
 For connecting rod
2:25:54 AM Page 198

 For drive pinion

 Pulling out. Refer to Pulling out large taper roller bearing outer race
 Pressing in. Refer to Heating transmission housing in order to install outer race for taper roller
bearing
18 - Circlip
 Removing. See Removing circlip
19 - Shim S3
 Note thickness
2:25:54 AM Page 199


20 - Needle bearing for input shaft
 Pulling out. See Pulling needle bearing out of transmission housing

 Tapping in. See Driving needle bearing into transmission housing
 Measuring insertion depth. See Insertion depth of needle bearing
21 - Locking bolt for selector shaft, 50 Nm

 Insert in transmission housing with sealing paste AMV 188 001 02
22 - Trunnion bolt, 40 Nm
 For push rod
23 - Breather
 Insertion depth of sleeve. See Insertion depth of breather sleeve

 Clip cap on
2:25:54 AM Page 200


24 - Selector shaft seal
 Can be replaced when transmission is removed but not disassembled

 Always replace
 Pulling out. See Pulling out selector shaft seal
 Tapping in. See Driving in selector shaft seal
 Always use assembly sleeve for installing. See Installing seal and selector shaft with assembly sleeve
26 - Solenoid
2:25:54 AM Page 201

 Clean
 Drive in (for example, with press tool VW 408 A) when replacing transmission
27 - Speedometer vehicle speed sensor -G22-
 Replacing. Refer to Speedometer vehicle speed sensor -G22-, removing and installing
28 - O-ring
 Always replace
Pulling out seal for flanged shaft
Fig. 277: Removing Drive Flange Seal Using Extractor Lever VW 681
NOTE:  Figure shows removing seal on right-hand side of transmission.

 The procedure is identical for left and right-hand seals.
Driving in seal for flanged shaft
2:25:54 AM Page 202


NOTE:  Figure shows installing seal on right-hand side of transmission.

 Insertion depth for repairs is 6.5 mm when a used flanged shaft is
employed.
Levering out input shaft seal when transmission is disassembled

Removing input shaft seal when transmission is not disassembled

2:25:55 AM Page 203

Drive in input shaft seal flush

 Pack new seal for input shaft between sealing lip and dust lip half full with sealing grease.
Pulling out ball sleeve
Fig. 282: Pulling Out Ball Sleeve

 Remove circlip.
A - Internal extractor 14.5 to 18.5 mm, e.g. Kukko 21/2
2:25:55 AM Page 204

Driving in ball sleeve
Fig. 283: Driving In Ball Sleeve

 Install ball sleeve with the inscribed side (thicker metal) facing the drift.
 Drive in onto stop.
Pulling out selector shaft seal
Fig. 284: Removing Selector Shaft Seal

NOTE: With transmission removed but not disassembled, carefully lever out seal
without damaging the shaft with a screwdriver.
2:25:55 AM Page 205


 Selector shaft installed or removed
 Pull assembly sleeve onto selector shaft. See Installing seal and selector shaft with assembly sleeve
 Drive seal into housing onto stop.
Installing seal and selector shaft with assembly sleeve
 To avoid damaging seal -C- always use assembly sleeve -A-, Part No. 01E 311 120, to install seal or
selector shaft.
Insertion depth of breather sleeve
2:25:55 AM Page 206

Fig. 287: Press-In Depth Of Breather Sleeve

Removing and installing reversing light switch
Fig. 288: Removing And Installing Back-Up Light Switch

 Tighten reversing light switch -A- to 20 Nm when installing.
Pulling needle bearing out of transmission housing
2:25:55 AM Page 207

Fig. 289: Pulling Needle Bearing Out Of Transmission Housing

Driving needle bearing into transmission housing
Fig. 290: Driving Needle Bearing Into Transmission Housing

 Installation position: Inscription on bearing faces drift

 Insertion depth. See Insertion depth of needle bearing
Insertion depth of needle bearing
2:25:55 AM Page 208

Fig. 291: Drive-In Depth Of Needle Bearing

Removing circlip
Fig. 292: Removing Circlip

 Lift circlip out of the groove by turning one end of circlip with a screwdriver -A-.
 Secure this end with a screwdriver -B-.
 Lever circlip out further by repositioning screwdriver -A-.
Selector shaft, disassembling and assembling
2:25:55 AM Page 209

Fig. 293: Selector Shaft, Completely Disassembling And Assembling

1 - Selector cylinder
2 - Spring pin
 Removing and driving in flush. See Removing and installing spring pin flush
 Installation position of spring sleeve: Slot longitudinal to line of force
3 - Selector shaft
 Tapping out. See Driving out selector shaft

 Tapping in. See Driving in selector shaft
 Installation position: Flat (arrow) and selector finger -Item 4 face in same direction
2:25:55 AM Page 210

4 - Selector finger
 Observe installation position to -Item 3
5 - Toggle for reversing light switch
Removing and installing spring pin flush
Fig. 294: Driving Out Spring Pin/Roll Pin And Driving In Flush
A - Drift
B - Vice clamps
Driving out selector shaft
Fig. 295: Driving Out Selector Shaft

A - Drift
B - Vice clamps
2:25:55 AM Page 211

Driving in selector shaft
Fig. 296: Driving In Selector Shaft

A - Wooden packing
NOTE:  Bring selector shaft/selector cylinder bores into alignment.

 Flat on selector shaft and selector finger point in same direction.

2:25:55 AM Page 212


 VW 519 Tube
 Feeler gauge
NOTE:
2:25:55 AM Page 213


 When installing new gears or the input shaft consult technical data. Refer
to Code letters, mechanical unit assignment, transmission ratios,
capacities.
2 - Needle bearing
 For input shaft

 Pulling out. Refer to Pulling needle bearing out of transmission housing
 Driving in. Refer to Driving needle bearing into transmission housing
2:25:55 AM Page 214

3 - Circlip
 For needle bearing
4 - Circlip
 For input shaft
5 - Thrust washer

6 - Needle bearing
 For 5th gear
2:25:55 AM Page 215

 Mark before removing

 Do not interchange with needle bearing for 3rd gear
 Oil with gear oil before installing
 Before installing, insert spring. See Inserting spring in sliding gear
9 - Locking collar
 Paired with synchro-hub

 Mark before removing. Refer to Fig. 172
2:25:55 AM Page 216


10 - Circlip
 When replacing synchro-hub, re-determine thickness. See Determining thickness of circlip

 Installation position: Ends align with groove of synchro-hub
11 - Synchro-hub for 3rd and 4th gear
 Pressing off. See Pressing off synchro hub for 3rd and 4th gear
 Installation position. See Installation position of synchro-hub
 Pressing on. See Pressing on synchro hub for 3rd and 4th gear
2:25:55 AM Page 217

 Coated with molybdenum

13 - 3rd sliding gear

 After pressing on -Item 11 check axial play using feeler gauge (0.15 to 0.35 mm)

14 - Needle bearing
 For 3rd gear

2:25:55 AM Page 218

 Do not interchange with needle bearing for 4th gear

15 - Input shaft
16 - Spring pin
 Replace
 Drive in when replacing input shaft. See Driving spring sleeve into input shaft
17 - Cylindrical roller bearing
 For input shaft

 Pressing out. Refer to Pressing cylinder roller bearing for input shaft out of bearing plate
 Pressing in. Refer to Pressing cylinder roller bearing for input shaft into bearing plate
18 - Bearing plate
2:25:55 AM Page 219


19 - Inner race

 Remove and install by hand
20 - Circlip
21 - Thrust washer

 Installation position: Shoulder toward circlip, smooth face contact surface toward needle bearing. Refer to
Fig. 193
2:25:55 AM Page 220

22 - Needle bearing
 For 6th gear


 After installing, check axial play. Refer to Fig. 197

2:25:55 AM Page 221

25 - Synchro-hub for 5th and 6th gear

 Installation position: Projecting hub toward 5th sliding gear
26 - Locking collar


 After installing, check axial play. Refer to Assembling
2:25:55 AM Page 222


29 - Inner race for needle bearing
 For 5th sliding gear

30 - Needle bearing
 For 5th gear

2:25:55 AM Page 223

 Ball bearing side

32 - End cover
33 - 2nd inner race for ball bearing


Inserting spring in sliding gear
Fig. 305: Inserting Spring Into Selector Gear

The bent end of the spring (arrow) must be hooked in the hole in the sliding gear.
2:25:55 AM Page 224


 Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -
C-.
 Add the measured values and divide by 3.
 The calculated value must not be less than 0.5 mm.
Determining thickness of circlip
Fig. 307: Determining Thickness Of Circlip

 Synchro-hub pressed onto stop
NOTE: The opening of circlip must align with groove in synchro-hub.
2:25:55 AM Page 225

1.90 1.96 2.02

1.93 1.99 2.05
Pressing off synchro hub for 3rd and 4th gear
Fig. 308: Pressing Off Synchronizer Hub For 3rd And 4th Gear
Installation position of synchro-hub
Fig. 309: Installed Position Of Synchronizer Hub

Oil groove in synchro-hub -arrow 1- must align with oil drilling -arrow 2- in input shaft
Pressing on synchro hub for 3rd and 4th gear
2:25:55 AM Page 226

Fig. 310: Pressing On Synchronizer Hub For 3rd And 4th Gear
 Heat synchro-hub to approx. 100 ° C, position and press home.
 Determine circlip and install. See Determining thickness of circlip.
Driving spring sleeve into input shaft
Fig. 311: Driving Roll Pin Into Input Shaft

 Guide a 9 mm diameter drift -A- into oil drilling and drive spring sleeve -B- in until it touches drift.
2:25:55 AM Page 227

DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING
Drive pinion and hollow shaft, disassembling and assembling
Fig. 312: Identifying Special Tools - Pinion And Hollow Shaft, Disassembling And Assembling
 VW 295 Drift
2:25:55 AM Page 228

 VW 415 A Tube
 VW 457 Mount rails
 2003/3 Inserter ring

 3062 Thrust disk
2:25:55 AM Page 229

 3118 Tube
 3138 Drift
 VAG 1416 Hot-air blower
 1 - Internal puller 21/1
NOTE:
2:25:55 AM Page 230

Fig. 315: Pinion and Hollow Shaft, Overview

 When installing new gears or the final drive set consult technical data.
Refer to Code letters, mechanical unit assignment, transmission ratios,
capacities.
1) Adjustments are required if these components are replaced. Refer to Adjustment overview.
2 - Shim S3
2:25:55 AM Page 231

 Pulling out. See Pulling out large taper roller bearing outer race
 Pressing in. See Inserting outer race for large taper roller bearing in transmission housing and
pressing home
4 - Drive pinion1)
 Is mated with ring gear, replace together as a set

 Adjusting drive pinion and ring gear. Refer to General notes

5 - Needle bearing
2:25:55 AM Page 232

 For flanged shaft/drive pinion

 Pulling out. See Removing needle bearing for flanged shaft/drive pinion
 Tapping in. See Inserting needle bearing for flanged shaft/drive pinion flush
6 - Taper roller bearing inner race, large1)
 Pressing off. See Pressing off large taper roller bearing inner race
 Pressing on. See Pressing on inner race for taper roller bearing
 Low friction bearing; do not oil when measuring frictional torque
7 - Circlip
 Redefine thickness. See Determining thickness of circlip
8 - Flange ring
 Installation position. Refer to Fig. 181
9 - Taper rollers
 23 pieces
10 - Supporting ring
2:25:55 AM Page 233


12 - Needle bearing
 For drive pinion/hollow shaft

13 - Hollow shaft 1)
 With gear wheels for 3rd and 4th gear
14 - Needle bearing
 For 2nd sliding gear

2:25:55 AM Page 234

15 - 2nd sliding gear
 Pressing off. See Pressing off 2nd gear sliding wheel with synchro-hub for 1st and 2nd gear
 Before installing, insert spring and slide needle bearing onto hollow shaft
 After installation, check axial play using feeler gauge (0.15 to 0.35 mm)

 Checking for wear. Refer to Checking synchro-ring for wear

17 - Synchro-hub for 1st and 2nd gear
2:25:55 AM Page 235

 Pressing on. See Installing 2nd sliding gear, pressing on synchro-hub for 1st and 2nd gear
 Installation position: Flush hub toward 2nd sliding gear
18 - Circlip
 Removing and installing. See Removing and installing circlip of synchro-hub and washer of 1st
sliding gear
19 - Washer
 For needle bearing for 1st sliding gear

sliding gear
20 - Locking collar, 1st and 2nd gear
 Installation position: Splines for reverse gear facing synchro-ring for 2nd gear
2:25:56 AM Page 236


22 - Needle bearing
 For 1st sliding gear

23 - 1st sliding gear
 Before installing, insert spring. Refer to Inserting spring in sliding gear

 After pressing on -Item 24, check axial play using feeler gauge (0.15 to 0.35 mm)
24 - Taper roller bearing inner race, small1)
 Pressing off. See Pressing off inner race of small taper roller bearing together with 1st sliding gear
2:25:56 AM Page 237

 Pressing on. See Pressing on inner race for small taper roller bearing
 Tapping out. See Driving out outer race for small taper roller bearing
 Pressing in. See Pressing in outer race/small taper roller bearing
26 - Shim S4

2:25:56 AM Page 238

27 - Bearing plate 1)
28 - 6th gear wheel

 Installation position: Shoulder faces toward inner race of small taper roller bearing
29 - Spacer sleeve
30 - Washer
31 - 5th gear wheel

32 - Circlip
 For 5th gear wheel

33 - End cover
Pulling out large taper roller bearing outer race
Fig. 321: Pulling Out Outer Race Of Large Tapered Bearing

2:25:56 AM Page 239

Stepped side of thrust pad 3062 rests against the outer race
Heating transmission housing in order to install outer race for taper roller bearing
Fig. 322: Heating Transmission Housing To Insert Outer Race Of Large Taper Roller Bearing
 Heat transmission housing in area of bearing seat for approx. 15 minutes, to approx. 100 ° C, with a hot
air blower.
Inserting outer race for large taper roller bearing in transmission housing and pressing home
Fig. 323: Inserting And Pressing Outer Race Of Large Taper Roller Bearing Into Transmission Housing
 Insert outer race only after heating transmission housing and push into position under workshop press
until heat exchange has taken place.
2:25:56 AM Page 240

Removing needle bearing for flanged shaft/drive pinion

A - Internal extractor 12 to 14.5 mm, e.g. Kukko 21/1
Inserting needle bearing for flanged shaft/drive pinion flush

Pressing off large taper roller bearing inner race
2:25:56 AM Page 241

Fig. 326: Pressing Off Inner Race Of Large Taper Roller Bearing
Bearing is destroyed when pressing off.
Pressing on inner race for taper roller bearing
Fig. 327: Pressing On Inner Race Of Large Taper Roller Bearing

2:25:56 AM Page 242

 Heat inner race to approx. 100 ° C and install.
 Press home ensuring there is no axial play.

 Determine the thickest circlip that will still just fit and install.

2.34 2.40 2.46
2.36 2.42 2.48
2.38 2.44
Pressing off inner race of small taper roller bearing together with 1st sliding gear
2:25:56 AM Page 243

Fig. 329: Pressing Off Inner Race Of Small Taper Roller Bearing Together With Selector Gear Of 1st
Gear
NOTE: Do not press off together with synchro-hub for 1st and 2nd gear and 2nd gear
sliding wheel.
Pressing on inner race for small taper roller bearing
Fig. 330: Pressing On Small Tapered Bearing Inner Race

 Oil needle bearing.

 Install circlip, washer for 1st/2nd gear synchro-hub, synchro-ring for 1st gear and 1st sliding gear together
with spring and needle bearing.
2:25:56 AM Page 244

NOTE:  Press down only on bearing inner race with collar of thrust pad 3118.
 Position shoulder of pipe section VW 415 A facing up toward press tool
VW 412
 After pressing on, check axial play of 1st sliding gear.
Removing and installing circlip of synchro-hub and washer of 1st sliding gear
Fig. 331: Removing And Installing Circlip For Synchronizer Hub And Shim For 1st Gear Selector Gear
 To remove circlip, remove washer -A- and then circlip -B-.

 To install circlip, install on circlip -B- and then washer -A-.
Pressing off 2nd gear sliding wheel with synchro-hub for 1st and 2nd gear
Fig. 332: Pressing Off 2nd Gear Selector Gear With 1st And 2nd Gear Synchronizer Hub
 Remove locking collar for 1st and 2nd gear and synchro-ring for 1st gear.
 Remove washer and circlip for synchro-hub.
 Press off 2nd speed sliding wheel with synchro-hub for 1st and 2nd gear
2:25:56 AM Page 245

NOTE: Do not press off together with 1st sliding gear and inner race of small taper
roller bearing.
Installing 2nd sliding gear, pressing on synchro-hub for 1st and 2nd gear
Fig. 333: Identifying Special Tools - Installing Selector Gear For 2nd Gear And Pressing On
Synchronizer Hub For 1st And 2nd Gear
 Install needle bearing, sliding gear (with spring) and synchro-ring for 2nd gear.
 Heat synchro-hub to approx. 100 ° C and install.
NOTE:  Install on pipe section VW 415 A with shoulder facing synchro-hub.

 Position thrust pad 3118 with shoulder facing press tool VW 412.
Determining size of circlip for synchro-hub for 1st and 2nd gear
2:25:56 AM Page 246

Fig. 334: Determining Thickest Circlip That Can Just Still Be Installed
 Determine the thickest circlip that will still just fit.

 Insert circlip in direction of arrow to synchro-hub.

1.90 1.96 2.02
1.93 1.99
Driving out outer race for small taper roller bearing
Fig. 335: Driving Out Outer Race Of Small Taper Roller Bearing
Pressing in outer race/small taper roller bearing
2:25:56 AM Page 247

Fig. 336: Pressing In/Out Small Outer Race/Tapered Bearing

 Insert shim S4 into bearing plate behind bearing seat.

 Position thrust pad 3062 with shoulder facing press tool VW 407.
 Pressing in outer race for small taper roller bearing onto stop

FLANGED SHAFT SEALS, REPLACING

2:25:56 AM Page 248


 2062 Driver
 Container
Removing
 Remove shield, if installed, from underneath transmission.
When replacing left seal:
 If necessary, partially remove the front part of the exhaust system.
Refer to
ENGINE CODE(S): BHF
Continuation for both seals:
2:25:56 AM Page 249


 Remove splash plate, if installed, above drive axles (arrows).

 Detach drive axles -1- from flanged shafts, and tie up as high as possible; do not damage surface
protection.
 Unscrew flanged shaft securing bolt; for this purpose, screw two bolts into the flange and counterhold the
flanged shaft using a tire lever.
 Pull out flanged shaft.
 Pull out flanged shaft seal with VW 681.
Installing
2:25:56 AM Page 250


 Drive in new seal for right-hand flanged shaft to a depth of 5.5 mm below surface of housing and for left-
hand flange to a depth of 5.5 below surface of cover.
NOTE:  Figure shows installation on right-hand side of the transmission.

 Do not cant seal when driving in.
employed.
 Pack space between sealing and dust lips with sealing grease G 052 128 A1.
 Insert flanged shaft.
 Fasten flanged shaft with cone head bolt.
 Bolt drive axle to flanged shaft.
 Bolt on cover plates for drive axle if present.

 If necessary, reinstall exhaust system and align free of stress.
Refer to
ENGINE CODE(S): BHF
 Top up oil in transmission and check oil level. Refer to Transmission oil level, checking.
2:25:56 AM Page 251

 Install shield.
Tightening torques
Component Nm
Flanged shaft to transmission 10 + 90 °
Drive axle heat shields 23
DRIVESHAFT FLANGE AT TRANSMISSION, REPLACING SEAL AND GROOVED BALL

BEARING
Driveshaft flange at transmission, replacing seal and grooved ball bearing
Fig. 342: Identifying Special Tools - Driveshaft Flange Seal And Grooved Ball Bearing At Transmission,
Replacing
2:25:56 AM Page 252

 VW 295a Adapter
 VW 415 A Tube
 VW 416 B Tube
Replacing
2:25:56 AM Page 253


 2005 Drift
Fig. 344: Driveshaft Flange Seal And Grooved Ball Bearing At Transmission, Overview
1 - Transmission
2:25:56 AM Page 254

3 - Bearing housing at vibration damper
4 - Seal
 Driving in. Refer to Fig. 354
5 - Flanged shaft
6 - Bolt, 25 Nm
 6 pieces
7 - O-ring
 Always replace
8 - Circlip
9 - Dished washer
 Mark installation position when removing: Large diameter (concave side) facing shims -Item 10
10 - Washers
11 - Spring

Removing
2:25:56 AM Page 255

it may be damaged.
 Remove exhaust system from the clamps.

 Detach rear part of exhaust system from hangers and remove.

 Unbolt heat shield for driveshaft -arrows-.



 Unscrew rear oil drain plug (at end cover) and drain gear oil.
2:25:56 AM Page 256

 Unscrew bolts attaching bearing housing.
NOTE: Bearing housing is pressed slightly off end cover by spiral spring when
mounting bolts are loosened.
Fig. 348: Pull Off Flange Shaft

 Pull flanged shaft together with bearing housing and vibration damper off end cover.
 Remove bearing housing.
 Remove circlip from flanged shaft.

 Press out flanged shaft.
2:25:56 AM Page 257


 Pull out flanged shaft seal.

 Thoroughly clean seat for seal.

 Press out grooved ball bearing.
Installing
2:25:56 AM Page 258


 Press grooved ball bearing into bearing housing.

 Lightly oil diameter of seal -B-.

 Install seal together with washer -A- Part No. 016 311 391 B (thickness 1.7 mm) onto drift 2005.
 Installation position: Open side of seal faces toward transmission.
2:25:56 AM Page 259


 Drive in flanged shaft seal.
 Remove washer after inserting seal.


 Press in flanged shaft.

 Install circlip onto flanged shaft.
 Lightly oil O-ring and insert into groove of bearing housing.
 Insert dished washer and shims into bearing housing.
 Installation position. Refer to Item 9.
2:25:56 AM Page 260

 Install spiral spring onto flanged shaft.

 Tighten bolts attaching bearing housing in stages and diagonally.
 Bolt on driveshaft.
SPEEDOMETER VEHICLE SPEED SENSOR -G22- AND TRIGGER WHEEL, REMOVING AND
INSTALLING

 Remove splash plate above left drive axle -1- if installed (arrows).
Fig. 357: Identifying Vehicle Speed Sensor (VSS)
2:25:56 AM Page 261

 Unplug connector from sender -B-.

 Press retaining clip down, turn sender sideways and pull out upward.
Installing
 Replace O-ring -A-.

 Handle sender carefully. If it is damaged it is possible that the speedometer will not indicate exactly.
Tightening torques
Component Nm
Heat shield for drive axle 23 Nm
Trigger wheel for speedometer vehicle speed sensor -G22-, removing and installing

2:25:56 AM Page 262



 Container
Removing
 Partially remove front part of exhaust system.
Refer to
ENGINE CODE(S): BHF
2:25:56 AM Page 263


 If installed, remove splash plate above left drive axle -1- (arrows).
 Unbolt drive axle from flanged shaft.
 Place drip tray underneath transmission.
Fig. 361: Removing/Installing Speedometer Drive Wheel

 Remove fastening screw -A- for flanged shaft -B-.

 Pull out flanged shaft seal -C- with VW 681.
Remove speedometer trigger wheel -D-:
 Lever out the trigger wheel from the grooves in the differential at the drive pegs -arrows- on alternate
sides.
Installing
Installation is carried out in the reverse order to removal, noting the following:
2:25:56 AM Page 264


The drive pegs -arrows- of the trigger wheel -D- must engage in the grooves of the differential.
 Drive in seal -C- for flanged shaft and install flanged shaft.
Tightening torque:
Component Nm
Drive axle heat shield 23
NOTE: The differential can be removed and installed with the transmission installed.
2:25:56 AM Page 265

Fig. 363: Differential, Removing And Installing, Overview

1 - Bolt, 10 Nm and turn 90 ° further
2 - Flanged shaft
 When removing, secure with a drift to prevent it turning
3 - Bolt, 25 Nm
 10 pieces
4 - Final drive cover
 Removing and installing speedometer trigger wheel. Refer to Trigger wheel for speedometer vehicle
2:25:57 AM Page 266

speed sensor -G22-, removing and installing

 If replaced: Adjust ring gear. Refer to Ring gear, adjusting

 Checking gear oil. Refer to Transmission oil level, checking
6 - Differential

2:25:57 AM Page 267


 VW 295 Drift
2:25:57 AM Page 268

 Installation and removal tool VW 459

 VW 470 Thrust ring for drive pinion bearings



 3138 Driver
2:25:57 AM Page 269


 VAG 1582 Taper roller bearing puller

 VAG 1582/3 Grip piece
2:25:57 AM Page 270

Fig. 368: Differential (Transmission Without Oil Pump), Overview

2 - Shim S2
 Note thickness
 Tapping out. See Driving outer race for small taper roller bearing out of transmission housing
 Tapping in. See Pressing outer race for small taper roller bearing into transmission housing
2:25:57 AM Page 271

 Pulling off. See Removing inner race for small taper roller bearing

5 - Ring gear1)
 Paired with pinion shaft (final drive set)

 Drive off with a drift. See Driving ring gear off housing
 Fit to differential housing. See Heat The Ring Gear To Approx. 100 ° C and install
2:25:57 AM Page 272

7 - Ring gear bolts - 60 Nm plus additional 45 ° turn
 Always replace
 Use only the original bolts
 Pulling off. See Removing inner race for large taper roller bearing

9 - Speedometer trigger wheel
 Removing and installing. Refer to Trigger wheel for speedometer vehicle speed sensor -G22-,
2:25:57 AM Page 273


 Installation position: Shoulder -arrow- faces toward differential; do not cant drive pegs in recess of
differential housing

 Tapping out. See Driving outer race for large taper roller bearing out of cover
 Tapping in. See Driving outer race for large taper roller bearing into cover
11 - Shim S1
 Note thickness
12 - Cover for final drive 1)
 With O-ring
 Replace O-ring
 Lubricate O-ring before installing
2:25:57 AM Page 274


 Redefine thickness. See Adjusting differential bevel gears

 Adjusting. See Adjusting differential bevel gears
15 - Threaded piece
16 - Thrust washer
2:25:57 AM Page 275

 Check for cracks and chipping

18 - Shaft for small bevel gears

 Before driving in, align thrust washers
19 - Roll pin
 Replace
 Drive in flush
Removing inner race for small taper roller bearing
Fig. 372: Pulling Off Small Inner Race/Tapered Bearing

 Install thrust plate 40-105 onto differential housing before installing puller.
Removing inner race for large taper roller bearing
2:25:57 AM Page 276

Fig. 373: Pulling Off Large Inner Race/Tapered Bearing

 Remove speedometer trigger wheel


2:25:57 AM Page 277

 Heat inner race to approx. 100 C, position and install.

Driving ring gear off housing
2:25:57 AM Page 278


Heat the ring gear to approx. 100 ° C and install

 When installing ring gear guide it on centering pins -A- (locally made).
 Allow the ring gear to cool off slightly before inserting the bolts. Then tighten to the specified torque.
2:25:57 AM Page 279


 Insert thrust washers for small bevel gear with a small amount of grease.
 Insert large bevel gears with correct shims. See Adjusting differential bevel gears
 Insert planet pinions turned through 180 ° and pivot into position (arrow).
 Insert threaded pieces.
 Installation position: Step toward large bevel gear
 Align thrust washers with hole.

 Drive small bevel gear shaft into final position and secure.
Adjusting differential bevel gears
Fig. 379: Differential Planetary Gears, Adjusting

 Insert large bevel gears with thinnest shims (0.5 mm).

 Insert small bevel gears with thrust washers and press in shaft.
NOTE: Do not now interchange large bevel gears and thrust washers.
2:25:57 AM Page 280

 Press small bevel gears outward and check play of large bevel gears by hand -arrows-.
 Adjust play by inserting an appropriate shim. Refer to The following shims are available.
 Specification: no more than 0.10 mm
NOTE:
Fig. 380: Installing Differential Bevel Gear Shim

The adjustment is also correct if no further play is perceptible, although it is still

possible to rotate the differential bevel gears -arrow-.

Shim thickness (mm)
0.50 0.70 0.90
0.60 0.80 1.00
Driving outer race for small taper roller bearing out of transmission housing
2:25:57 AM Page 281

Fig. 381: Driving Out Small Taper Roller Bearing Outer Race From Transmission Housing
Pressing outer race for small taper roller bearing into transmission housing
Fig. 382: Driving Small Taper Roller Bearing Outer Race Into Transmission Housing
Driving outer race for large taper roller bearing out of cover
Fig. 383: Driving Out Large Taper Roller Bearing Outer Race From Cover
2:25:57 AM Page 282

 Use suitable base, e.g. VW 470 with recess toward cover.
Fig. 384: Driving Large Taper Roller Bearing Outer Race Into Cover
DRIVE PINION AND RING GEAR, ADJUSTING
General notes
Careful adjustment of the drive pinion and ring gear is important for the service life and smooth running of the
final drive. For this reason, drive pinions and ring gears are paired up during manufacturing and are checked
with a tester for correct positioning of carrier pattern and low noise emission. The position for quietest possible
running is achieved by moving the drive pinion in an axial direction, whereby the backlash remains within the
specified tolerance.
Deviation "r" with reference to the master gauge "Ro" is recorded on the outer circumference of the ring gear.
Final drive set (drive pinion and ring gear) must only be replaced together.
Gear sets, adjusting and marking
2:25:57 AM Page 283

Fig. 385: Gear Sets, Adjustments And Markings

1 - Marking "K831" indicates Klingelnberg final drive set with transmission ratio 31 : 8.
2 - Gear set pairing number (312).
3 - Deviation (tolerance) "r" is based on the test machine master gauge used in production. The deviation
"r" is always given in 1/100 mm. Example: "25" means r = 0.25 mm
Ro - Length of test machine master gauge used. "Ro" = 59.65 mm
2:25:57 AM Page 284


R - Actual dimension between ring gear and face of pinion shaft at point with quietest running for this
pinion set.
Vo - Hypoid offset
Position of shims
2:25:57 AM Page 285


S1 - Adjustment shim for ring gear in transmission housing cover
S2 - Adjustment shim for ring gear in transmission housing
S3 - Adjustment shim for drive pinion in transmission housing
S4 - Adjustment shim for drive pinion in bearing plate
Adjustment overview
NOTE: In the case of repairs to the transmission it is only necessary to adjust the
pinion shaft, ring gear or final drive set if components have been replaced
which have a direct effect on the adjustments of the final drive. To eliminate
2:25:57 AM Page 286

unnecessary adjustments observe following table:
To adjust: Ring gear Pinion shaft Pinion shaft Backlash

(S1 and S2) (S3 and S4) shim only 0.12 -0.22 mm
using deviation "r" S4
Refer to Ring Refer to Drive Refer to Re- Refer to
gear, adjusting pinion, adjusting determining shim S4 Adjusting
backlash
Component replaced
Bearing plate X X
Taper roller bearings X X
for pinion shaft
differential
Final drive X X X
Hollow shaft X X
Gear set, recommended adjustment sequence
When ring gear and pinion shaft have to be adjusted, in the interests of a rational sequence, keep to the
following order:

2:25:57 AM Page 287

 Determine total shim thickness "Stotal" (S1 plus S2) for the specified preload of taper roller bearings for
differential.
 Determine total shim thickness "Stotal" (S3 plus S4) for the specified preload for taper roller bearings for
drive pinion.
 Distribute total shim thickness "Stotal" (S3 plus S4) so that the distance from center of ring gear to face of
pinion shaft is the same as distance "R" determined during production.
 Distribute total shim thickness "Stotal" (S1 plus S2) so that the specified backlash exists between ring
gear and drive pinion.
The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test
machine in production. Maximum care and cleanliness are essential for achieving good results when performing
repairs and taking measurements.
Drive pinion, adjusting
Fig. 389: Identifying Special Tools - Pinion, Adjusting
2:25:57 AM Page 288

(Adjusting drive pinion and hollow wheel)
 VW 385 Universal measuring tool

 VW 387 Universal dial gauge holder

 3062 Thrust disc
Fig. 390: 3114/2 Straightening Tool

 3114/2 Straightening tool

 3116 Spring pin
2:25:57 AM Page 289

 Torque gauge 0 to 600 Ncm

 Dial gauge
 Dial gauge extension 6.5 mm
Re-adjustment of the drive pinion according to the following instructions is only necessary if the final drive set,
taper roller bearing for drive pinion and transmission housing are being replaced. Refer to Adjustment
overview.
Determine total shim thickness "Stotal"(S3 plus S4)
(Setting preload of taper roller bearing for drive pinion).
 Differential is removed.
Fig. 392: Preloading Pinion/Hollow Shaft To 10 Nm, While Holding Hollow Shaft
 Clamp drive pinion in vice using vice clamps -A-.

 Insert taper rollers with grease, assemble drive pinion and hollow shaft.
 Rotate hollow shaft against drive pinion 5 turns in both directions to settle taper roller bearing.
 Preload drive pinion/hollow shaft to 10 Nm, hold hollow shaft tight for this step.
 Install large taper roller bearing outer race into transmission housing without shim. Refer to Heating
transmission housing in order to install outer race for taper roller bearing and Inserting outer race
for large taper roller bearing in transmission housing and pressing home
2:25:57 AM Page 290


 Press small taper roller bearing outer race together with a 1.00 mm thick provisional shim S4* fully into
bearing plate.
NOTE: For measurement purposes a shim S4 with a thickness of 1.00 mm is inserted

provisionally. It is referred to as S4* in the following. After determining
measurement "e", S4* is replaced by the final shim S4.
 Insert completely assembled pinion shaft in transmission housing.

 Install bearing plate with dowel sleeves and tighten bolts to tightening torque.
 Rotate drive pinion and hollow shaft 8 turns in both directions prior to each measurement in order to
settle taper roller bearing.
Fig. 394: Installing Measuring Tools

2:25:57 AM Page 291

 Install measuring tools.

 Use 30 mm dial gauge extension
 Position dial gauge extension in middle of measuring plate VW 385/17.
 Set dial gauge (3 mm measuring range) to zero with 2 mm preload.
 Move drive pinion upward and downward without turning; read off play on dial gauge and note.
(Example: 0.90 mm)
 Before each measuring procedure the drive pinion must be turned together with the hollow shaft in order
to avoid obtaining a false reading.
The specified bearing pre-load is obtained by adding a constant pre-load value (0.15 mm) to reading obtained
(0.90 mm) and thickness of shim S4* (1.0 mm).
Stotal = S4* + reading obtained + pre-load
Example:
Inserted shim S4* 1.00 mm

Pre-load (constant value) +0.15 mm
Reading obtained (Example) +0.90 mm
Stotal = 2.05 mm
Determining thickness of provisional shim S3*
Provisional shim S3* = Stotal - S4*
Example:
Total shim thickness Stotal (S3 + S4) 2.05 mm

Inserted shim S4* -1.00 mm
Provisional shim thickness S3* = 1.05 mm
 Removing outer race for large taper roller bearing. Refer to Pulling out large taper roller bearing outer
race, Inserting provisional shim S3* into transmission housing and re-installing outer race. Refer to
Heating transmission housing in order to install outer race for taper roller bearing and Inserting
outer race for large taper roller bearing in transmission housing and pressing home.
 Insert completely assembled pinion shaft in transmission housing again.
 Install bearing plate with dowel sleeves and tighten to 25 Nm.
 Rotate drive pinion and hollow shaft 8 turns in both directions prior to each measurement to settle taper
roller bearing.
Determining measurement "e"
2:25:57 AM Page 292


 Set universal mandrel VW 385/1 setting ring to dimension a = 65 mm.

 Adjust moveable setting ring to measure b = 55 mm.
Fig. 396: Assemble Measuring Bar According

 Arrange universal mandrel as illustrated. Dial gauge extension VW 385/15 = 9.3 mm. Set master gauge
VW 385/30 to Ro = 59.65 mm and install onto mandrel.
 Place end measuring plate VW 385/17 onto drive pinion head.
2:25:57 AM Page 293

Fig. 397: Insert Measuring Mandrel Into Housing

 Remove master gauge and insert measuring mandrel in the housing. Centering disc VW385/3 faces
toward cover for final drive.
 Using sliding setting ring to pull 2nd centering disc VW 385/2 outward until mandrel can still just be
turned by hand.
 Measure dimension "e".
Turn mandrel until the dial gauge extension touches the final measuring plate on pinion shaft head, then
measure maximum deflection (return point). The measured value is dimension "e".
2:25:57 AM Page 294

Example:
0.16 mm (red scale)
 Turn mandrel until the dial gauge point touches the end measuring plate on drive pinion head, then
measure maximum deflection (return point).
Measurement in following example: "e" = 0.16 mm (in red scale on dial)
Determining thickness of shim S3
S3 = S3* + r + e
("e" in black scale)
S3 = S3* + r + e
("e" in red scale)
NOTE:  The deviation "r", which is related to the master gauge "Ro" is measured
for the final drive sets supplied as replacement parts and marked on the
outer circumference of the ring gear.
 If dial gauge reading is in red scale, subtract dimension "e".
 If dial gauge reading is in black scale, add dimension "e".
Example:

Dimension "r" indicated on ring gear +0.38 mm
Determined value "e" (red scale) -0.16 mm
Shim thickness S3 = 1.27 mm
Shim thickness (mm)

0.45 0.60 0.75
0.50 0.65 0.80
0.55 0.70 0.85
 Different tolerances make it possible to obtain exact shim thickness required.
S4 = Stotal - S3
2:25:57 AM Page 295

Example:

Thickness of shim S3 -1.27 mm
Thickness of shim S4 = 0.78 mm
Shim thickness (mm)

0.45 0.65 0.85
0.50 0.70 1.25
0.55 0.75
0.60 0.80
Carry out check measurement - checking dimension "r"
 Install pinion shaft with measured shims S3 and S4 and turn several times in both directions.
Insert universal mandrel and measure dimension "r".
If the correct shims have been selected the D.T.I. must now indicate the mark dimension "r" (reading anti-
clockwise on red scale) within a tolerance of ± 0.04 mm.
Measuring frictional torque (check)
NOTE: Taper roller bearings for drive pinion/hollow shaft are low friction bearings.
Therefore the frictional torque only has a limited use as a check. Correct
2:25:58 AM Page 296

adjustment is only possible by determining the total shim thickness Stotal.
Fig. 400: Do Not Use Additional Oil

 Install new taper roller bearings in delivery condition and do not oil additionally.
Fig. 401: Measure Friction Torque

 Measuring frictional torque
With torque gauge -A-, 0 to 600 Ncm, standard commercially available
New bearings Used bearings 1)

80 to 150 Ncm 30 to 60 Ncm
2:25:58 AM Page 297

1) with at least 50 km service

 VW 295 Drift
 VW 382 Special socket and measuring tools
2:25:58 AM Page 298

 VW 388 Test lever


 VW 459 Installation and removal tool

 VW 521 Adjustment tool for ring gear

 Dial gauge
2:25:58 AM Page 299

 Dial gauge extension
It is necessary to readjust the ring gear when:
Transmission housing, cover for final drive, taper roller bearing outer race for differential, final drive
housing or final drive set are replaced.
Adjustment overview. Refer to Adjustment overview
Determine total shim thickness "Stotal" (S1 plus S2)
 Drive pinion is removed.

 Remove outer races of differential taper roller bearings and remove shims. Refer to Differential,
 Drive outer race for taper roller bearing with shim S2 into transmission housing. For measurement
purposes use a 1.20 mm thick S2* shim (2 shims of 0.60 mm).

provisionally. It is referred to as S2* in the following. After determining the
backlash, S2* is replaced by the final shim S2.
2:25:58 AM Page 300

 Press taper roller bearing outer race without shim into cover for differential.
 Insert differential into housing without speedometer trigger wheel.
The side of the ring gear is positioned on the right side (cover side).
 Install cover and tighten bolts to 25 Nm.

 Turn transmission so that cover for differential faces up.
 Place measuring plate VW 385/17 onto differential.
2:25:58 AM Page 301


A - Dial gauge extension 30 mm
Fig. 407: Move Differential With Ring Gear Adjuster VW 521 Up And Down
 Move differential up and down with special tool VW 521 (direction of arrow).
 Read off play from dial gauge
Example:
0.62 mm
"Stotal" = S2* + reading obtained + pre load
Example:
Inserted shim(s) S2* 1.20 mm

Stotal = 2.07 mm
Determining thickness of shim S1*
NOTE:  After determining the backlash, provisional shim S1* is replaced by the
final shim S1.
 The total shim thickness "Stotal" remains the same.
S1* = Stotal - S2*
2:25:58 AM Page 302

Example:

Inserted shim(s) S2* -1.20 mm
Thickness of shim S1* = 0.87 mm
Adjusting backlash
Drive pinion inserted with S3 and S4
 Differential with ring gear: S1* is installed in the cover side, S2* in the transmission housing.
 Install final drive cover and tighten bolts to 25 Nm.
 Turn differential several times in both directions so that the taper roller bearings settle.


 Use dial gauge extension VW 382/10 (6 mm flat).
Set measuring lever VW 388 to dimension "a" = 79 mm.
 Turn ring gear to stop. Set dial gauge to zero, turn back ring gear and read off backlash. Note value.
 After turning ring gear through a further 90 ° , repeat measuring process a further 3 times. Add up the
four measured values and calculate average backlash
Calculating average backlash
Example:
1st measurement 0.49 mm

+ 2nd measurement 0.48 mm
+ 3rd measurement 0.50 mm
2:25:58 AM Page 303

+ 4th measurement 0.49 mm

Total 1.96 mm
Center backlash = 1.96 mm: 4 = 0.49 mm
If the individual measurements differ by more than 0.06 mm from each other, the installation of the ring gear or
the final drive set itself is not correct. Recheck the installation, and if necessary replace ring gear and pinion.
Determining shim thickness S2
(opposite ring gear)
S2* = Inserted shim(s)

- Average backlash
+ Lift (constant)
Lift = 0.15 mm
Example:
S2*= Inserted shim(s) 1.20 mm

- Average backlash 0.49 mm
= 0.71 mm
+ Lift (constant) 0.15 mm
Shim thickness (mm)

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Determining adjustment shim thickness S1
(Ring gear side)
S1 = Stotal - S2
Example:
2:25:58 AM Page 304


Shim thickness (mm)

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Install determined shims, S1 on the ring gear side, S2 opposite ring gear, use 2 shims if necessary.
Performing check measurement
Measuring backlash. Refer to Adjusting backlash
 It must be 0.12 to 0.22 mm.
2:25:58 AM Page 305


Gear shift lever mechanism, installation position
Fig. 72: Gear Shift Lever Mechanism, Installation Position

1 - Selector rod
2 - Front push rod
3 - Connecting rod
4 - Gear selector lever
2:27:54 AM
2:28:08 Page 1
Component overview

Part 1
NOTE: Lubricate bearing areas and slide surfaces with polycarbamide grease, Part No.
G 052 142 A2.
1 - Ball
2:27:54 AM Page 2
2 - Rubber ring
3 - Ball guide
4 - Rubber ring
5 - Washer
 Shoulder faces ball guide (Item 3 Component overview)
6 - Snap ring
 Remove to remove the ball

2:27:54 AM Page 3
7 - Compression spring
8 - Spacer bushing
9 - Washer
10 - Snap ring
11 - Noise insulation cover
12 - Shift knob
 with cover
 Removing and installing. Refer to Shift knob and cover, removing and installing
13 - Nut - 10 Nm
14 - Ball housing
15 - Inner Torx bolt
2:27:54 AM Page 4

16 - Shift lever
 Angled area faces rear
17 - Bolt
18 - Nut - 10 Nm
19 - Shift mechanism housing
20 - Shift fork
21 - Nut - 10 Nm
2:27:54 AM Page 5
 Self-locking
 Always replace
22 - Bushing

Part 2
1 - Ball socket
 To remove, bend back peenings on shift rod -Item 19 Component overview
2 - Washer
2:27:54 AM Page 6
3 - Ball socket
4 - Boot
5 - Transmission shift lever
6 - Nut - 23 Nm
7 - Bolt - 23 Nm
8 - Operating rod
2:27:54 AM Page 7

9 - Locking clamp
10 - Bolt - 40 Nm
11 - Pivot rod
 with bushing, bolt and washers
13 - Washer
14 - Ball housing
16 - Boot
 Carefully pull over shift rods when removing

 When installing, place on markings of shift rod and pivot rod
2:27:54 AM Page 8

18 - Clamping piece
19 - Shift rod
20 - Shift fork
21 - Nut - 10 Nm
22 - Nipple
Shift knob and cover, removing and installing
2:27:54 AM Page 9
Removing
NOTE: Remove shift knob together with shift lever cover and cover for center console.

 Unclip cover for center console and lift this out upward -arrows-.

 Detach connecting part -1- in direction of arrow and pull off shift knob together with shift lever cover
upward.
Installing
2:27:54 AM Page 10

 VAG1383A engine/transmission hoist
Removing
 Remove A/C Control Head.
2:27:55 AM Page 11
 Lift up panel -1- first in direction of arrow -A- and pull it out in the direction of arrow -B-.
All:
 Remove bolts -arrows C- and then remove ashtray -2- from center console.
 Lift out noise insulation upward.
 Remove noise insulation cover for shift mechanism housing (arrows).

2:27:55 AM Page 12
it may be damaged.



2:27:55 AM Page 13


 Remove heat shield -1- -arrows-.
 Remove heat shield.
 Tie up the drive axle -2- on transmission to the side.

2:27:55 AM Page 14

Wood
 Remove shift mechanism toward rear.
Installing
NOTE: Always replace gaskets and self-locking nuts.
 Install tunnel cross member.
2:27:55 AM Page 15
Refer to
ENGINE CODE(S): BHF
 Adjust shift mechanism. Refer to Shift lever mechanism, adjusting.
Tightening torques
Component Nm
Transmission shift lever to shift rod 23
Shift lever mechanism, adjusting
NOTE: The following are prerequisites for correct gear linkage adjustment:
 Perfect gear linkage operating and transfer elements.

 Gear shift lever mechanism moves smoothly.
Work sequence
 Remove A/C control head.
2:27:55 AM Page 16
 Lift panel -1- first in direction of arrow -A- and pull out in direction of arrow -B-.
All:
 Unscrew the bolts -arrows C- and pull out the ashtray -2- from the center console.
 Lift out the noise insulation upward.
 Unscrew noise insulation cover for shift lever housing -arrows-.
2:27:55 AM Page 17

 Measure distance -a- between the two threaded studs in the shift lever mechanism
 Specified value: Distance a = 85 mm
NOTE: Measure from the centers of the two threaded studs.
 If this is not the case, adjust distance -a- as follows:

 Loosen push rod bolt (arrow).
 Rear push rod (in shift lever mechanism) should move freely in both directions on slide.
 Set distance -a- by moving rear push rod (in shift lever mechanism).
 Tighten push rod bolt -arrow- to 23 Nm.

 Loosen bolt for selector rod -arrow-.
 Connection between selector rod and shift lever mechanism should move freely.
2:27:55 AM Page 18
Align the shift lever as follows:

 Center the bottom of the gear lever in the center of the ball housing.
 The distance between the ball housing and the bottom of the gear lever -arrows- must be equal at all
points.
 Shift lever in vertical position to direction of travel.
 Shift lever held in this position.

 Tighten selector rod bolt -arrow- to 23 Nm.
NOTE: The shift lever must remain in the same position while the bolt is being
tightened.
Shift lever alignment, checking
2:27:55 AM Page 19
 The shift lever must rest in the 3rd/4th gear gate when the transmission is in neutral.
 Depress clutch.
 Check that all gears can be engaged.
 It should only be possible to engage the R gear after releasing the block.
 The gear lever must return automatically from the R gear gate to the 3rd/4th gear gate.
If after repeated selection of a gear it fails to engage smoothly, shift lever alignment must be repeated.
 Install covers and shift lever knob


Cabriolet
.


Cabriolet
.
2:27:55 AM Page 20

 10-222A Engine support bridge

 2024A Engine Sling
 3282 transmission support
 3282/12 adjustment plate
 VAG 1383 A Engine/transmission hoist
Removing
2:27:55 AM Page 21
Refer to

Cabriolet
Fig. 98: Removing Battery Cover

 Slide cover over the battery to the right (arrow 1) and pull it off upward (arrow 2).

 Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.
2:27:55 AM Page 22

 Remove rear engine cover (arrows).

 Remove front engine cover (arrows).

2:27:55 AM Page 23
 Remove cover -1- in engine compartment (right side).
 Remove bolts for holding plate -3- for solenoid valves (arrows).
 Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
 Remove hose -4- of crankshaft housing ventilation from air duct -2-.
 Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
 Disconnect hose -1- from air duct.
NOTE: Illustration depicts air guide with the removed engine from rear.
 Remove engine/transmission connecting bolts accessible from above.
2:27:55 AM Page 24
 Position 10-222A engine support bridge on bolted flanges of fenders.

 Remove eyelet for 2024A engine sling.

 Insert bolt -1- in the center bore of 2024A Engine Sling and secure with a cotter pin.
 Attach bolt for 2024A engine sling at 10-222A engine support bridge spindle.
 Attach 2024A Engine Sling to sling clamps at front and rear of engine.
WARNING: Take-up hooks and pins at engine sling must be secured using securing
pins (arrows) as shown in illustration.
 Slightly pre-tension engine using engine support bridge spindle.
Vehicles with auxiliary heater:
2:27:55 AM Page 25
Fig. 107: Fasteners

 Remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
All:

 Remove the sound-proofing material (arrows).
2:27:55 AM Page 26

 Unbolt bracket for noise insulation panel (arrow).
it may be damaged.




2:27:55 AM Page 27

Wood
2:27:55 AM Page 28
Wood
 Release slowly the tunnel cross member using VAG1383A engine/transmission hoist.

 Remove nuts -1- and -2-.

 Remove bolts (arrows) and remove tunnel cross member downward using transmission mount.
2:27:55 AM Page 29

 Remove left and right heat shields for drive axles (arrows).
 Remove drive axles from transmission drive flange.
NOTE: Take care not to damage protective coating on drive axles.
Between
 Raise transmission using punch of VAG 1383 A engine/transmission hoist high enough, so that a piece of
wood (arrow) can be placed in between.
2:27:55 AM Page 30

 Remove the three bottom engine/transmission connecting bolts (arrows).


 Unbolt starter -1- (arrows) and remove it from transmission bell housing.
 Remove remaining mounting bolts for engine/transmission. One bolt remains tightened by hand.
2:27:55 AM Page 31
 Disconnect harness connector for back-up light switch at right of transmission and set aside electrical
wire.
Fig. 121: Disconnecting Harness Connector From Speedometer Vehicle Speed Sensor (VSS) -G22- At
 Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of
transmission.
 Unbolt heat shield for engine speed (RPM) sensor.
 Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.
2:27:55 AM Page 32


Fig. 125: 3282 Transmission Support, 3282/12 Adjustment Plate And VAG1383A Engine/Transmission
2:27:55 AM Page 33
Hoist
 Set up 3282 transmission support for removing manual transmission 01E all wheel drive using 3282/12
adjustment plate and VAG1383A engine/transmission hoist.
A - Attachments
NOTE:
Fig. 126: Identifying Attachments Symbols On Adjustment Plate

 Attachments -A- are shown in schematic form, arrow -B- points in the
direction of travel.
 3282/12 adjustment plate only fits in one position.
Fig. 127: Place Transmission Jack And Adjustment Plate 3282/12 Under Transmission
 Roll VAG 1383 A engine/transmission hoist underneath transmission. Arrow B (Refer to Illustration Fig.
126) on adjustment plate 3282/12 points in the direction of travel.
2:27:55 AM Page 34
Fig. 128: Align Adjustment Plate 3282/12 Parallel To Transmission And Lock Safety Supports On
Transmission
 Remove last mounting bolts for engine/transmission.
 Press transmission off dowel sleeves and lower carefully using VAG 1383 A engine/transmission hoist
just enough for access to slave cylinder.
NOTE: When lowering the transmission, make sure the hydraulic line/hose to clutch
slave cylinder is not damaged.

 Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect line.
NOTE: Ensure freedom of movement of drive axles when lowering.
Installing
2:27:55 AM Page 35
NOTE: Always replace seals, gaskets and self-locking nuts.
 Clean input shaft splines and (in case of used clutch plates) clean hub splines. remove corrosion and apply
only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
 Coat contact surface of clutch release lever plunger with a thin layer of copper grease, e.g. Z 381 351 TE.

 If the plastic ring of the release bearing is loose, adhere it to the bearing ring again using adhesive AMV-
195-KD1-01.
 3 rectangular tabs (arrows) of the plastic ring reach into the cutouts of the bearing ring.
 If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.
 All threaded bores in which self-locking bolts are threaded must be cleaned of remaining locking fluid
using a tap.
 Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or
replace if necessary.
 Place intermediate plate onto the dowel sleeves on engine flange.
 Tie electrical wires off to the side before installing, so that they are not pinched between engine and
transmission.
 Lift transmission until clutch slave cylinder with mounting bracket for line/hose can be installed (arrow).
2:27:55 AM Page 36

 Secure slave cylinder with a new bolt (arrow).

 Install starter and secure connecting bolts for engine/transmission on left and right side.
 Install connecting rods and pivot rods for shift mechanism.
Between
 Place a piece of wood (arrow) onto punch of VAG 1383 A engine/transmission hoist and raise
transmission slightly.
2:27:55 AM Page 37

 Tighten the three bottom engine/transmission connecting bolts (arrows).

 Guide the tunnel cross member with loosely inserted transmission mount over front exhaust pipes.
it may be damaged.
Wood
 Place a piece of wood (arrow) onto punch of VAG 1383 A engine/transmission hoist and raise tunnel
cross member and transmission slightly.
 Next, tighten bolts -1- to -4- hand-tight.
 Release slowly the VAG 1383 A engine/transmission hoist.
 Tighten bolts for tunnel cross member.
2:27:55 AM Page 38
Fig. 135: Identifying Transmission Raised Using Punch Of VAG 1383 A, A Piece Of Wood And
Transmission Mount Bolts
 For tension-free installation, raise transmission using punch of VAG 1383 A engine/transmission hoist
high enough so that a piece of wood -1- can be placed in between.
 Tighten bolts (arrows) for transmission mount.
 Slowly lower transmission again.
 Tighten nuts -2- and -3-.
 Bolt drive axles on drive flange.
 Check adjustment of shift mechanism and adjust if necessary. Refer to Shift lever mechanism,
adjusting.
Refer to
ENGINE CODE(S): BHF
 Check transmission oil level in manual transmission. Refer to Transmission oil level, checking.
See Caution for disconnecting Telematics battery. Refer to Transmission, removing and installing
2:27:55 AM Page 39
Refer to

Tightening torques

Securing engine/transmission for manual transmission with All Wheel Drive (with intermediate plate)
Item no. Bolt Nm

1, 10, 11 M10 x 60 45
2 M12 x 130 65
3 M10 x 150 45
4 M12 x 80 65
5, 6, 8 M12 x 80 65
7 M12 x 105 65
9 M10 x 59 45
A: Alignment bushing
Component Nm
Clutch slave cylinder to transmission 23 1)
Connecting rod for shift rod to transmission 23
Engine Speed (RPM) sensor -G28- 10
Transmission mount with console to transmission 23
2:27:55 AM Page 40

Heat shield for drive axle to cover for Torsen differential 25
Air duct to throttle valve supports 10
1) Always replace bolt
NOTE:  The vehicle should be absolutely horizontal when checking transmission

oil level. This work is best performed over an inspection pit or using a 4 -
column lifting platform.
 The prescribed oil level is to be adhered to exactly; the transmission
reacts very sensitively to overfilling.
Fig. 137: Location Of Sealing Plug For Gear Oil Inspection

 Remove oil filler plug -B- to check final drive oil level.
 Check oil level using a shop-built tool, e.g. a piece of angled wire.
 Specification: Oil level 4 mm ± 1 below bottom edge of oil filler hole
 Top up with gear oil, if necessary: Specification. Refer to Code letters, mechanical unit assignment,
Tightening torque
Component Nm
Oil filler plug 40
2:27:55 AM Page 41
Fig. 138: Transmission, Disassembling And Assembling, Sequence

Assembly sequence. Refer to Assembly sequence
1 - Bearing housing, Torsen differential and end cover
 Removing and installing. Refer to Bearing housing, Torsen differential and end cover, removing and
installing
2 - Manual transmission and selector shaft
2:27:55 AM Page 42
 Removing and installing. Refer to Manual transmission and selector shaft, removing and installing
3 - Transmission housing and differential

 Servicing transmission housing. Refer to Transmission housing, servicing
Bearing housing, Torsen differential and end cover, removing and installing
1 - Bearing housing
 Disassembling and assembling. Refer to Bearing housing, disassembling and assembling
2:27:55 AM Page 43
2 - Bolt, 25 Nm
 6 pieces
3 - Dished washer
4 - Washer
 Qty. 2 or 3
2:27:55 AM Page 44
5 - Oil collector
 Disassembling and assembling. Refer to Fig. 208


7 - 2nd inner race for four-point bearing
 Roller bearing side

8 - Spring
 Servicing only possible at manufacturer

 Servicing mount for Torsen differential. Refer to Mount for Torsen differential, servicing
2:27:55 AM Page 45
10 - Bolt, 25 Nm
 5 pieces
11 - End cover
12 - Gasket
 Always replace
13 - Dowel sleeve
2:27:55 AM Page 46
 2 pieces
 Removing and installing 5th and 6th gear. Refer to 5th and 6th gear, removing and installing
and installing
16 - Solenoid
2:27:55 AM Page 47
 2 pieces
 Clean
17 - Supporting plate
 Installation position: Lug faces magnet
18 - Bolt, 25 Nm
 2 pieces
Manual transmission and selector shaft, removing and installing

2:27:55 AM Page 48
1 - 5th and 6th gear
 Transmission remains flanged to transmission housing

 Removing and installing. Refer to 5th and 6th gear, removing and installing
and installing
3 - Bolt, 25 Nm
 3 pieces
 Inserted with sealing paste AMV 188 001 02

2:27:55 AM Page 49


 Disassembling and assembling. Refer to Selector shaft, disassembling and assembling
 4 pieces
2:27:55 AM Page 50
9 - Differential
 Covered by final drive cover.


11 - Dowel sleeve
2:27:55 AM Page 51
 2 pieces
12 - Bolt, 25 Nm
 12 pieces
5th and 6th gear, removing and installing

2:27:55 AM Page 52
2 - Needle bearing for 5th gear
3 - Inner race for 5th sliding gear


5 - Spring pin
 Pressing out. Refer to Fig. 171

 Pressing in. Refer to Fig. 198
6 - Follower for 5th and 6th gear
 Only replace complete with selector rod for 5th and 6th gear -Item 8- 5th and 6th gear, removing and
installing
7 - Selector fork, 5th and 6th gear
 Can be replaced separately
 Only replace complete with follower for 5th and 6th gear
9 - Locking collar/synchro-hub for 5th and 6th gear

10 - Circlip
11 - 5th gear wheel
2:27:55 AM Page 53
 Pull off together with synchro-hub and inner race for 5th gear. Refer to Fig. 174
13 - Needle bearing
 For 6th gear
14 - Thrust washer
2:27:56 AM Page 54
 Installation position: Grooves face circlip, smooth face contact surface toward needle bearing
15 - Circlip
16 - Inner race

 Remove by hand. Refer to Fig. 178
17 - Washer
2:27:56 AM Page 55
18 - Spacer sleeve
 Length 39.6 mm
19 - 6th gear wheel
 To press off, remove bearing plate. Refer to Fig. 176

Input shaft, drive pinion, hollow shaft and shift lever mechanism in transmission, removing and installing
2:27:56 AM Page 56
1 - Bearing plate
 Only replace complete with follower for 5th and 6th gear. Refer to 5th and 6th gear, removing and
installing, Item 6
 Pulling out ball housing. Refer to Pulling ball sleeve out of follower for reverse gear
 Driving in ball housing. Refer to Driving ball sleeve flush into follower for reverse gear
4 - Selector fork, 3rd and 4th gear

 Installation position: Rib toward follower
2:27:56 AM Page 57
 Only replace complete with follower for 3rd and 4th gear
6 - Input shaft
7 - Follower for 1st and 2nd gear
2:27:56 AM Page 58
8 - Circlip
 2 pieces
 Only replace complete with pinned selector fork for 1st and 2nd gear
10 - Hollow shaft
2:27:56 AM Page 59
11 - Pinion shaft
 4 pieces
Assembly sequence
Removing and installing bearing housing, Torsen differential, end cover, shift lever mechanism in
2:27:56 AM Page 60
transmission, input shaft, drive pinion and hollow shaft

 VW 415 A Tube
 VW 447 H Thrust plate

2:27:56 AM Page 61
 VW 540 Engine and transmission support

 30-23 Extension

 30-211 A Support bridge

 2064 Setting pin
 3116 Spring pin
2:27:56 AM Page 62
 3121 Drift
 3275 Internal puller
Fig. 155: Pressure Device 3276

 Pressure device 3276
Fig. 156: Identifying Special Tools - Kukko 20/10 Puller Set

 1 - 2-Arm puller Kukko 20/10

 2 - Puller hooks V/170
 Container
 Depth gauge
Disassembling
2:27:56 AM Page 63
Fig. 157: Transmission In Assembly Fixture

 Clamp transmission in VW 540 holding fixture.

 Drain gear oil.

 Screw out bolts -1- and detach leaf spring -2-.

 Remove clutch release lever -4- together with release bearing -3- and intermediate piece -5-.
 Unbolt guide sleeve.
2:27:56 AM Page 64
Fig. 159: Unbolt Bearing Housing And Pull Off

 Unscrew bearing housing -arrow- and pull off.

Bearing housing is pushed away slightly from end cover by coil spring -A- when it is being pulled off.
 When detaching bearing housing, observe installation position of dished washer -C-.
 Installation position: Outside diameter (concave side) facing shims -B-
 Remove shims -B-, note thickness and re-determine if necessary. Refer to Fig. 213.
2:27:56 AM Page 65
Fig. 161: Identifying Torsen Differential

 Pull Torsen differential out of end cover.

 Pull oil collector sufficiently far out of end cover -arrow- until it moves freely.
Fig. 163: Removing Oil Diverter Out End Cover Hole

2:27:56 AM Page 66
 Swivel oil collector -arrow- down and guide it out through hole of end cover.
 Remove oil collector.
 Remove locking bolts -A- for selector shaft from transmission housing.
 Remove 3 bolts -B- for cover for selector shaft, remove cover.
Rails
arrows-.
2:27:56 AM Page 67
Fig. 166: Remove Support Plate For Needle Bearing

 Slacken multi-point socket head bolt -arrow B- in input shaft through hole -arrow A- in end cover and
unscrew.
 Remove supporting plate.
 Remove supporting plate for needle bearing.

 Remove 2 magnets -arrows A- and clean.

 Slacken 5 bolts -arrows B- for attaching end cover to manual transmission and remove.
2:27:56 AM Page 68
Fig. 168: Pull 2nd Inner Race For 4-Point Bearing (Roller Bearing Side) Off From Input Shaft
 Pull off 2nd inner race of four-point bearing (roller bearing side) for input shaft.
NOTE: Internal puller 3275 engages in a circular groove in the inner race when pulling
off -arrow-.
 Remove end cover together with end cover/bearing plate gasket.

 Pull dowel sleeves out of bearing plate.
Fig. 169: Pulling Off Selector Gear For 5th Gear With Spring Together With 1st Inner Race For 4-Point
Bearing (Ball Bearing Side) For Input Shaft
 Pull off 5th sliding gear and spring together with 1st inner race -A- of four-point bearing (ball bearing
side) for input shaft.
B - Two-arm puller, e.g. Kukko 20/10
 Remove 5th gear synchro-ring.

 Remove circlip for 5th gear wheel.
 Lock hollow shaft in position by engaging two gears. Refer to Fig. 165
2:27:56 AM Page 69
Fig. 170: Pull Off Drive Gear For 5th Gear

 Pull off 5th gear wheel.
NOTE: Only use hexagon bolt of spring sleeve 3116, length 50 mm
C - Two arm puller, e.g. Kukko 20/10 with 200 mm hooks
 Remove shim -B- for 5th gear wheel, note thickness and re-determine if necessary. Refer to Fig. 199.
 Remove spacer sleeve -A-.
Fig. 171: Pressing Out Spring Pin For Selector Fork For 5th and 6th Gear
 Press out spring pin -A- for selector fork for 5th and 6th gear.
NOTE:  Do not damage synchro-ring for 6th gear when pressing out spring pin.
 Do not drive out spring pin, otherwise selector rod bearing will be
damaged.
 Pull selector rod on follower together with selector fork for 5th and 6th gear and locking collar as far as
2:27:56 AM Page 70
possible away from bearing plate (until stop is felt).
 Mark relative positions -arrow 3- of locking collar for 5th and 6th gears -arrow 1- and synchro-hub -A-
(paired) -arrow 1-.
Fig. 173: Pulling Off Yoke Together With Selector Fork And Locking Collar From Selector Rod
 Pull follower together with selector fork and locking collar off selector rod.
2:27:56 AM Page 71
Fig. 174: Pull Off 6th Gear Selector Gear, 6th Gear Synchronizer Ring, 5th And 6th Gear Synchronizer
Hub And Needle Bearing Inner Race For 5th Gear Selector Gear
 Pull off 6th sliding gear, synchro-ring for 6th gear, synchro-hub for 5th and 6th gears and inner race for
5th sliding gear needle bearing.
A - Two-arm puller, e.g. Kukko 20/10 with 200 mm hooks

 Unscrew selector rod locking bolts.
D - Reverse gear
 Drive out dowel sleeves on bearing plate and remove bearing plate from transmission housing.
2:27:56 AM Page 72
 Secure drive pinion opposite hollow shaft e.g. with hose strap, to prevent it slipping out.
 Detach bearing plate with input shaft, drive pinion and hollow shaft and with shift lever mechanism in
transmission from transmission housing.
 Remove circlip from selector rod for 1st and 2nd gear and remove follower -A-.
 Pull out selector rod -B- for 5th and 6th gear.
 Remove follower -C- for reverse gear.

 Pull thrust washer -arrow A- for needle bearing for 6th gear off shaft.
 Remove circlip -arrow B- for cylinder roller bearing inner race with pliers.
 Take out inner race -arrow C- for cylinder roller bearing (not a press fit).
2:27:56 AM Page 73
 Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out at an angle from bearing
plate.

 Unscrew hexagon bolt -D-, remove spring clasp -B- and retaining plate -A-, pull out shaft -C- for reverse
idler gear.
 Take out spring, synchro-ring and reverse idler gear.
 Remove relay lever for reverse gear.
NOTE:  Drive pinion and hollow shaft can be removed complete if it is possible to
easily lever off 6th gear wheel.
 If, however, it is necessary to press off 6th gear wheel, the drive pinion
must be pulled out from hollow shaft.
 Remove temporary locking element preventing drive pinion from slipping out.
2:27:56 AM Page 74
 Pull drive pinion out of hollow shaft -D- collect taper rollers -A- (23 off) when carrying out this step.
 Remove corrugated spring -B- and needle roller assembly -C-.
NOTE: Carefully protect mount from contamination, clean if necessary.
Fig. 181: Checking Pinion/Hollow Shaft Bearing

 Check drive pinion/hollow shaft bearing.
1 - Flange ring (conical contact surface facing taper rollers)
2 - Taper rollers (23 off) with large diameter facing drive pinion head
2:27:56 AM Page 75
3 - Supporting ring (conical contact surface facing taper rollers)
5 - Circlip for taper roller bearings for drive pinion
Fig. 182: Pressing Off Drive Gear For 6th Gear

 Pressing off 6th gear wheel
NOTE: Because of the type of fit, it may be possible to press gear off easily.
 Remove hollow shaft or drive pinion and hollow shaft from bearing plate together with selector rod and
selector fork for 1st and 2nd gears.
Assembling
 Install hollow shaft with selector fork and selector rod for 1st and 2nd gear (without follower) into
bearing plate.
2:27:56 AM Page 76
Fig. 183: Press On To Stop So That There Is No Play

 Heat 6th gear to approx. 100 ° C and install.
 Installation position: Shoulder toward taper roller bearing
 Press fully in until zero play.

 Insert taper roller bearing of drive pinion/hollow shaft with multi-purpose grease.
 Arrangement: Refer to Fig. 181
2:27:56 AM Page 77
A - Flange ring, taper roller (23 off) and supporting ring
B - Corrugated spring
C - Needle roller assembly
D - Hollow shaft
 Oil needle bearing well.

 Insert drive pinion into hollow shaft and secure with hose strap, to prevent it from slipping down.
Fig. 185: Install Synchronizer Ring

 Install relay lever -A- for reverse gear over relay lever bolt. paying attention to pin (for limiting
movement of relay lever relevant to synchro-ring).
 Insert reverse idler gear -B- and engage relay lever with groove on reverse idler gear.
 Insert synchro-ring -C-.
 Installation position: Position flat on synchro-ring circumference to face input shaft (not as yet installed) -
arrow 1-.
 Insert spring.
 Installation position: Hook single angled end into recess on synchro-ring -arrow 2-. Turn double angled
end anti-clockwise and insert into opening on bearing plate -arrow 3-.
2:27:56 AM Page 78

 Insert shaft for reverse idler gear -C-.

 Install retaining plate -A-.
 Installation position: Chamfers of holes for locking pins of synchro-ring face bearing plate
 Insert spring clasp -B- into locking pins of synchro-ring.

 Replace self-locking nut -D- and tighten to 25 Nm.
 Slide input shaft -A- with selector rod and selector fork for 3rd and 4th gear at an angle into bearing plate.
 Selector fork installation position: Rib toward follower. Refer to Input shaft, drive pinion, hollow shaft
and shift lever mechanism in transmission, removing and installing, Item 4-
2:27:56 AM Page 79

 Press inner race -arrow C- for cylinder roller bearing onto input shaft.
 Install circlip -arrow B- using pliers.
Fig. 189: Engage Free End Of Relay Lever Into Notch In Reverse Gear Yoke
 Engage recess in follower for reverse gear with the free end of relay lever -arrow A-.
 Slide selector rod for 5th and 6th through follower for reverse gear in direction of -arrow B-.
2:27:56 AM Page 80
 Slide follower -A- for 1st and 2nd gear onto selector rod and secure with circlips.
 Lubricate selector rods and all bearings of input shaft and drive pinion in transmission housing and
bearing plate with gear oil.

 Lever used input shaft seal carefully out of transmission housing with VW 681.
 Coat sealing surfaces between bearing plate and transmission housing with sealing paste AMV 188 001
02.
 Insert complete bearing plate into transmission housing.
NOTE: When inserting the complete bearing plate, ensure that the selector rods align
with their mounting points.
 Drive in 2 dowel sleeves for bearing plate/transmission housing.

 Tighten bolts in diagonal sequence to 25 Nm.
2:27:56 AM Page 81
 Insert locking bolts for selector rods with sealing paste AMV 188 001 02 and tighten to 50 Nm.
D - Reverse gear
Fig. 193: Identifying Thrust Washer

 Install thrust washer -arrow A- for needle bearing for 6th gear.
 Installation position: Shoulder toward circlip -arrow B-, smooth contact surface to shaft end
 Lubricate needle bearing for 6th sliding gear with gear oil and install.
 Slide on 6th sliding gear with spring and synchro-ring.
 Installation position: The lugs of synchro-ring engage into recesses below in sliding gear.
2:27:56 AM Page 82
Fig. 194: Supporting Input Shaft With Bracket 30-211 A

 Support input shaft with support bridge 30-211 A.
Fig. 195: Installation Location Of Synchronizer Hub For 5th and 6th Gear
Installation position of 5th and 6th gear synchro-hubs:
 Side with projecting face -arrow 1- faces shaft end.

 The input shaft oil bore -arrow 2- and the synchro-hub oil groove -arrow 3- are aligned.
2:27:56 AM Page 83
Fig. 196: Driving On 5th and 6th Gear Synchronizer Hub

 Heat synchro-hub for 5th and 6th gears to approx. 100 ° C, install and drive on up to stop.
 Align markings -arrow 3- on paired synchro -hub -A- and locking collar for 5th and 6th gears -arrow 1-.
 Install locking collar -arrow 1- with selector fork -arrow 2- onto synchro-hub -A-, and at the same time
install follower for 5th and 6th gears -B- onto selector rod -C-.
NOTE:  Selector fork rib -arrow 2- must face toward shaft end.
 When sliding follower onto selector rod for 5th and 6th gear, note holes for
spring pin.
2:27:56 AM Page 84
Fig. 198: Pressing In Spring Pin

 Press in spring pin -A- flush.
NOTE:  Do not drive in spring pin, otherwise selector rod bearing will be damaged.
 Mount spring pin groove in direction of force as shown in illustration.
Fig. 199: Determine Shim For 5th Gear Drive Gear

 Re-determine shim for 5th gear wheel:
 Install spacer sleeve -A- (length 39.6 mm) onto hollow shaft.
 When installing circlip, press indirection of arrow until fully home.
 Measure size between sleeve and installed circlip using depth gauge -B-.
Measured range (mm) Shim thickness (mm)

31.01 to 31.11 1.05
31.11 to 31.21 1.15
2:27:56 AM Page 85
31.21 to 31.31 1.25

31.31 to 31.41 1.35
Fig. 200: Set Selected Shim Onto Hollow Shaft

 Install selected size of shim -arrow- onto hollow shaft.
Fig. 201: Driving On 5th Gear

 Heat 5th gear to approx. 100 ° C, install and drive on up to stop.
 Installation position: Shoulder toward spacer sleeve
2:27:56 AM Page 86
Fig. 202: Redetermine Shim For 5th Gear Drive Gear

 Re-determine circlip for 5th gear wheel:
 Determine and attach the thickest 2nd circlip that will still just fit.
Available circlips

2.32 2.40 2.48
2.34 2.42 2.50
2.36 2.44
2.38 2.46
Fig. 203: Drive On Inner Race Of Needle Bearing For 5th Gear Selector Gear
 Drive on inner race for 5th sliding gear free of axial play.
 Oil needle bearing with gear oil and install.
2:27:56 AM Page 87
 Place synchro-ring for 5th gear in locking collar.

 Slide on 5th sliding gear with spring.
Fig. 204: Installing 1st Inner Race For Four-Point Bearing For Input Shaft Onto Input Shaft And Drive
On Up To Stop
 Heat 1st inner race for four-point bearing (ball bearing side) for input shaft to approx. 100 ° C, install
onto input shaft and drive on up to stop.
 Insert dowel sleeves into bearing plate.

 Install new gasket for end cover.

2:27:56 AM Page 88
 Install end cover and insert securing bolts -arrows B-.
NOTE: Do not tighten bolts at this stage.
 Clean 2 magnets -arrow A- and insert.

 Insert supporting plate. Refer to Fig. 166 and tighten by hand.
 Installation position: Lugs face magnets.
 Tighten bolts for end cover in diagonal sequence.
Fig. 206: Installing 2nd Inner Race Of The 4-Point Bearing (Roller Bearing Side)
 Lubricate 2nd inner race for four-point bearing (roller bearing side) and insert onto input shaft with track
for ball facing four-point bearing of input shaft and drive over hole in end cover.
 Remove support bridge 30-211 A.
Rails
2:27:56 AM Page 89
arrows-.
 Tighten multi-point socket head bolt to 150 Nm.
 Check neutral position of followers.
 Gear gates must align.
Fig. 208: Identifying Oil Diverter

 Use screwdriver to unclip cover for oil collector -3- from oil collector -1- at long end and remove magnet
-2-.
4 - O-ring
5 - Positioning segment
 Clean oil collector.

 Assemble oil collector.

2:27:56 AM Page 90
 Guide oil collector, with supporting arm ahead, from interior of end cover through hole of end cover
sufficiently far -arrow-, so that the new O-ring can be installed onto oil collector from outside.
 Lightly oil new O-ring and insert.

 Insert oil pipe of oil collector in input shaft.
Fig. 210: Turning Oil Diverter Until Positioning Segment Lies In The Recess Of End Cover
 Rotate oil collector until positioning segment is positioned in milled recess of end cover -arrow-.
 Press in oil collector onto stop.
 Slide assembly sleeve -A-, Part No. 01E 311 120, onto selector shaft -B-.
 Installation position: Flat of selector shaft faces downward
2:27:56 AM Page 91
 Insert locking bolts -A- for selector rod with sealing paste AMV 188 001 02 and tighten to 50 Nm.
 Lightly oil new O-ring for selector shaft cover and install.
 Install cover for selector shaft.

 Install bolts -B- (x 3) with sealing paste AMV 188 001 02 and tighten to 25 Nm.
 Push Torsen differential onto splines of hollow shaft.
Fig. 213: Determine Required Shim(s), Press Torsen Differential In Direction Of Arrow
 Press Torsen differential in direction of arrow; measure distance between top edge of bolted end cover
and front edge of outer race of ball bearing for Torsen differential.
 Determine shim(s) required according to table.
The following adjustment shims are available:

7.05 to 7.30 1 1.65
2:27:56 AM Page 92
1 1.45
1 1.20
7.30 to 7.55 1 1.65
1 1.45
1 0.95
7.55 to 7.80 1 1.65
1 1.45
1 0.70
7.80 to 8.05 1 1.65
1 1.45
1 0.45
8.05 to 8.25 2 1.65
8.25 to 8.50 1 1.65
1 1.45
8.50 to 8.75 1 1.65
1 1.20

8.75 to 9.00 1 1.65
1 0.95
9.00 to 9.25 1 1.65
1 0.70
9.25 to 9.50 1 1.65
1 0.45

 Insert dished washer -C- into bearing housing.
 Install shims determined from table -B-.
2:27:56 AM Page 93
 Install spring -A- onto end of flanged shaft.

 Lightly oil new O-ring for bearing housing and insert.
 Oil small needle bearing in drive pinion.
 Insert complete bearing housing and pre-tighten evenly.

 Tighten bolts in diagonal sequence.
 Pack space between sealing lip and dust lip of new seal for input shaft with sealing grease.

 Tap in input shaft seal.

 Install release bearing, clutch release lever and guide sleeve. Refer to Clutch release mechanism,
servicing.
 Install connecting rod.
 Top off manual transmission with gear oil and check oil level. Refer to Transmission oil level, checking.
BEARING HOUSING, DISASSEMBLING AND ASSEMBLING
Bearing housing, disassembling and assembling
2:27:57 AM Page 94
 VW 295a Adapter

 VW 415 A Tube
2:27:57 AM Page 95
 VW 416 B Tube
 VW 457 Mounting rail

 2005 Drift
2:27:57 AM Page 96
Fig. 218: Thrust Pad 2007

 Thrust pad 2007

2:27:57 AM Page 97
Fig. 219: Bearing housing, Overview

1 - Flanged shaft
 Pressing out. See Pressing out flanged shaft

 Pressing in. See Pressing cylinder roller bearing for input shaft into end cover
 Pressing off. See Pressing off vibration damper

 Pressing on. See Pressing on vibration damper
3 - Seal
 Pulling out. See Removing seal
2:27:57 AM Page 98
 Preparing for installation. See Preparing seal for installing

 Tapping in. See Inserting seal
4 - Bearing housing
5 - O-ring
 Replace
 Coat lightly with gear oil when installing
6 - Ball bearing
 For flanged shaft

 Pressing out. See Pressing out ball bearing for flanged shaft
 Pressing in. See Pressing in ball bearing for flanged shaft
7 - Circlip
Pressing out flanged shaft

 Remove circlip before pressing out flanged shaft.
Pressing in flanged shaft
2:27:57 AM Page 99

 Press on vibration damper before pressing in flanged shaft. See Pressing on vibration damper.
Pressing off vibration damper
Fig. 222: Pressing Off Vibration Damper

Pressing on vibration damper
2:27:57 AM Page 100

Fig. 223: Pressing On Vibration Damper

NOTE: Observe position of holes.
Removing seal

Preparing seal for installing
2:27:57 AM Page 101


A - Washer
Part no. 016 311 391 B (1.7 mm thick)
B - Seal
 Install washer and seal onto tool as illustrated.
 Installation position: Open side of seal faces toward bearing housing
Inserting seal

 Remove washer.
Pressing out ball bearing for flanged shaft
2:27:57 AM Page 102


Pressing in ball bearing for flanged shaft

MOUNT FOR TORSEN DIFFERENTIAL, SERVICING
Mount for Torsen differential, servicing
2:27:57 AM Page 103



2:27:57 AM Page 104

 3116 Spring pin

NOTE: The shims for Torsen differential have to be re-determined after replacing
following components. Refer to Fig. 213:
2:27:57 AM Page 105


 End cover
 Inner race for needle bearing
 Torsen differential
 Torsen differential ball bearing
1 - Ball bearing

 Pressing off. See Pressing off ball bearing from Torsen differential
2:27:57 AM Page 106

 Servicing only at manufacturer

3 - Inner race
 For Torsen differential needle bearing

 Pulling off. See Pulling off inner race for Torsen differential needle bearing
 Pressing on. See Pressing on inner race for Torsen differential needle bearing
4 - Needle bearing
2:27:57 AM Page 107

 For drive pinion/Torsen differential

 Pulling out. See Removing needle bearing for drive pinion/Torsen differential
 Pressing in. See Inserting needle bearing for drive pinion/Torsen differential
Pressing off ball bearing from Torsen differential

Installation position: Thrust pad 3118 with shoulder facing press tool VW 412
Pulling off inner race for Torsen differential needle bearing
2:27:57 AM Page 108

Fig. 235: Pulling Off Inner Race Of Torsen Differential Needle Bearing
A - Inner race
B - Separating tool 22 to 115 mm, e.g. Kukko 17/2
Pressing on inner race for Torsen differential needle bearing
Fig. 236: Pressing On Inner Race Of Torsen Differential Needle Bearing

Removing needle bearing for drive pinion/Torsen differential
2:27:57 AM Page 109

Fig. 237: Pulling Out Needle Bearing For Pinion/Torsen Differential

B - Counter support, e.g. Kukko 22/1
Inserting needle bearing for drive pinion/Torsen differential
Fig. 238: Pressing In Needle Bearing For Pinion/Torsen Differential

 Pressing in needle bearing flush with inner edge.
END COVER, SERVICING
End cover, servicing
2:27:57 AM Page 110

Fig. 239: Identifying Special Tools - End Cover, Servicing


 VW 415 A Tube

 2006 A Supporting ring
2:27:57 AM Page 111


2:27:57 AM Page 112

Fig. 241: End Cover, Overview

1 - End cover
 Re-determine shims for Torsen differential. Refer to Fig. 213
 Pressing out. See Pressing cylinder roller bearing for input shaft out of end cover
 Pressing in flush. See Pressing cylinder roller bearing for input shaft into end cover
4 - Four-point bearing for input shaft
2:27:57 AM Page 113

5 - Circlip
 Re-determining thickness. Refer to Available circlips

6 - Baffle plate
 Replace
 Installing and peening in position when replacing four-point bearing for input shaft. See Peening baffle
plate in position when replacing ball bearing for input shaft
 Installing and peening in position when replacing end cover. See Peening baffle plate in position when
replacing end cover
7 - Needle bearing

 Pulling out. See Removing needle bearing for Torsen differential from end cover
 Tapping in. See Insert needle bearing of Torsen differential flush in end cover.
Pressing cylinder roller bearing for input shaft out of end cover
Fig. 242: Pressing Roller Bearing For Input Shaft Out Of End Cover
B - Counter support spindle, e.g. Kukko 22/2
2:27:57 AM Page 114

Pressing cylinder roller bearing for input shaft into end cover
Fig. 243: Pressing Roller Bearing For Input Shaft Into End Cover
Shoulder of pipe section VW 415 A faces toward press tool VW 412.
Removing ball bearing for input shaft out of end cover
Fig. 244: Set Screwdriver In Place As Shown, Drive It Into Baffle Ring And Pry It Out
 Position screwdriver as illustrated, drive into baffle plate -arrow- and lever out.
 Remove circlip.
 Take out bearing, remove peening indentations if necessary.
Installing ball bearing for input shaft in end cover
2:27:57 AM Page 115

Fig. 245: Installation Position Of Circlip

Installation position of circlip:
 Ends of circlip -arrows- face toward roller sleeve for drive pinion.
NOTE: The thickness of the circlip must be re-determined if the bearing or the end
cover are replaced.
 Determining thickness of circlip for four-point bearing for input shaft:
 Press outer race of four-point bearing onto stop.

 Axial play: no more than 0.08 mm
Available circlips
2.55 2.65
2.60 2.70
Peening baffle plate in position when replacing ball bearing for input shaft
2:27:57 AM Page 116

Fig. 246: Peening Baffle Ring When Replacing 4-Point Bearing For Input Shaft
 Use a blunt punch with a ball-shaped end (ball-diameter 5 mm) to peen in position.
 First peen at points marked with -arrows 1-.
 Then peen at points marked with -arrows 2- at distance -a- from first position.
Peening baffle plate in position when replacing end cover
2:27:57 AM Page 117

Fig. 247: Peening Baffle Ring When Replacing End Cover

 Use a blunt punch with a ball shaped end (ball-diameter 5 mm) to peen in position.
 Peen in first peening point -arrow- at distance -d- from the center line of the two shafts.
 Dimension d = 10 mm
 Peen in second and third peening points in same manner at distance -a-.
Removing needle bearing for Torsen differential from end cover
2:27:57 AM Page 118

Fig. 248: Pulling Torsen Differential Needle Bearing Out Of End Cover
B - Spindle from counter support, e.g. Kukko 22/2
Insert needle bearing of Torsen differential flush in end cover.
Fig. 249: Driving Torsen Differential Needle Bearing Flush Into End Cover
 Install pressure plate VW 412 onto bearing with shoulder facing up.
BEARING PLATE, SERVICING
Bearing plate, servicing
2:27:57 AM Page 119

Fig. 250: Identifying Special Tools - Gear Carrier, Servicing


 30-504 Press tool

 Depth gauge
2:27:57 AM Page 120


1 - Bearing plate
2 - Outer race/small taper roller bearing for drive pinion
 Driving out. Refer to Driving out outer race for small taper roller bearing
 Pressing in. Refer to Pressing in outer race/small taper roller bearing
3 - Shim S4
2:27:57 AM Page 121

 Re-determining thickness. Refer to Re-determining shim S4
 Pressing out. See Pressing cylinder roller bearing for input shaft out of bearing plate
 Pressing in. See Pressing cylinder roller bearing for input shaft into bearing plate
 Measuring insertion depth. See Measuring insertion depth of cylinder roller bearing for input shaft

5 - Ball sleeves
 4 pieces
 Removing and driving in. See Driving out and driving in ball sleeves for selector rods
2:27:57 AM Page 122

For follower for reverse gear:
 Pulling out. See Pulling ball sleeve out of follower for reverse gear
 Tapping in. See Driving ball sleeve flush into follower for reverse gear
6 - Bolt, 35 Nm
 For relay lever
7 - Dowel pin (7 x 28)
 Drive in and drive out with drift
 With locking pins

 Installation position: Position flat on synchro-ring circumference to face input shaft. Refer to Fig. 185
2:27:57 AM Page 123


10 - Spring
 Installation position: Hook single angled end into recess on synchro-ring. Turn double angled end anti-
clockwise and insert into opening on bearing plate
11 - Reverse idler gear axle
 Installation position: Chamfers of holes for locking pins of synchro-ring face bearing plate. Refer to Fig.
186
13 - Spring clasp
2:27:57 AM Page 124

14 - Bolt, 25 Nm
 Self-locking
 Always replace

15 - Relay lever for reverse gear
 Pulling out ball sleeve. See Pulling ball sleeve out of follower for reverse gear
 Driving in ball sleeve. See Driving ball sleeve flush into follower for reverse gear
2:27:57 AM Page 125

 Replace only together with follower. Refer to 5th and 6th gear, removing and installing, Item 6
Driving out and driving in ball sleeves for selector rods
Fig. 255: Driving Selector Rod Ball Sleeves Out And In

 Insertion depth a = 2.5 mm

 Press synchro-ring onto reverse idler gear cone and measure gap "a" with feeler gauge.
 Dimension, new: 0.75 to 2.3 mm

 Wear limit: 0.2 mm
Pulling ball sleeve out of follower for reverse gear
2:27:57 AM Page 126

Fig. 257: Pulling Reverse Gear Ball Sleeve Out Of Yoke

A - Counter support, e.g. Kukko 22/1
B - Internal extractor 14.5 to 18.5 mm, e.g. Kukko 21/2
Driving ball sleeve flush into follower for reverse gear
Fig. 258: Driving Ball Sleeve Flush Into Reverse Gear Yoke
2:27:57 AM Page 127

Pressing cylinder roller bearing for input shaft out of bearing plate
Pressing cylinder roller bearing for input shaft into bearing plate
 Measuring insertion depth. See Measuring insertion depth of cylinder roller bearing for input shaft
Measuring insertion depth of cylinder roller bearing for input shaft
2:27:57 AM Page 128

Fig. 261: Measuring Press-In Depth Of Input Shaft Roller Bearing

Dimension a = 7 mm
Re-determining shim S4
Fig. 262: VW 385/32 End Measuring Plate

 VW 385/32 End measuring plate
2:27:57 AM Page 129


 3116 Spring pin

 Digital depth gauge accurate to within at least 5/100 mm.
Determining New Shim S 4, Overview
2:27:57 AM Page 130


This procedure must be carried out when replacing the following components:
 Bearing plate. Refer to Determining thickness of shim when replacing bearing plate
 Hollow shaft. Refer to Determining thickness of shim when replacing hollow shaft
The procedure restores the required preload of the taper roller bearings for the drive pinion and hollow shaft.
1 - Shim S4
2 - Bearing plate
2:27:57 AM Page 131

4 - Hollow shaft
5 - Taper roller bearing of drive pinion/hollow shaft
6 - Pinion shaft

a - Bearing plate housing depth
b - Dimension from drive pinion head to shoulder of taper roller bearing on hollow shaft
 Taper roller bearing (drive pinion/hollow shaft) pre-tensioned to 10 Nm
S4 - Thickness of shim S4
2:27:58 AM Page 132

NOTE: When replacing the drive pinion (final drive set), observe adjustment overview.
Refer to Adjustment overview.
Determining thickness of shim when replacing bearing plate
Fig. 266: Measuring Difference In Depths Between Old And New Gear Carriers
 Measure difference of depth "a" on old and new bearing plates.
Example:
Depth "a" of old bearing plate 124.40 mm

Depth "a" of new bearing plate 124.65 mm
 If new bearing plate is deeper, install a thicker S4 shim.

 If old bearing plate was deeper, install a thinner S4 shim.
Example:
Previous shim S4 0.95 mm

Difference +0.25 mm
New shim S4 = 1.20 mm
Available shims. Refer to table. Refer to Available shims for S4.
Determining thickness of shim when replacing hollow shaft
 Use a caliper gauge accurate to within at least 5/100 mm.
2:27:58 AM Page 133

Fig. 267: Tighten Clamping Sleeve To Exactly 10 Nm

 Tighten spring pin to exactly 10 Nm.
A - Vice clamps

 Place end measuring plate VW 385/32 onto drive pinion head and measure dimension "d".
 Top measuring point is shoulder for inner race of small taper roller bearing.
 Install new hollow shaft and once again measure dimension "d".
2:27:58 AM Page 134


 Determine the difference:
Dimension "d" of old hollow shaft 248.50 mm

Dimension "d" of new hollow shaft 248.70 mm
 Install appropriately thinner shim S4 if dimension "d" of new hollow shaft is larger.
 Install appropriately thicker shim S4 if dimension "d" of new hollow shaft is smaller.
Shim thickness (mm)

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Different tolerances make it possible to obtain the exact shim thickness required, if necessary, install 2 shims.
2:27:58 AM Page 135



 VW 423 Tube

2:27:58 AM Page 136



 40-503 Inserting drift

 Depth gauge
 Assembly sleeve Part No. 01E 311 120
1) Adjustments are required if these components are replaced. Refer to Adjustment overview: Refer to
2:27:58 AM Page 137


1 - Seal for flanged shaft
 Pulling out. See Pulling out seal for flanged shaft

 Tapping in. See Driving in seal for flanged shaft
 Pack space between sealing lips with sealing grease
 Replacing with transmission installed. Refer to Removing input shaft seal when transmission is not
disassembled
2 - Cover1)
 For final drive
3 - O-ring
2:27:58 AM Page 138

 For cover for final drive

 Always replace
4 - Shim S1
 Note thickness

 Removing and installing. Refer to Driving outer race for large taper roller bearing out of coverand
2:27:58 AM Page 139

 Removing and installing. Refer to Driving outer race for small taper roller bearing out of
transmission housing and Pressing outer race for small taper roller bearing into transmission
housing
7 - Shim S2
 Note thickness
8 - Seal
 For input shaft

 Levering out. See Levering out input shaft seal when transmission is disassembled
 Tapping in. See Drive in input shaft seal flush
 Always replace when removing input shaft
 Replacing when transmission is not disassembled. See Removing input shaft seal when transmission is
not disassembled and Drive in input shaft seal flush
10 - Ball sleeve for selector shaft
 Pulling out. See Pulling out ball sleeve

 Tapping in. See Driving in ball sleeve
11 - Ball sleeves for selector rods
 Pulling out as -Item 10 Transmission housing, servicing. See Pulling out ball sleeve
 Driving in as -Item 10 Transmission housing, servicing. See Driving in ball sleeve
12 - Circlip
 Installation position: Eyes facing up
13 - Switch for reversing light, 20 Nm
 Removing and installing. See Removing and installing reversing light switch
14 - O-ring
2:27:58 AM Page 140


 Always replace


16 - Ball stud, 20 Nm
 For connecting rod
2:27:58 AM Page 141

 For drive pinion

 Pulling out. Refer to Pulling out large taper roller bearing outer race
 Pressing in. Refer to Heating transmission housing in order to install outer race for taper roller
bearing
18 - Circlip
 Removing. See Removing circlip
19 - Shim S3
 Note thickness
2:27:58 AM Page 142


20 - Needle bearing for input shaft
 Pulling out. See Pulling needle bearing out of transmission housing

 Tapping in. See Driving needle bearing into transmission housing
 Measuring insertion depth. See Insertion depth of needle bearing
21 - Locking bolt for selector shaft, 50 Nm

 Insert in transmission housing with sealing paste AMV 188 001 02
22 - Trunnion bolt, 40 Nm
 For push rod
23 - Breather
 Insertion depth of sleeve. See Insertion depth of breather sleeve

 Clip cap on
2:27:58 AM Page 143


24 - Selector shaft seal
 Can be replaced when transmission is removed but not disassembled

 Always replace
 Pulling out. See Pulling out selector shaft seal
 Tapping in. See Driving in selector shaft seal
 Always use assembly sleeve for installing. See Installing seal and selector shaft with assembly sleeve
26 - Solenoid
2:27:58 AM Page 144

 Clean
 Drive in (for example, with press tool VW 408 A) when replacing transmission
27 - Speedometer vehicle speed sensor -G22-
 Replacing. Refer to Speedometer vehicle speed sensor -G22-, removing and installing
28 - O-ring
 Always replace
Pulling out seal for flanged shaft
NOTE:  Figure shows removing seal on right-hand side of transmission.

Driving in seal for flanged shaft
2:27:58 AM Page 145


NOTE:  Figure shows installing seal on right-hand side of transmission.

employed.
Levering out input shaft seal when transmission is disassembled

Removing input shaft seal when transmission is not disassembled

2:27:58 AM Page 146

Drive in input shaft seal flush

 Pack new seal for input shaft between sealing lip and dust lip half full with sealing grease.
Pulling out ball sleeve

 Remove circlip.
A - Internal extractor 14.5 to 18.5 mm, e.g. Kukko 21/2
2:27:58 AM Page 147

Driving in ball sleeve

 Install ball sleeve with the inscribed side (thicker metal) facing the drift.
 Drive in onto stop.
Pulling out selector shaft seal

NOTE: With transmission removed but not disassembled, carefully lever out seal
without damaging the shaft with a screwdriver.
2:27:58 AM Page 148


 Selector shaft installed or removed
 Pull assembly sleeve onto selector shaft. See Installing seal and selector shaft with assembly sleeve
 Drive seal into housing onto stop.
Installing seal and selector shaft with assembly sleeve
 To avoid damaging seal -C- always use assembly sleeve -A-, Part No. 01E 311 120, to install seal or
selector shaft.
Insertion depth of breather sleeve
2:27:58 AM Page 149

Fig. 287: Press-In Depth Of Breather Sleeve

Removing and installing reversing light switch
Fig. 288: Removing And Installing Back-Up Light Switch

 Tighten reversing light switch -A- to 20 Nm when installing.
Pulling needle bearing out of transmission housing
2:27:58 AM Page 150

Fig. 289: Pulling Needle Bearing Out Of Transmission Housing

Driving needle bearing into transmission housing
Fig. 290: Driving Needle Bearing Into Transmission Housing

 Installation position: Inscription on bearing faces drift

 Insertion depth. See Insertion depth of needle bearing
Insertion depth of needle bearing
2:27:58 AM Page 151

Fig. 291: Drive-In Depth Of Needle Bearing

Removing circlip
Fig. 292: Removing Circlip

 Lift circlip out of the groove by turning one end of circlip with a screwdriver -A-.
 Secure this end with a screwdriver -B-.
 Lever circlip out further by repositioning screwdriver -A-.
Selector shaft, disassembling and assembling
2:27:58 AM Page 152

Fig. 293: Selector Shaft, Completely Disassembling And Assembling

1 - Selector cylinder
2 - Spring pin
 Removing and driving in flush. See Removing and installing spring pin flush
 Installation position of spring sleeve: Slot longitudinal to line of force
3 - Selector shaft
 Tapping out. See Driving out selector shaft

 Tapping in. See Driving in selector shaft
 Installation position: Flat (arrow) and selector finger -Item 4 face in same direction
2:27:58 AM Page 153

4 - Selector finger
 Observe installation position to -Item 3
5 - Toggle for reversing light switch
Removing and installing spring pin flush
Fig. 294: Driving Out Spring Pin/Roll Pin And Driving In Flush
A - Drift
B - Vice clamps
Driving out selector shaft
Fig. 295: Driving Out Selector Shaft

A - Drift
B - Vice clamps
2:27:58 AM Page 154

Driving in selector shaft
Fig. 296: Driving In Selector Shaft

A - Wooden packing
NOTE:  Bring selector shaft/selector cylinder bores into alignment.

 Flat on selector shaft and selector finger point in same direction.
2:27:58 AM Page 155



 VW 519 Tube
 Feeler gauge
NOTE:
2:28:46 AM
2:29:03 Page 1

 When installing new gears or the input shaft consult technical data. Refer
to Code letters, mechanical unit assignment, transmission ratios,
capacities.
2 - Needle bearing
 For input shaft

 Pulling out. Refer to Pulling needle bearing out of transmission housing
 Driving in. Refer to Driving needle bearing into transmission housing
2:28:47 AM Page 2
3 - Circlip
 For needle bearing
4 - Circlip
 For input shaft
5 - Thrust washer

6 - Needle bearing
 For 5th gear
2:28:47 AM Page 3

 Do not interchange with needle bearing for 3rd gear
9 - Locking collar

2:28:47 AM Page 4

10 - Circlip
 When replacing synchro-hub, re-determine thickness. See Determining thickness of circlip

 Installation position: Ends align with groove of synchro-hub
11 - Synchro-hub for 3rd and 4th gear
 Pressing off. See Pressing off synchro hub for 3rd and 4th gear
 Installation position. See Installation position of synchro-hub
 Pressing on. See Pressing on synchro hub for 3rd and 4th gear
2:28:47 AM Page 5

13 - 3rd sliding gear

 After pressing on -Item 11 check axial play using feeler gauge (0.15 to 0.35 mm)

14 - Needle bearing
 For 3rd gear

2:28:47 AM Page 6
 Do not interchange with needle bearing for 4th gear

15 - Input shaft
16 - Spring pin
 Replace
 Drive in when replacing input shaft. See Driving spring sleeve into input shaft
17 - Cylindrical roller bearing
 For input shaft

 Pressing out. Refer to Pressing cylinder roller bearing for input shaft out of bearing plate
 Pressing in. Refer to Pressing cylinder roller bearing for input shaft into bearing plate
18 - Bearing plate
2:28:47 AM Page 7

19 - Inner race

 Remove and install by hand
20 - Circlip
21 - Thrust washer

 Installation position: Shoulder toward circlip, smooth face contact surface toward needle bearing. Refer to
Fig. 193
2:28:47 AM Page 8
22 - Needle bearing
 For 6th gear


 After installing, check axial play. Refer to Fig. 197

2:28:47 AM Page 9
25 - Synchro-hub for 5th and 6th gear

 Installation position: Projecting hub toward 5th sliding gear
26 - Locking collar


 After installing, check axial play. Refer to Assembling
2:28:47 AM Page 10

29 - Inner race for needle bearing
 For 5th sliding gear

30 - Needle bearing
 For 5th gear

2:28:47 AM Page 11
 Ball bearing side

32 - End cover
33 - 2nd inner race for ball bearing


Inserting spring in sliding gear
Fig. 305: Inserting Spring Into Selector Gear

The bent end of the spring (arrow) must be hooked in the hole in the sliding gear.
2:28:47 AM Page 12

 Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -
C-.
 Add the measured values and divide by 3.
 The calculated value must not be less than 0.5 mm.

 Synchro-hub pressed onto stop
NOTE: The opening of circlip must align with groove in synchro-hub.
2:28:47 AM Page 13
1.90 1.96 2.02

1.93 1.99 2.05
Pressing off synchro hub for 3rd and 4th gear
Fig. 308: Pressing Off Synchronizer Hub For 3rd And 4th Gear
Installation position of synchro-hub
Fig. 309: Installed Position Of Synchronizer Hub

Oil groove in synchro-hub -arrow 1- must align with oil drilling -arrow 2- in input shaft
Pressing on synchro hub for 3rd and 4th gear
2:28:47 AM Page 14
Fig. 310: Pressing On Synchronizer Hub For 3rd And 4th Gear
 Heat synchro-hub to approx. 100 ° C, position and press home.
 Determine circlip and install. See Determining thickness of circlip.
Driving spring sleeve into input shaft
Fig. 311: Driving Roll Pin Into Input Shaft

 Guide a 9 mm diameter drift -A- into oil drilling and drive spring sleeve -B- in until it touches drift.
2:28:47 AM Page 15
DRIVE PINION AND HOLLOW SHAFT, DISASSEMBLING AND ASSEMBLING
Drive pinion and hollow shaft, disassembling and assembling
 VW 295 Drift
2:28:47 AM Page 16
 VW 415 A Tube
 VW 457 Mount rails
 2003/3 Inserter ring

2:28:47 AM Page 17
 3118 Tube
 3138 Drift
 VAG 1416 Hot-air blower
 1 - Internal puller 21/1
NOTE:
2:28:47 AM Page 18

 When installing new gears or the final drive set consult technical data.
Refer to Code letters, mechanical unit assignment, transmission ratios,
capacities.
2 - Shim S3
2:28:47 AM Page 19
 Pulling out. See Pulling out large taper roller bearing outer race
 Pressing in. See Inserting outer race for large taper roller bearing in transmission housing and
pressing home
4 - Drive pinion1)
 Is mated with ring gear, replace together as a set

 Adjusting drive pinion and ring gear. Refer to General notes

5 - Needle bearing
2:28:47 AM Page 20
 For flanged shaft/drive pinion

 Pulling out. See Removing needle bearing for flanged shaft/drive pinion
 Tapping in. See Inserting needle bearing for flanged shaft/drive pinion flush
 Pressing off. See Pressing off large taper roller bearing inner race
7 - Circlip
8 - Flange ring
9 - Taper rollers
 23 pieces
10 - Supporting ring
2:28:47 AM Page 21

12 - Needle bearing
 For drive pinion/hollow shaft

13 - Hollow shaft 1)
 With gear wheels for 3rd and 4th gear
14 - Needle bearing
 For 2nd sliding gear

2:28:47 AM Page 22
15 - 2nd sliding gear
 Before installing, insert spring and slide needle bearing onto hollow shaft
 After installation, check axial play using feeler gauge (0.15 to 0.35 mm)


17 - Synchro-hub for 1st and 2nd gear
2:28:47 AM Page 23
 Pressing on. See Installing 2nd sliding gear, pressing on synchro-hub for 1st and 2nd gear
 Installation position: Flush hub toward 2nd sliding gear
18 - Circlip
sliding gear
19 - Washer
 For needle bearing for 1st sliding gear

sliding gear
20 - Locking collar, 1st and 2nd gear
 Installation position: Splines for reverse gear facing synchro-ring for 2nd gear
2:28:47 AM Page 24

22 - Needle bearing
 For 1st sliding gear

23 - 1st sliding gear
 Before installing, insert spring. Refer to Inserting spring in sliding gear

 After pressing on -Item 24, check axial play using feeler gauge (0.15 to 0.35 mm)
 Pressing off. See Pressing off inner race of small taper roller bearing together with 1st sliding gear
2:28:47 AM Page 25
 Tapping out. See Driving out outer race for small taper roller bearing
 Pressing in. See Pressing in outer race/small taper roller bearing
26 - Shim S4

2:28:47 AM Page 26
27 - Bearing plate 1)
28 - 6th gear wheel

 Installation position: Shoulder faces toward inner race of small taper roller bearing
29 - Spacer sleeve
30 - Washer
31 - 5th gear wheel

32 - Circlip
 For 5th gear wheel

33 - End cover
Pulling out large taper roller bearing outer race
Fig. 321: Pulling Out Outer Race Of Large Tapered Bearing

2:28:47 AM Page 27
Stepped side of thrust pad 3062 rests against the outer race
Heating transmission housing in order to install outer race for taper roller bearing
 Heat transmission housing in area of bearing seat for approx. 15 minutes, to approx. 100 ° C, with a hot
air blower.
Inserting outer race for large taper roller bearing in transmission housing and pressing home
Fig. 323: Inserting And Pressing Outer Race Of Large Taper Roller Bearing Into Transmission Housing
 Insert outer race only after heating transmission housing and push into position under workshop press
2:28:47 AM Page 28
Removing needle bearing for flanged shaft/drive pinion

A - Internal extractor 12 to 14.5 mm, e.g. Kukko 21/1
Inserting needle bearing for flanged shaft/drive pinion flush

Pressing off large taper roller bearing inner race
2:28:47 AM Page 29
Fig. 326: Pressing Off Inner Race Of Large Taper Roller Bearing
Bearing is destroyed when pressing off.

2:28:47 AM Page 30

 Determine the thickest circlip that will still just fit and install.

2.34 2.40 2.46
2.36 2.42 2.48
2.38 2.44
Pressing off inner race of small taper roller bearing together with 1st sliding gear
2:28:47 AM Page 31
Fig. 329: Pressing Off Inner Race Of Small Taper Roller Bearing Together With Selector Gear Of 1st
Gear
NOTE: Do not press off together with synchro-hub for 1st and 2nd gear and 2nd gear
sliding wheel.


 Install circlip, washer for 1st/2nd gear synchro-hub, synchro-ring for 1st gear and 1st sliding gear together
with spring and needle bearing.
2:28:47 AM Page 32
NOTE:  Press down only on bearing inner race with collar of thrust pad 3118.
 Position shoulder of pipe section VW 415 A facing up toward press tool
VW 412
 After pressing on, check axial play of 1st sliding gear.
Removing and installing circlip of synchro-hub and washer of 1st sliding gear
Fig. 331: Removing And Installing Circlip For Synchronizer Hub And Shim For 1st Gear Selector Gear
 To remove circlip, remove washer -A- and then circlip -B-.

 To install circlip, install on circlip -B- and then washer -A-.
Pressing off 2nd gear sliding wheel with synchro-hub for 1st and 2nd gear
Fig. 332: Pressing Off 2nd Gear Selector Gear With 1st And 2nd Gear Synchronizer Hub
 Remove locking collar for 1st and 2nd gear and synchro-ring for 1st gear.
 Remove washer and circlip for synchro-hub.
 Press off 2nd speed sliding wheel with synchro-hub for 1st and 2nd gear
2:28:47 AM Page 33
NOTE: Do not press off together with 1st sliding gear and inner race of small taper
roller bearing.
Installing 2nd sliding gear, pressing on synchro-hub for 1st and 2nd gear
Fig. 333: Identifying Special Tools - Installing Selector Gear For 2nd Gear And Pressing On
Synchronizer Hub For 1st And 2nd Gear
 Install needle bearing, sliding gear (with spring) and synchro-ring for 2nd gear.
 Heat synchro-hub to approx. 100 ° C and install.
NOTE:  Install on pipe section VW 415 A with shoulder facing synchro-hub.

 Position thrust pad 3118 with shoulder facing press tool VW 412.
Determining size of circlip for synchro-hub for 1st and 2nd gear
2:28:47 AM Page 34
Fig. 334: Determining Thickest Circlip That Can Just Still Be Installed
 Determine the thickest circlip that will still just fit.

 Insert circlip in direction of arrow to synchro-hub.

1.90 1.96 2.02
1.93 1.99
Driving out outer race for small taper roller bearing
Fig. 335: Driving Out Outer Race Of Small Taper Roller Bearing
Pressing in outer race/small taper roller bearing
2:28:47 AM Page 35

 Insert shim S4 into bearing plate behind bearing seat.

 Position thrust pad 3062 with shoulder facing press tool VW 407.
 Pressing in outer race for small taper roller bearing onto stop
2:28:47 AM Page 36

FLANGED SHAFT SEALS, REPLACING


 2062 Driver
 Container
Removing
2:29:34 AM
2:29:39 Page 1
When replacing left seal:
 If necessary, partially remove the front part of the exhaust system.
Refer to
ENGINE CODE(S): BHF
Continuation for both seals:

 Remove splash plate, if installed, above drive axles (arrows).

 Detach drive axles -1- from flanged shafts, and tie up as high as possible; do not damage surface
protection.
 Unscrew flanged shaft securing bolt; for this purpose, screw two bolts into the flange and counterhold the
flanged shaft using a tire lever.
2:29:34 AM Page 2
Installing

 Drive in new seal for right-hand flanged shaft to a depth of 5.5 mm below surface of housing and for left-
hand flange to a depth of 5.5 below surface of cover.
NOTE:  Figure shows installation on right-hand side of the transmission.

 Do not cant seal when driving in.
employed.
2:29:34 AM Page 3
 Insert flanged shaft.

 Fasten flanged shaft with cone head bolt.
 Bolt drive axle to flanged shaft.
 Bolt on cover plates for drive axle if present.

 If necessary, reinstall exhaust system and align free of stress.
Refer to
ENGINE CODE(S): BHF
 Install shield.
Tightening torques
Component Nm
Flanged shaft to transmission 10 + 90 °
Drive axle heat shields 23
DRIVESHAFT FLANGE AT TRANSMISSION, REPLACING SEAL AND GROOVED BALL

BEARING
Driveshaft flange at transmission, replacing seal and grooved ball bearing
2:29:34 AM Page 4
Replacing
 VW 295a Adapter
 VW 415 A Tube
 VW 416 B Tube
2:29:34 AM Page 5
Replacing

 2005 Drift
2:29:34 AM Page 6
Fig. 344: Driveshaft Flange Seal And Grooved Ball Bearing At Transmission, Overview
1 - Transmission
3 - Bearing housing at vibration damper
4 - Seal
 Driving in. Refer to Fig. 354
5 - Flanged shaft
6 - Bolt, 25 Nm
2:29:34 AM Page 7
 6 pieces
7 - O-ring
 Always replace
8 - Circlip
9 - Dished washer
 Mark installation position when removing: Large diameter (concave side) facing shims -Item 10
10 - Washers
11 - Spring

Removing
it may be damaged.
 Remove exhaust system from the clamps.

 Detach rear part of exhaust system from hangers and remove.
2:29:34 AM Page 8

 Unbolt heat shield for driveshaft -arrows-.



 Unscrew rear oil drain plug (at end cover) and drain gear oil.
 Unscrew bolts attaching bearing housing.
NOTE: Bearing housing is pressed slightly off end cover by spiral spring when
mounting bolts are loosened.
2:29:34 AM Page 9
Fig. 348: Pull Off Flange Shaft

 Pull flanged shaft together with bearing housing and vibration damper off end cover.
 Remove bearing housing.
 Remove circlip from flanged shaft.

 Press out flanged shaft.
2:29:34 AM Page 10

 Pull out flanged shaft seal.

 Thoroughly clean seat for seal.

 Press out grooved ball bearing.
Installing
2:29:34 AM Page 11

 Press grooved ball bearing into bearing housing.

 Lightly oil diameter of seal -B-.

 Install seal together with washer -A- Part No. 016 311 391 B (thickness 1.7 mm) onto drift 2005.
 Installation position: Open side of seal faces toward transmission.
2:29:34 AM Page 12

 Drive in flanged shaft seal.
 Remove washer after inserting seal.


 Press in flanged shaft.

 Install circlip onto flanged shaft.
 Lightly oil O-ring and insert into groove of bearing housing.
 Insert dished washer and shims into bearing housing.
 Installation position. Refer to Item 9.
2:29:34 AM Page 13
 Install spiral spring onto flanged shaft.

 Tighten bolts attaching bearing housing in stages and diagonally.
 Bolt on driveshaft.
SPEEDOMETER VEHICLE SPEED SENSOR -G22- AND TRIGGER WHEEL, REMOVING AND
INSTALLING

 Remove splash plate above left drive axle -1- if installed (arrows).
Fig. 357: Identifying Vehicle Speed Sensor (VSS)
2:29:34 AM Page 14
 Unplug connector from sender -B-.

 Press retaining clip down, turn sender sideways and pull out upward.
Installing
 Replace O-ring -A-.

 Handle sender carefully. If it is damaged it is possible that the speedometer will not indicate exactly.
Tightening torques
Component Nm
Heat shield for drive axle 23 Nm
Trigger wheel for speedometer vehicle speed sensor -G22-, removing and installing

2:29:34 AM Page 15


 Container
Removing
 Partially remove front part of exhaust system.
Refer to
ENGINE CODE(S): BHF
2:29:34 AM Page 16

 If installed, remove splash plate above left drive axle -1- (arrows).
 Unbolt drive axle from flanged shaft.
 Place drip tray underneath transmission.

 Remove fastening screw -A- for flanged shaft -B-.

 Pull out flanged shaft seal -C- with VW 681.
Remove speedometer trigger wheel -D-:
 Lever out the trigger wheel from the grooves in the differential at the drive pegs -arrows- on alternate
sides.
Installing
Installation is carried out in the reverse order to removal, noting the following:
2:29:34 AM Page 17

The drive pegs -arrows- of the trigger wheel -D- must engage in the grooves of the differential.
 Drive in seal -C- for flanged shaft and install flanged shaft.
Tightening torque:
Component Nm
Drive axle heat shield 23
NOTE: The differential can be removed and installed with the transmission installed.
2:29:34 AM Page 18

1 - Bolt, 10 Nm and turn 90 ° further
2 - Flanged shaft
 When removing, secure with a drift to prevent it turning
3 - Bolt, 25 Nm
 10 pieces
4 - Final drive cover
 Removing and installing speedometer trigger wheel. Refer to Trigger wheel for speedometer vehicle
2:29:34 AM Page 19
speed sensor -G22-, removing and installing


 Checking gear oil. Refer to Transmission oil level, checking
6 - Differential

2:29:34 AM Page 20

 VW 295 Drift
2:29:34 AM Page 21
 Installation and removal tool VW 459

 VW 470 Thrust ring for drive pinion bearings



 3138 Driver
2:29:35 AM Page 22

 VAG 1582 Taper roller bearing puller

2:29:35 AM Page 23

2 - Shim S2
 Note thickness
 Tapping out. See Driving outer race for small taper roller bearing out of transmission housing
 Tapping in. See Pressing outer race for small taper roller bearing into transmission housing
2:29:35 AM Page 24
 Pulling off. See Removing inner race for small taper roller bearing

5 - Ring gear1)
 Paired with pinion shaft (final drive set)

 Drive off with a drift. See Driving ring gear off housing
 Fit to differential housing. See Heat The Ring Gear To Approx. 100 ° C and install
2:29:35 AM Page 25
7 - Ring gear bolts - 60 Nm plus additional 45 ° turn
 Always replace
 Use only the original bolts
 Pulling off. See Removing inner race for large taper roller bearing

9 - Speedometer trigger wheel
 Removing and installing. Refer to Trigger wheel for speedometer vehicle speed sensor -G22-,
2:29:35 AM Page 26

 Installation position: Shoulder -arrow- faces toward differential; do not cant drive pegs in recess of
differential housing

 Tapping out. See Driving outer race for large taper roller bearing out of cover
 Tapping in. See Driving outer race for large taper roller bearing into cover
11 - Shim S1
 Note thickness
 With O-ring
 Replace O-ring
 Lubricate O-ring before installing
2:29:35 AM Page 27

 Redefine thickness. See Adjusting differential bevel gears

15 - Threaded piece
16 - Thrust washer
2:29:35 AM Page 28
 Check for cracks and chipping

18 - Shaft for small bevel gears

 Before driving in, align thrust washers
19 - Roll pin
 Replace
 Drive in flush
Removing inner race for small taper roller bearing
Fig. 372: Pulling Off Small Inner Race/Tapered Bearing

Removing inner race for large taper roller bearing
2:29:35 AM Page 29
Fig. 373: Pulling Off Large Inner Race/Tapered Bearing

 Remove speedometer trigger wheel


2:29:35 AM Page 30

Driving ring gear off housing
2:29:35 AM Page 31

Heat the ring gear to approx. 100 ° C and install

 When installing ring gear guide it on centering pins -A- (locally made).
 Allow the ring gear to cool off slightly before inserting the bolts. Then tighten to the specified torque.
2:29:35 AM Page 32

 Insert thrust washers for small bevel gear with a small amount of grease.
 Insert large bevel gears with correct shims. See Adjusting differential bevel gears
 Insert planet pinions turned through 180 ° and pivot into position (arrow).
 Insert threaded pieces.
 Installation position: Step toward large bevel gear
 Align thrust washers with hole.

 Drive small bevel gear shaft into final position and secure.
Adjusting differential bevel gears
Fig. 379: Differential Planetary Gears, Adjusting

 Insert large bevel gears with thinnest shims (0.5 mm).

 Insert small bevel gears with thrust washers and press in shaft.
NOTE: Do not now interchange large bevel gears and thrust washers.
2:29:35 AM Page 33
 Press small bevel gears outward and check play of large bevel gears by hand -arrows-.
 Adjust play by inserting an appropriate shim. Refer to The following shims are available.
 Specification: no more than 0.10 mm
NOTE:
Fig. 380: Installing Differential Bevel Gear Shim

The adjustment is also correct if no further play is perceptible, although it is still

possible to rotate the differential bevel gears -arrow-.

Shim thickness (mm)
0.50 0.70 0.90
0.60 0.80 1.00
Driving outer race for small taper roller bearing out of transmission housing
2:29:35 AM Page 34
Fig. 381: Driving Out Small Taper Roller Bearing Outer Race From Transmission Housing
Pressing outer race for small taper roller bearing into transmission housing
Driving outer race for large taper roller bearing out of cover
Fig. 383: Driving Out Large Taper Roller Bearing Outer Race From Cover
2:29:35 AM Page 35
 Use suitable base, e.g. VW 470 with recess toward cover.
DRIVE PINION AND RING GEAR, ADJUSTING
General notes
Careful adjustment of the drive pinion and ring gear is important for the service life and smooth running of the
final drive. For this reason, drive pinions and ring gears are paired up during manufacturing and are checked
with a tester for correct positioning of carrier pattern and low noise emission. The position for quietest possible
running is achieved by moving the drive pinion in an axial direction, whereby the backlash remains within the
specified tolerance.
Deviation "r" with reference to the master gauge "Ro" is recorded on the outer circumference of the ring gear.
Final drive set (drive pinion and ring gear) must only be replaced together.
Gear sets, adjusting and marking
2:29:35 AM Page 36

1 - Marking "K831" indicates Klingelnberg final drive set with transmission ratio 31 : 8.
2 - Gear set pairing number (312).
3 - Deviation (tolerance) "r" is based on the test machine master gauge used in production. The deviation
"r" is always given in 1/100 mm. Example: "25" means r = 0.25 mm
Ro - Length of test machine master gauge used. "Ro" = 59.65 mm
2:29:35 AM Page 37

R - Actual dimension between ring gear and face of pinion shaft at point with quietest running for this
pinion set.
Vo - Hypoid offset
Position of shims
2:29:35 AM Page 38

S1 - Adjustment shim for ring gear in transmission housing cover
S3 - Adjustment shim for drive pinion in transmission housing
S4 - Adjustment shim for drive pinion in bearing plate
Adjustment overview
NOTE: In the case of repairs to the transmission it is only necessary to adjust the
pinion shaft, ring gear or final drive set if components have been replaced
which have a direct effect on the adjustments of the final drive. To eliminate
2:29:35 AM Page 39
unnecessary adjustments observe following table:
To adjust: Ring gear Pinion shaft Pinion shaft Backlash

(S1 and S2) (S3 and S4) shim only 0.12 -0.22 mm
using deviation "r" S4
Refer to Ring Refer to Drive Refer to Re- Refer to
gear, adjusting pinion, adjusting determining shim S4 Adjusting
backlash
Component replaced
Bearing plate X X
Taper roller bearings X X
for pinion shaft
differential
Final drive X X X
Hollow shaft X X
Gear set, recommended adjustment sequence
When ring gear and pinion shaft have to be adjusted, in the interests of a rational sequence, keep to the
following order:

2:29:35 AM Page 40
 Determine total shim thickness "Stotal" (S1 plus S2) for the specified preload of taper roller bearings for
differential.
 Determine total shim thickness "Stotal" (S3 plus S4) for the specified preload for taper roller bearings for
drive pinion.
 Distribute total shim thickness "Stotal" (S3 plus S4) so that the distance from center of ring gear to face of
pinion shaft is the same as distance "R" determined during production.
 Distribute total shim thickness "Stotal" (S1 plus S2) so that the specified backlash exists between ring
gear and drive pinion.
The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test
machine in production. Maximum care and cleanliness are essential for achieving good results when performing
repairs and taking measurements.
Drive pinion, adjusting
Fig. 389: Identifying Special Tools - Pinion, Adjusting
2:29:35 AM Page 41
(Adjusting drive pinion and hollow wheel)



 3114/2 Straightening tool

 3116 Spring pin
2:29:35 AM Page 42

 Dial gauge
 Dial gauge extension 6.5 mm
Re-adjustment of the drive pinion according to the following instructions is only necessary if the final drive set,
taper roller bearing for drive pinion and transmission housing are being replaced. Refer to Adjustment
overview.
Determine total shim thickness "Stotal"(S3 plus S4)
(Setting preload of taper roller bearing for drive pinion).
 Differential is removed.
Fig. 392: Preloading Pinion/Hollow Shaft To 10 Nm, While Holding Hollow Shaft
 Clamp drive pinion in vice using vice clamps -A-.

 Insert taper rollers with grease, assemble drive pinion and hollow shaft.
 Rotate hollow shaft against drive pinion 5 turns in both directions to settle taper roller bearing.
 Preload drive pinion/hollow shaft to 10 Nm, hold hollow shaft tight for this step.
 Install large taper roller bearing outer race into transmission housing without shim. Refer to Heating
transmission housing in order to install outer race for taper roller bearing and Inserting outer race
for large taper roller bearing in transmission housing and pressing home
2:29:35 AM Page 43

 Press small taper roller bearing outer race together with a 1.00 mm thick provisional shim S4* fully into
bearing plate.

provisionally. It is referred to as S4* in the following. After determining
measurement "e", S4* is replaced by the final shim S4.

 Install bearing plate with dowel sleeves and tighten bolts to tightening torque.
 Rotate drive pinion and hollow shaft 8 turns in both directions prior to each measurement in order to
settle taper roller bearing.

2:29:35 AM Page 44

 Use 30 mm dial gauge extension
 Move drive pinion upward and downward without turning; read off play on dial gauge and note.
(Example: 0.90 mm)
 Before each measuring procedure the drive pinion must be turned together with the hollow shaft in order
to avoid obtaining a false reading.
The specified bearing pre-load is obtained by adding a constant pre-load value (0.15 mm) to reading obtained
(0.90 mm) and thickness of shim S4* (1.0 mm).
Stotal = S4* + reading obtained + pre-load
Example:

Stotal = 2.05 mm
Determining thickness of provisional shim S3*
Provisional shim S3* = Stotal - S4*
Example:
Total shim thickness Stotal (S3 + S4) 2.05 mm

Inserted shim S4* -1.00 mm
Provisional shim thickness S3* = 1.05 mm
 Removing outer race for large taper roller bearing. Refer to Pulling out large taper roller bearing outer
race, Inserting provisional shim S3* into transmission housing and re-installing outer race. Refer to
Heating transmission housing in order to install outer race for taper roller bearing and Inserting
outer race for large taper roller bearing in transmission housing and pressing home.
 Insert completely assembled pinion shaft in transmission housing again.
 Install bearing plate with dowel sleeves and tighten to 25 Nm.
 Rotate drive pinion and hollow shaft 8 turns in both directions prior to each measurement to settle taper
roller bearing.
Determining measurement "e"
2:29:35 AM Page 45

 Set universal mandrel VW 385/1 setting ring to dimension a = 65 mm.

 Adjust moveable setting ring to measure b = 55 mm.
Fig. 396: Assemble Measuring Bar According

 Arrange universal mandrel as illustrated. Dial gauge extension VW 385/15 = 9.3 mm. Set master gauge
VW 385/30 to Ro = 59.65 mm and install onto mandrel.
 Place end measuring plate VW 385/17 onto drive pinion head.
2:29:35 AM Page 46
Fig. 397: Insert Measuring Mandrel Into Housing

 Remove master gauge and insert measuring mandrel in the housing. Centering disc VW385/3 faces
toward cover for final drive.
 Using sliding setting ring to pull 2nd centering disc VW 385/2 outward until mandrel can still just be
turned by hand.
 Measure dimension "e".
Turn mandrel until the dial gauge extension touches the final measuring plate on pinion shaft head, then
measure maximum deflection (return point). The measured value is dimension "e".
2:29:35 AM Page 47
Example:
0.16 mm (red scale)
 Turn mandrel until the dial gauge point touches the end measuring plate on drive pinion head, then
Measurement in following example: "e" = 0.16 mm (in red scale on dial)
S3 = S3* + r + e
("e" in black scale)
S3 = S3* + r + e
("e" in red scale)
NOTE:  The deviation "r", which is related to the master gauge "Ro" is measured
for the final drive sets supplied as replacement parts and marked on the
outer circumference of the ring gear.
 If dial gauge reading is in red scale, subtract dimension "e".
 If dial gauge reading is in black scale, add dimension "e".
Example:

Dimension "r" indicated on ring gear +0.38 mm
Determined value "e" (red scale) -0.16 mm
Shim thickness S3 = 1.27 mm
Shim thickness (mm)

0.45 0.60 0.75
0.50 0.65 0.80
0.55 0.70 0.85
S4 = Stotal - S3
2:29:35 AM Page 48
Example:

Shim thickness (mm)

0.45 0.65 0.85
0.50 0.70 1.25
0.55 0.75
0.60 0.80
Carry out check measurement - checking dimension "r"
 Install pinion shaft with measured shims S3 and S4 and turn several times in both directions.
Insert universal mandrel and measure dimension "r".
If the correct shims have been selected the D.T.I. must now indicate the mark dimension "r" (reading anti-
clockwise on red scale) within a tolerance of ± 0.04 mm.
Measuring frictional torque (check)
NOTE: Taper roller bearings for drive pinion/hollow shaft are low friction bearings.
Therefore the frictional torque only has a limited use as a check. Correct
2:29:35 AM Page 49
adjustment is only possible by determining the total shim thickness Stotal.
Fig. 400: Do Not Use Additional Oil

 Install new taper roller bearings in delivery condition and do not oil additionally.
Fig. 401: Measure Friction Torque

 Measuring frictional torque
With torque gauge -A-, 0 to 600 Ncm, standard commercially available
New bearings Used bearings 1)

80 to 150 Ncm 30 to 60 Ncm
2:29:35 AM Page 50
1) with at least 50 km service

 VW 295 Drift
 VW 382 Special socket and measuring tools
2:29:35 AM Page 51
 VW 388 Test lever


 VW 459 Installation and removal tool

 VW 521 Adjustment tool for ring gear

 Dial gauge
2:29:35 AM Page 52
 Dial gauge extension
It is necessary to readjust the ring gear when:
Transmission housing, cover for final drive, taper roller bearing outer race for differential, final drive
housing or final drive set are replaced.
Adjustment overview. Refer to Adjustment overview
Determine total shim thickness "Stotal" (S1 plus S2)
 Drive pinion is removed.

 Remove outer races of differential taper roller bearings and remove shims. Refer to Differential,
 Drive outer race for taper roller bearing with shim S2 into transmission housing. For measurement
purposes use a 1.20 mm thick S2* shim (2 shims of 0.60 mm).

provisionally. It is referred to as S2* in the following. After determining the
backlash, S2* is replaced by the final shim S2.
2:29:35 AM Page 53
 Press taper roller bearing outer race without shim into cover for differential.
 Insert differential into housing without speedometer trigger wheel.
The side of the ring gear is positioned on the right side (cover side).
 Install cover and tighten bolts to 25 Nm.

 Turn transmission so that cover for differential faces up.
 Place measuring plate VW 385/17 onto differential.
2:29:35 AM Page 54

A - Dial gauge extension 30 mm
Fig. 407: Move Differential With Ring Gear Adjuster VW 521 Up And Down
 Move differential up and down with special tool VW 521 (direction of arrow).
 Read off play from dial gauge
Example:
0.62 mm
"Stotal" = S2* + reading obtained + pre load
Example:
Inserted shim(s) S2* 1.20 mm

Stotal = 2.07 mm
Determining thickness of shim S1*
NOTE:  After determining the backlash, provisional shim S1* is replaced by the
final shim S1.
 The total shim thickness "Stotal" remains the same.
S1* = Stotal - S2*
2:29:35 AM Page 55
Example:

Inserted shim(s) S2* -1.20 mm
Thickness of shim S1* = 0.87 mm
Adjusting backlash
Drive pinion inserted with S3 and S4
 Differential with ring gear: S1* is installed in the cover side, S2* in the transmission housing.
 Install final drive cover and tighten bolts to 25 Nm.
 Turn differential several times in both directions so that the taper roller bearings settle.


 Use dial gauge extension VW 382/10 (6 mm flat).
Set measuring lever VW 388 to dimension "a" = 79 mm.
 Turn ring gear to stop. Set dial gauge to zero, turn back ring gear and read off backlash. Note value.
 After turning ring gear through a further 90 ° , repeat measuring process a further 3 times. Add up the
four measured values and calculate average backlash
Calculating average backlash
Example:
1st measurement 0.49 mm

+ 2nd measurement 0.48 mm
+ 3rd measurement 0.50 mm
2:29:35 AM Page 56
+ 4th measurement 0.49 mm

Total 1.96 mm
Center backlash = 1.96 mm: 4 = 0.49 mm
If the individual measurements differ by more than 0.06 mm from each other, the installation of the ring gear or
the final drive set itself is not correct. Recheck the installation, and if necessary replace ring gear and pinion.
Determining shim thickness S2
(opposite ring gear)
S2* = Inserted shim(s)

- Average backlash
+ Lift (constant)
Lift = 0.15 mm
Example:
S2*= Inserted shim(s) 1.20 mm

- Average backlash 0.49 mm
= 0.71 mm
+ Lift (constant) 0.15 mm
Shim thickness (mm)

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Determining adjustment shim thickness S1
(Ring gear side)
S1 = Stotal - S2
Example:
2:29:35 AM Page 57

Shim thickness (mm)

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Install determined shims, S1 on the ring gear side, S2 opposite ring gear, use 2 shims if necessary.
Performing check measurement
Measuring backlash. Refer to Adjusting backlash
 It must be 0.12 to 0.22 mm.
2:29:35 AM Page 58
TRANSMISSION
6-speed manual transmission 01X, front-wheel drive
00 TECHNICAL DATA
The 6 Spd. Manual Transmission 01X Front Wheel Drive is installed on the AudiA42001 --> in conjunction
with the 2.0liter and 3.0liter engines.

 Code letters and date of manufacture - arrow1 - or - arrow 3 -

 Manual transmission 01X - arrow2 -

2:31:21 AM
2:31:34 Page 1
Code letters and date of manufacture of transmission - arrow1 -
Example: GJU 14 06 3
I I I I
I I I I
stickers.
Fig. 3: Code Letters For Transmission On The Vehicle Data Stickers

Manual transmission 01X - arrow2 -
Code letters, allocation, transmission ratios, capacities
Manual transmission 6-speed 01X (front-wheel drive)

Code letters HCK GVD
to
Allocation Model A4 2001 --> A4 2001 -->
Engine 2.0 ltr. TDI -118kW 2.0 ltr. - 147 kW

i = Z2 : Z1 1st gear 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 39 : 19 = 2.053 39 : 19 = 2.053
3rd gear 36 : 28 = 1.286 37 : 27 = 1.370
4th gear 31 : 33 = 0.939 32 : 31 = 1.032
2:31:21 AM Page 2
5th gear 26 : 37 = 0.703 28 : 35 = 0.800

6th gear 23 : 40 = 0.575 25 : 38 = 0.658
Reverse gear 34 : 10 = 3.400 34 : 10 = 3.400
Capacity 3.0 liters
Clutch actuation Hydraulic
Clutch plate diameter 240 mm 240 mm
Drive shaft flange diameter 88 mm 88 mm
Manual transmission 6-speed 01X (front-wheel drive)

Code letters GVC GJU
to 05.04
Engine 3.0 ltr. - 162 kW 3.0 ltr. - 162 kW

i = Z2 : Z1 1st gear 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 39 : 19 = 2.053 39 : 19 = 2.053
3rd gear 37 : 26 = 1.423 37 : 26 = 1.423
4th gear 33 : 31 = 1.065 33 : 31 = 1.065
5th gear 29 : 34 = 0.853 29 : 34 = 0.853
6th gear 27 : 37 = 0.730 27 : 37 = 0.730
Reverse gear 34 : 10 = 3.400 34 : 10 = 3.400
Capacity 3.0 liters
Drive shaft flange 88 mm 88 mm
TRANSMISSION LAYOUT
Transmission layout
Identification
2:31:21 AM Page 3

1 - Engine
2 - Clutch
 Diagram of transmission layout --> Transmission, overview
5 - Differential
6 - Pinion shaft (output shaft)
2:31:21 AM Page 4

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
2:31:21 AM Page 5
A - Final drive
CALCULATING RATIO "I"
Transmission ratio
Ratios Formula
Example:
Calculations:
iG = 25 : 38 = 0.658
iA = 30 : 8 = 3.750
iov = 0.658 x 3.750 = 2.467
Proper tools and the maximum possible care and cleanliness are essential for successful transmission repairs.
The usual basic safety precautions also naturally apply when carrying out vehicle repairs.
repeated at numerous places in the article - are summarized under the designation "Components"-->
Components. They apply to the work described in this article.
Components
Transmission
 Select the correct bolts and other components according to transmission code letters --> Code letters,
allocation, transmission ratios, capacities.
2:31:21 AM Page 6
 When installing a new transmission, check the oil level and fill up with oil if necessary --> Transmission
oil level, checking.
 Capacities and specifications --> Code letters, allocation, transmission ratios, capacities
Sealants


 The open side of the oil seals face the side with fluid filling.
 Lightly oil O-rings before installing to prevent them from being trapped and damaged when assembling.
Transmission oil level, checking.
2:31:21 AM Page 7
Locking elements

 Locking rings/circlips must be properly seated in the base of the groove.

 Replace spring pins. Position: slit - A - should be in line with the line of force - arrow -.
Nuts, bolts
 Loosen the nuts and bolts in reverse sequence to the specified tightening sequence.
them straight.

 Clean the threads of bolts which are secured by a locking compound with a wire brush. Then lubricate
bolts with locking compound AMV185101A1 again before installing.
(using a tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being
removed.
Shims
2:31:21 AM Page 8
Bearings
 Install new tapered roller bearings as supplied; do not additionally lubricate with oil.
 Lubricate all bearings (except tapered roller bearings) with gear oil before installing in transmission.
 Heat inner races of tapered roller bearings to approx. 100° C before installing. Press in onto stop when
installing so there is no axial clearance.
 Do not interchange the outer or inner races of bearings of the same size (the bearings are paired).
 If required, replace the tapered roller bearings on one shaft together and use new bearings from a single
manufacturer.
 Install needle bearings so the lettering (side with thicker metal) faces the installing tool.
 Grease needle bearing for transmission input shaft in rear of flywheel.
Synchronizer rings
 Do not interchange synchronizer rings. When reusing always install to the same gear.
Gear wheels and synchronizing hubs
 Before installing, clean and heat on a hotplate to 130° C (maximum).

 Press in onto stop when installing so there is no axial clearance.
 The temperature can be measured with temperature tester V.A.G1558, ignition tester V.A.G 1767 or
diesel tester V.A.G 1743.
Selector gears
 After installing, check 1st to 6th selector gears for minimal axial play and freedom of movement.
Clutch actuation
 When removing transmission, remove clutch slave cylinder without disconnecting lines.
 Do not depress the clutch pedal after removing the clutch slave cylinder if the hydraulic line is still
connected. Otherwise the piston will be pressed out of the clutch slave cylinder. As a result the clutch
slave cylinder will be destroyed.
(further measures --> Notes on removing and installing master cylinder and slave cylinder).
2:31:21 AM Page 9
 Make sure that the pressure plate is kept straight: loosen and tighten bolts in a diagonal sequence and in
several gradual stages (does not apply to SAC pressure plates).
installing.
 On vehicles with SAC pressure plate an adjuster ring has to be reset when only the clutch plate is
replaced --> Adjuster ring in SAC clutch pressure plate, adjusting.
 If the clutch has burned out, thoroughly clean the bell housing, flywheel and parts of the engine facing the
30 CLUTCH


Cabriolet
.
G052142A2 .
side -->
.
2:31:21 AM Page 10
I - Pedal cluster - LHD vehicles, assembly overview --> Pedal cluster - LHD vehicles, assembly overview
II - Pedal cluster - RHD vehicles, assembly overview --> Pedal cluster - RHD vehicles, assembly overview
Pedal cluster - LHD vehicles, assembly overview
2:31:21 AM Page 11

3 - Retaining clip
5 - Brake pedal
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 Only installed one time
 Replace
8 - Clutch pedal
9 - Retaining clip
10 - Retaining clip


14 - Clutch pedal starter interlock switch F194
 Only for USA

 Engine can only be started when clutch is fully depressed ( clutch pedal starter interlock switch activated).
 Replace
2:31:21 AM Page 13
NOTE:  Clutch pedal switch F36 may only be installed once so as to ensure a firm
fit.
Removing

clutch pedal switch F36 should then rest against the clutch pedal.
 Release clutch pedal switch F36 - 2 - by turning 45° counter-clockwise and remove from guide.
Installing
2:31:21 AM Page 14
 Pull out operating rod - arrow - all the way before installing clutch pedal switch F36.

 Guide clutch pedal switch F36 through mounting hole, press against clutch pedal and attach by turning
45° clockwise.
 Plug in connector for clutch pedal switch F36.
Removing and installing clutch pedal starter interlock switch F194
Removing

2:31:21 AM Page 15
 Disconnect electrical connector - 3 - on clutch pedal starter interlock switch.

 At the same time, release clutch pedal starter interlock switch - 2 - by turning it 45° in the direction
Installing
2:31:21 AM Page 16
 When installing clutch pedal starter interlock switch, press clutch pedal - 1 - all the way down - arrow A
-. Hold clutch pedal in this position.
 Guide clutch pedal starter interlock switch - 2 - through opening in retainer, and at the same time push
operating rod against clutch pedal and secure switch by turning it 45° in the direction indicated - arrow B
-.
 Connect electrical connector - 3 - on clutch pedal starter interlock switch.
2:31:21 AM Page 17

 Assembly clamp T40025
Removing


downward.
Installing
2:31:21 AM Page 18
clamp.
Pedal cluster - RHD vehicles, assembly overview

2:31:21 AM Page 19
2 - Washer
3 - Brake pedal

 Replace
7 - Bearing sleeve
8 - Clutch pedal
9 - Retaining clip

13 - Bolt -22 Nm-
 Self-locking
 Replace
14 - Lever
2:31:21 AM Page 20
15 - Washer
16 - Mounting
18 - Bolt, 25 Nm

2:31:21 AM Page 21
2 - Supply hose
 For plug-in connections on master cylinder and slave cylinder

 Disconnecting from clutch slave cylinder Disconnecting slave cylinder from hose/line assembly
4 - Grommet
6 - Clutch pedal
7 - Master cylinder

9 - Retaining clip

arrow - ).
10 - Transmission
11 - Slave cylinder
bleeding
2:31:21 AM Page 22
12 - Bleeder valve
13 - Dust cap
14 - Clip
15 - Bracket


 Self-locking
 Replace
17 - Retaining clip
18 - Gasket
19 - Securing bolt
2:31:21 AM Page 23


Removing
 To remove hose/line assembly, use a screwdriver to pry off clip - A - as far as stop. Only then can
Installing

 Insert hose/line assembly - B - in slave cylinder and make sure that it engages audibly.
2:31:21 AM Page 24
function check.
 After installing the slave cylinder, carefully press the clutch pedal. If you feel an unusually strong
resistance when depressing the clutch pedal, you must not press it down further. The push rod of the slave
cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be
Function check for master cylinder and slave cylinder
Before you replace the clutch master or slave cylinder you must - in the case of the following malfunctions -
first carry out the appropriate checks.
 replace relevant component.
 Check whether clutch pedal returns all the way to its initial position, thereby uncovering the ventilation
opening in the master cylinder.
of time.

 If you identify any leaks you must replace the leaking component.
High pedal force:

Pedal forces:
2:31:21 AM Page 25
 Needle bearing in flywheel (centering bearing for input shaft) faulty, replace needle bearing -->
.

 Wrong components used or components omitted when performing repair work (e.g. intermediate plate).

 Hose clamp 3094
2:31:21 AM Page 26

 Spark plug connector pliers V.A.G1922
Removing


Cabriolet
.

2:31:22 AM Page 27

.

 Use screwdriver to pry off the two caps - 3 -.

 Remove nuts - 4 - and detach the two wiper arms - 2 -.
 Pull off clips - 1 - and detach cowl panel grille - 5 -.
Take the electronics box out of the plenum chamber as follows:
2:31:22 AM Page 28



2:31:22 AM Page 29



2:31:22 AM Page 30
 Pry out retaining clip - C - using a screwdriver and pull out line/hose assembly - B - slightly.

 Remove brake fluid reservoir bolt - 1 - and disconnect connector for brake fluid level warning contact
downward.


2:31:22 AM Page 31

.

2:31:22 AM Page 32
 Disconnect connectors from clutch pedal switch - 1 - , brake light switch - 2 - and accelerator pedal
module - 3 -.
 If installed, disconnect connector from clutch pedal starter interlock switch F194.
1922
 Apply spark plug connector pliers V.A.G1922 in clutch pedal recesses, press on sides of retaining clip
and detach clutch pedal from master cylinder.
2:31:22 AM Page 33
Installing
 Install master cylinder - 4 - and tighten bolts - 3 - to 20Nm.
Clutch Pedal

2:31:22 AM Page 34
assembly into master cylinder from plenum chamber.

2:31:22 AM Page 35



contact.
2:31:22 AM Page 36
 If installed, plug in connector for clutch pedal switch F194.

.
2:31:22 AM Page 37


 Route engine wiring harness and connect connector in console.
 Install engine control module-->
 28 - IGNITION/GLOW PLUG SYSTEM for AVK
 28 - IGNITION/GLOW PLUG SYSTEM for BPG
 97 WIRING

2:31:22 AM Page 38
 Brake filler bleeder unit VAS 5234
Procedure
clutch mechanism.
 The clutch hydraulic system should be bled at the same intervals as the
brake system.
 Connect brake filler bleeder unit VAS 5234, but do not switch on.
2:31:22 AM Page 39



Tightening torques
Component Nm
2:31:22 AM Page 40


 Press tube 2040

2:31:22 AM Page 41


1 - Release bearing

plastic ring
2:31:22 AM Page 42
plastic ring
grease Z381351TE .
3 - Torx bolt, 35Nm
 3 (Qty.)
5 - Guide sleeve

6 - Oil seal
 For input shaft

7 - O-ring
 Always replace
8 - Convex washer
10 - Ball head stud
11 - Transmission
12 - Slave cylinder
2:31:22 AM Page 43

 Self-locking
 Replace
14 - Bracket

15 - Operating rod

 Before installing the transmission, glue the loose plastic ring back onto the bearing ring with adhesive
AMV195KD101 .
2:31:22 AM Page 44
Three square tabs - arrows - of the plastic ring engage in recesses of bearing ring.

 The release bearing must be replaced if plastic ring - 1 - has come loose.
 The release bearing - 3 - must be replaced if groove - arrow2 - worn on the plastic ring - 1 - is deeper
than 0.8mm.

B - Internal puller 23.5...30 mm, e.g. Kukko 21/4
2:31:22 AM Page 45


2:31:22 AM Page 46
Fig. 57: Fasteners

Removing
auxiliary/heater to sound insulation.

2:31:22 AM Page 47


surface protection.
2:31:22 AM Page 48


 Remove bolt - arrow - and remove slave cylinder from rear.
2:31:22 AM Page 49

Installing
installed easily.

2:31:22 AM Page 50
G052150A2 .
Z381351TE .

2:31:22 AM Page 51



 If line/hose assembly was disconnected at slave cylinder, the clutch system has to be bled after installing
2:31:22 AM Page 52



 Install exhaust system and perform stress-free alignment --> 3.0 Liter 6-Cyl. 5V Engine Mechanical,
Tightening torques
Component Nm
* replace bolt
CLUTCH, SERVICING
Clutch, servicing
2:31:22 AM Page 53


 Locking bar 3067

2:31:22 AM Page 54
cylinder.
Adjuster ring in SAC clutch pressure plate, adjusting.
 Check that SAC pressure plate is not warped Check SAC pressure plate
for warpage, cracks and burns
 If the vehicle is installed with a self-adjusting clutch (Sachs version), the
 Replace clutch plate and pressure plate if riveted fastening is damaged or
loose.
 To avoid damaging dual-mass flywheel during removal please observe
backward and forward on input shaft until hub moves freely on shaft. It is
important to remove excess grease.
servicing

installing.
2:31:22 AM Page 55


 Always replace
2:31:22 AM Page 56
3 - Clutch plate
4 - Pressure plate
5 - Bolt, 22 Nm
6 - Needle bearing


2:31:22 AM Page 57


2:31:22 AM Page 58
seated tightly.
Checking wire ring

broken.
replaced together.

installing.
2:31:22 AM Page 59

1 - Bolt, 22 Nm
2 - Pressure plate
 Self-adjusting
2:31:22 AM Page 60
3 - Clutch plate

 The marking "Getriebeseite" (transmission side), if provided, faces toward pressure plate/transmission.
 Always replace

6 - Needle bearing

Identification
2:31:22 AM Page 61


2:31:22 AM Page 62

seated tightly.
Checking wire ring

broken.
2:31:22 AM Page 63


for the appropriate engine code.

2:31:22 AM Page 64
 Flywheel retainer 3067



 Attach flywheel retainer 3067 or counter-hold tool 10 - 201 before loosening bolts.
2:31:22 AM Page 65

is released.
 Stop - 2 - (position sensor) with pin - 1 - should come free when bolts are loosened.
Installing

 To remove, reverse position of flywheel retainer 3067 or counter-hold tool 10 - 201.

2:31:22 AM Page 66

always adhere to the following procedure when installing pressure plate:

 Make sure that the stop mechanism (position sensor) - arrow - is free to move.
 The stop pin - arrow - should then lift away from pressure plate.

 Remove transmission before working on clutch --> Transmission, removing and installing.
2:31:22 AM Page 67


2 - Needle bearing
2:31:23 AM Page 68

 Always replace

4 - Clutch plate
 Marking "Getriebeseite" (if provided) faces pressure plate/transmission.
 Centralize
 Resetting adjuster ring --> Adjuster ring in SAC clutch pressure plate, adjusting
6 - Bolt -22 Nm-
2:31:23 AM Page 69


seated tightly.
2:31:23 AM Page 70
A - Straightedge
B - Feeler gauge


 When removing bolts - B - , make sure bolt heads do not contact flywheel - arrows - because this would
damage flywheel when bolts are turned further.
2:31:23 AM Page 71

.
Fig. 93: Counterhold 10-201



2:31:23 AM Page 72
plate is released.
Installing
NOTE:  Before re-installing the SAC pressure plate check that it is not warped
clutch pressure plate, adjusting.
2:31:23 AM Page 73


Adjuster ring in SAC clutch pressure plate, adjusting

ring.
reset.

2:31:23 AM Page 74
 Thrust disc VW412

 Thrust pad 3062
Procedure
 Insert 3bolts for securing pressure plate - A - into mounting holes on pressure plate at 120° (13) intervals,
as illustrated.
2:31:23 AM Page 75

 Place SAC pressure plate onto thrust disc so that only 3 bolt heads - arrows - make contact.
off.
2:31:23 AM Page 76

 Apply two screwdrivers to forks on adjuster ring. Use thrust disc to apply pressure to pressure plate until
it is just possible to move adjuster ring.
 Hold adjuster ring against stop and reduce pressure applied by thrust disc so that the adjuster ring is held
in this position.
Installation position of selector mechanism
2:31:23 AM Page 77
Fig. 102: Installation Position Of Selector Mechanism, Gear Selection Movement And Gate Selection
Movement
1 - Selector rod
2 - Push rod
3 - Connecting rod
Selector mechanism components, assembly overview
2:31:23 AM Page 78
Part I
G052142A2 .
Fig. 103: Shift Mechanism Remove/Install Components -- Part I

1 - Ball
2 - Rubber ring
3 - Ball guide
4 - Rubber ring
2:31:23 AM Page 79
5 - Washer
6 - Circlip
7 - Spring
8 - Spacer sleeve
9 - Washer
10 - Circlip
11 - Sound insulation
 - Arrow - marked on sound insulation points in direction of travel
 With cover
 Removing and installing --> Gear lever knob with boot, removing and installing
13 - Nut -10 Nm-
14 - Ball housing
16 - Gear lever
17 - Bolt
18 - Nut, 10 Nm
21 - Nut, 10 Nm
 Self-locking
 Replace
2:31:23 AM Page 80
22 - Bushing
Part II
G052142A2 .
Fig. 104: Shift Mechanism Remove/Install Components -- Part II

1 - Boot
 Secure to selector rod with commercially available instant adhesive
2 - Washer
2:31:23 AM Page 81
3 - Ball socket
4 - Cap nut, 23 Nm
5 - Ball stud
6 - Ball socket
7 - Connecting rod
8 - Bushing
9 - Bushing
10 - Bolt, 23 Nm
11 - Sleeve
12 - Retaining clip
13 - Bolt, 40 Nm
14 - Push rod
 With bushing, bolt and washers
16 - Washer
18 - Clamping ring for boot
19 - Boot
21 - Clamp
22 - Selector rod
24 - Cap nut, 10 Nm
2:31:23 AM Page 82
 Self-locking
 Replace
Gear lever knob with boot, removing and installing


Removing
 Open ashtray.
2:31:23 AM Page 83
Gear lever knob with clip:


Gear lever knob with locking mechanism:
 Release connecting element - 1 - in direction of - arrow - and pull gear lever knob off upward together
2:31:23 AM Page 84
Installing

Removing
 Remove gear lever knob together with boot --> Gear lever knob with boot, removing and installing.
Vehicles with large radio slot:
Vehicles with small radio slot:
2:31:23 AM Page 85
 Lift trim panel - 1 - in direction of - arrow A - , then pull it out in direction of - arrow B -.
 Remove bolts - arrows C - and then pull ashtray - 2 - out of center console.
 Lift out sound insulation.
 Remove sound insulation for gear lever housing - arrows -.

2:31:23 AM Page 86
Fig. 113: Fasteners


2:31:23 AM Page 87
Fig. 115: Cross Member Bolts

Remove tunnel cross piece (rear) - arrows -.


 Remove rear section of exhaust system -->
 26 EXHAUST SYSTEM, EMISSION CONTROLS for AVK
 A second technician is required for removing the rear section of the
exhaust system.
Fig. 117: Rear Section Of Exhaust System And Front Cross Member
2:31:23 AM Page 88
 Disconnect exhaust system at clamp - 2 -.
 Remove tunnel cross piece (front) - 1 - - arrows -.

 Remove heat shield for exhaust system - 4 - from below selector mechanism.
Wood
 Remove universal transmission mounting V.A.G1359/2 from engine/transmission jack V.A.G 1383 A
and place a wooden block - arrow - on press tool instead.
 Support tunnel cross member (rear) using engine/transmission jack V.A.G 1383 A.
 Remove bolts - 1 - and - 2 - , then bolts - 3 - and - 4 -.
2:31:23 AM Page 89
 Carefully lower tunnel cross member (rear) using engine/transmission jack V.A.G 1383 A until distance
between cross member (rear) and body reaches dimension "x".
 Dimension x = 60 mm

 Remove heat shield - arrow - for drive axle (right side) and, if installed, also for drive axle (left-side).
2:31:23 AM Page 90
 Remove connecting rod - 2 - for selector rod.

 Detach push rod - 1 - ; to do so, unscrew hex socket head bolt.

 Remove selector mechanism to rear.
Installing

2:31:23 AM Page 91
.
 Adjust selector mechanism --> Selector mechanism, adjusting.
Tightening torques
Component Nm
Selector shaft lever to selector shaft 23
Tunnel cross member (front) to body 55
Tunnel cross member (rear) to body 60
sound insulation to selector mechanism 10
Selector mechanism, adjusting
The following are requirements for correct gear lever alignment:
 Gear selector linkage must be in proper condition and undamaged.

 Selector mechanism must move freely.
Procedure
2:31:23 AM Page 92
2:31:23 AM Page 93

 Measure distance - a - between two studs in selector mechanism.
 Specification: distance a = 85 mm



2:31:23 AM Page 94

Align gear lever
 Position bottom of gear lever in center of ball guide.
 Distance between ball guide and bottom of gear lever - arrows - must be equal at all points.

 Align gear lever so that it points slightly (1.5°) to right (as seen in direction of travel).
2:31:23 AM Page 95

 Tighten bolt for push rod - arrow - to 23Nm.
tightened.
 The gear lever should rest in the 3rd/4th gear gate when transmission is in neutral.

 The gear lever should return by itself from reverse gear gate to 3rd / 4th gear gate.
If gear lever sticks or bauks repeatedly when engaging a gear, perform adjustment procedure again.
 Install trim parts and gear lever knob --> Gear lever knob with boot, removing and installing.
 Transmission, removing from vehicles with 4-cylinder engine --> Transmission, removing from
vehicles with 4-cylinder engine.
 Transmission, installing in vehicles with 4-cylinder or 6-cylinder engine --> Transmission, installing in
vehicles with 4-cylinder or 6-cylinder engine.
Transmission, removing from vehicles with 4-cylinder engine
2:31:23 AM Page 96
Fig. 130: Identifying Special Tools - Transmission, Removing From Vehicles



2:31:23 AM Page 97


Procedure


Cabriolet
.
2:31:23 AM Page 98
 With ignition switched off, disconnect battery Ground (GND) strap - arrow -.

 Detach rubber seal from edges of wing mounting flanges.

 To avoid damaging edges of fenders with engine support bridge 10-222 A, insert wing compensation
plates T40045 on both sides between fender mounting flange and body panel underneath.
2:31:23 AM Page 99
Fig. 136: Fasteners

2:31:23 AM Page 100


NOTE:  - Item 3 - and - item B - can be disregarded.

 Remove bracket - arrow - for sound insulation.
2:31:23 AM Page 101


 Unbolt heat shield - arrow - for drive axle (right side) from transmission.

 Separate exhaust system at clamp - arrow - and slide clamp to rear.
2:31:23 AM Page 102

Fig. 141: Retaining Bracket For Front Exhaust Pipe, Bolt And Nut
 Remove bolt - 1 - and nut - 2 - and detach retaining bracket for front exhaust pipe.
Fig. 142: Torque Reaction Support

Cabriolet:
NOTE:  On Audi Cabriolet vehicles the following steps are required in order to
remove the three bottom engine/transmission bolts:
 Unbolt torque reaction support - arrows -.
2:31:23 AM Page 103

 Remove nuts - 1 - on left and right sides, and swivel stabilizer bar - 2 - downward.
 Remove nut - 3 - on left and right engine mountings until bottom of nut is flush with end of stud - arrow
-.
 Use engine support bridge 10-222 A to lift engine just enough for nuts - 3 - to make contact with bottom
surface of left and right consoles.

 Remove three lower engine/transmission securing bolts - arrow -.
Cabriolet:
 Lower engine back down.
2:31:23 AM Page 104

Fig. 145: Locating Starter Bolt

 Detach starter from engine/transmission and secure if necessary -->

NOTE:  Starter cables do not have to be disconnected.

 Drill a hole of 10.2mmdiameter - arrow - in supporting elements of transmission support 3282.
2:31:23 AM Page 105

Fig. 147: Support Elements 3282/49 And 3282/52 And Arrow On The Adjustment Plate
 To remove manual transmission 01X, set up transmission support 3282 with adjustment plate 3282/43
and place on engine/transmission jack V.A.G 1383 A.
NOTE:  The support elements 3282/49 - arrows A - and 3282/52 - arrows B - are
shown in schematic form on the adjustment plate. The arrow on the
adjustment plate points toward the direction of travel.
 Adjustment plate can only be installed in one position.
Fig. 148: Supporting Elements Secured To Left Side Of Transmission

 Align adjustment plate parallel to transmission.

 Secure supporting elements to left side of transmission, as shown in illustration. Tighten bolt - arrow - on
right side to 20 Nm.
2:31:23 AM Page 106

Fig. 149: Supporting Elements Secured To Right Side Of Transmission

 Secure supporting elements to right side of transmission, as shown in illustration. Tighten bolt - arrow -
on left side to 20 Nm.
Fig. 150: Tunnel Cross Member Mounting Bolts

 Remove bolts - 1 - and bolts - 2 -.
2:31:23 AM Page 107

 Remove nuts - arrows - and detach tunnel cross member.

 Lower transmission slightly using engine/transmission jack V.A.G 1383 A.
Fig. 152: Back-Up Light Switch F4 Electrical Connector

 Disconnect electrical connector - arrow - for back-up light switch F4 and move electrical wire clear.

 Remove push rod - 1 - by using an 8 mm hex key when removing bolt.
2:31:24 AM Page 108


Fig. 155: Upper Engine/Transmission Securing Bolts

 Remove upper engine/transmission securing bolts - arrows 1 - and - arrows 2 -. Please note that
retaining brackets for wires/lines and coolant pipe may be secured on bolts - arrows2 - (important for
installation).
 If installed, remove retaining clips/cable ties together with Lambda probe wiring from transmission.
2:31:24 AM Page 109

 Remove remaining engine/transmission securing bolts - arrow A - and - arrow B -.

 Press transmission off dowel sleeves and lower carefully with engine/transmission jack V.A.G 1383 A
just far enough to gain access to slave cylinder.
NOTE:  When lowering transmission, make sure hydraulic line to slave cylinder is
not damaged.

 Remove slave cylinder from transmission - arrow - and secure with wire; do not open line/hose system.
 Lower transmission completely with engine/transmission jack V.A.G 1383 A.
2:31:24 AM Page 110

drive axles.
 Before carrying out assembly work, secure transmission to assembly stand, using holding fixture VW 540
--> Transmission, mounting on assembly stand.
Fig. 158: Transmission Mounting

Installing transmission --> Transmission, installing in vehicles with 4-cylinder or 6-cylinder engine.
2:31:24 AM Page 111




2:31:24 AM Page 112

Fig. 160: Engine Sling 2024 A

 Engine sling 2024 A

Procedure
replaced in the same position when installing.

Cabriolet
2:31:24 AM Page 113




2:31:24 AM Page 114



 Unfasten coolant expansion tank - arrow -.

coolant expansion tank. Move coolant expansion tank (with coolant hoses - 1to 3 - attached) clear to one
side.
2:31:24 AM Page 115


 Remove bolts - arrows - from solenoid valve mounting plate - 3 -.

 Disconnect air intake hose - 1 - from mass air flow sensor.
 Pull hose - 4 - for crankcase breather system off air duct - 2 -.
2:31:24 AM Page 116

 Loosen bolt - arrow - and disconnect air duct - 2 - from throttle valve module.
 If installed, disconnect hose - 1 - from air duct.
NOTE:  In the illustration, the air duct is shown from the rear and with the engine
removed.
 Remove engine/transmission securing bolts which are accessible from above.

 Disconnect connectors - 1 to 4 - from retainer at left of bulkhead.

 Move oxygen sensor wires clear.
 Remove retainer for connectors.

2:31:24 AM Page 117

 Remove nut - 1 - (access from above), connecting left front exhaust pipe with exhaust manifold.

 To avoid damaging edges of fenders use Engine support bridge 10-222 A, insert insert pad for front
 Set up Engine support bridge 10-222 A on fender mounting flanges.
2:31:24 AM Page 118


 Remove eye of lifting tackle 2024A.

 Re-insert pin - 1 - in middle hole on lifting tackle and secure it with split pin.
 Hook pin on lifting tackle 2024A onto spindle on Engine support bridge 10-222 A.
 Hook lifting tackle 2024A into lifting eyes at front and rear of engine.
 Slightly pretension engine with spindle of Engine support bridge.
Fig. 174: Fasteners

auxiliary/additional heater to sound insulation.
2:31:24 AM Page 119


 If installed, loosen quick-release fasteners - 3 - and remove rear sound insulation - B -.

2:31:24 AM Page 120


 Remove heat shield - arrow - for drive axles (left and right).

 If installed, remove tunnel cross member (front) - 1 to 4 -.
2:31:24 AM Page 121



 Remove bracket for exhaust pipe (front right) from transmission.
 Remove nuts - 1 - at bottom of engine mountings (left and right).
2:31:24 AM Page 122

 If installed, unclip operating rod for Left Front Level Control System Sensor G78 from lower transverse
link - arrow -.

 Before loosening subframe, use testing mandrel 3393 to check whether holes - 1 - and - 2 - are aligned.
If holes are not aligned, a wheel alignment has to be performed after installing the subframe.
2:31:24 AM Page 123

 Remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
 Lower subframe at front.

2:31:24 AM Page 124

 Temporarily secure subframe again.
Temporary tightening torque:
1 - approx. 100 Nm
2 - approx. 70 Nm
3 - approx. 70 Nm

 Remove drive axles - 1 - from flange shafts and tie up to side.
NOTE:  Do not damage surface coating on drive axles.
 Support transmission with engine/transmission jack V.A.G 1383 A.

 Remove bolts - 2 - and then bolts - 3 - at tunnel cross member.
 Remove two nuts - 4 - and detach tunnel cross member.
 Carefully lower engine/transmission jack V.A.G 1383 A and move it aside.
2:31:24 AM Page 125


 Disconnect push rod - 1 - ; by removing hex socket-head bolt.
Fig. 188: Back-Up Light Switch Connector

 Disconnect connector - arrow - for back-up light switch on right side of transmission.
2:31:24 AM Page 126

Fig. 190: Locating Cable Ties And Oxygen Sensor Wiring At Side
 Open cable ties - arrows A and B - , unclip oxygen sensor wiring at side - arrows C - and move wiring
clear.


2:31:24 AM Page 127

 If installed, remove engine speed (RPM) sensor G28 from left side of transmission - arrow - and lay
aside.
 Remove upper engine/transmission securing bolts as well as those on the side, except for bolts marked
with - arrow A - and - arrow B -.
2:31:24 AM Page 128

 To remove manual transmission 01X set up transmission support 3282 with adjustment plate 3282 /43
NOTE:  The adjustment plate 3282/49 - arrows A - and 3282/52 - arrows B - are



2:31:24 AM Page 129


 Press transmission off dowel sleeves and lower carefully using engine/transmission jack V.A.G 1383 A
NOTE:  When lowering transmission, ensure hydraulic line to slave cylinder is not
damaged.

2:31:24 AM Page 130


drive axles.

 If installing a new transmission instead of the one removed, the transmission mounting has to be
transferred to new transmission - arrows -.
Transmission, installing in vehicles with 4-cylinder or 6-cylinder engine
Installation is perform in reverse sequence; note the following:
 Use a thread tap to remove any remaining locking fluid from all threaded holes which will accommodate
self-locking bolts.
 Always replace self-locking bolts and nuts.
apply only a very thin coating of grease for clutch plate splines G000100 to splines. Do not grease
guide sleeve.
It should be possible to push the clutch plate back and forth slightly on the input shaft.
2:31:24 AM Page 131



 Check that dowel sleeves for centralizing engine/transmission are in cylinder block, install if necessary.
 Before installing transmission, tie electrical wires and brackets off to one side so that they are not trapped
between engine and the transmission.
2:31:24 AM Page 132

 Lightly lubricate surface where operating rod and clutch release lever make contact - arrow B - using
 Raise transmission far enough to be able to install slave cylinder with bracket for hose/line assembly.

 Secure slave cylinder with new bolt - arrow -.

 Insert transmission, making sure there is sufficient clearance to drive axles.
2:31:24 AM Page 133

 Install engine/transmission securing bolts - arrow A - and - arrow B -.


2:31:24 AM Page 134


 Carefully lower transmission a short distance using engine/transmission jack V.A.G 1383 A.
 If possible, tighten upper engine/transmission securing bolts - arrows1 - and - arrows2 -.
 If installed, secure all electrical wiring to transmission again - arrows A to C -.
2:31:24 AM Page 135

 If installed, install engine speed (RPM) sensor G28 on left side of transmission.

 Install push rod - 1 - ; by tightening hex socket-head bolt.

2:31:24 AM Page 136


 Connect electrical connector - arrow - for reversing light switch on transmission (right side).

 Lift transmission again using engine/transmission jack V.A.G 1383 A.

 Attach tunnel cross member to body with new bolts - 2 - and - 3 - (tighten hand-tight only).
 Secure tunnel cross member to transmission mounting - 4 - --> 40 - FRONT SUSPENSION .
 Bolt drive axles - 1 - to flange shafts --> 40 - FRONT SUSPENSION .
2:31:24 AM Page 137

 Weight of engine is supported with engine support bridge Fig. 172.

 Tighten three lower engine/transmission securing bolts at bottom - arrows -.
2:31:24 AM Page 138

 Replace front subframe bolts - 1 - , - 2 - and - 3 - on both sides of vehicle.
Before tightening subframe, it must be aligned with body using testing mandrel 3393.
 Hole - 1 - and hole - 2 - of subframe and hole - 3 - of aluminum bracket must be flush on both sides.
NOTE:  This alignment can only replace a subsequent wheel alignment if holes - 1
- and - 2 - coincided before the repair work was perform.
2:31:24 AM Page 139

Cabriolet vehicles with 4-cylinder engine:
 Lift engine slightly using spindles.

 Tighten bottom engine/transmission securing bolts - arrows -.

2:31:24 AM Page 140


 Secure torque reaction support - arrows -.
 Tighten nuts - 1 - for engine mountings -->

 10 ENGINE - ASSEMBLY for AVK
 10 - ENGINE - ASSEMBLY for BPG

 Install exhaust system and align stress free -->
.
 Check selector mechanism setting and adjust if necessary --> Selector mechanism, adjusting.
2:31:24 AM Page 141

 Check fluid level in transmission --> Transmission oil level, checking.

.
 Wheel alignment is not necessary if subframe was located in relation to body using testing mandrel 3393
prior to disassembling and assembly of subframe (before tightening bolts).
 Wheel alignment must, however, be perform if the subframe was not located in relation to body using
testing mandrel 3393 or if it was not possible to fully insert two pins into holes.
Tightening torques


Engine/transmission attachment (2.0 ltr. engine)
Item Bolt Nm
1 * See note M12x75 65
2:31:24 AM Page 142

4, 6 M12x90 65
5 * See note M12x110 65
8, 9, 10 M10x45 45
11 * See note M12x110 65
*For securing starter to transmission
*With bracket for wiring harness
*Hammer head bolt with nut
*With nut

Engine/transmission attachment (6-cylinder 3.0 ltr. engine)
Item Bolt Nm
1, 10, 11 M10x60 45
2 * See note M10x150 65
3 * See note M12x130 65
4 M12x85 65
5, 6 M12x90 65
7 M12x100 65
8 M12x95 65
2:31:24 AM Page 143

Component Nm
Slave cylinder to transmission 23 * See note
Transmission selector lever to transmission 23
*replace bolt
Transporting the transmission

2:31:24 AM Page 144

Fig. 223: Transmission Lift Hook T40013

 Transmission lift hook T40013
Procedure
Fig. 224: Hook Of Workshop Crane Fastened In 4th Notch On Lifting Tackle
 Insert transmission lift hook T40013 in lifting eye on transmission and secure.
 Fasten hook of workshop crane in 4th notch - arrow - on lifting tackle.
 Lift transmission with workshop crane and transmission lift hook T40013.
2:31:25 AM Page 145



Removing
2:31:25 AM Page 146


Between
 Use engine/transmission jack V.A.G 1383 A to lift transmission up slightly. Insert a wooden block - 1 -
between transmission and transmission jack.


 Remove two nuts - 1 - and push tunnel cross member backward slightly.
2:31:25 AM Page 147


 Remove transmission mounting - arrows -.

Installing
Installation is in reverse sequence. Note the following:
 Secure transmission mounting to transmission - arrows - (tightening torque: 23 Nm).
2:31:25 AM Page 148



 Lift transmission far enough to be able to screw in bolts - 2 -.

 Tighten bolts - 2 - and then bolts - 1 - --> 40 - FRONT SUSPENSION .
NOTE:  Replace bolts - 1 - and - 2 -.
 Install exhaust system so it is free of stress -->

Tightening torques
Component Nm
2:31:25 AM Page 149




Procedure
2:31:25 AM Page 150

 To check gear oil level, remove oil filler plug - arrow -.
Fig. 236: Identifying Correct Oil Level

Oil level is correct when transmission is filled up to edge of housing - arrow -.
 Top off with gear oil if necessary. Specification --> Code letters, allocation, transmission ratios,
capacities.
 Install oil filler plug and tighten.

Note the following when filling with new oil:
 Remove oil filler plug - arrow -.
2:31:25 AM Page 151


 Fill with gear oil up to edge of housing - arrow -.

 Start engine, engage a gear and allow transmission to turn for approx. 2 minutes.
 Switch off engine and remove oil filler plug.
Once more, fill with gear oil up to edge of housing - arrow -.
 Screw in oil filler plug and tighten.
Tightening torque
Component Nm
Oil filler plug 45
TRANSMISSION, MOUNTING ON ASSEMBLY STAND
Transmission, mounting on assembly stand
2:31:25 AM Page 152

Fig. 239: Identifying Special Tools - Transmission, Mounting On Assembly Stand

 Support clamp VW313

 Engine/transmission support VW540
 Workshop crane VAS6100
2:31:25 AM Page 153

Procedure
 Fasten hook of workshop crane VAS6100 in 4th notch - arrow - on transmission lift hook T40013.
 Lift transmission with workshop crane VAS6100 and transmission lift hook T40013.
Fig. 241: Holding Fixture VW 540 Secured To Transmission And Installed Into Support Clamp VW313
 Secure holding fixture VW 540 to transmission and install into support clamp VW313.
Transmission, overview
2:31:25 AM Page 154


1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - 6th gear
7 - Reverse gear
2:31:25 AM Page 155

10 - Bearing housing
12 - Ball bearing
 For input shaft
14 - Differential
Assembly overview
Sequence for disassembling and assembling --> Disassembling and assembling sequence
2:31:25 AM Page 156

Fig. 243: Transmission Overview

1 - Transmission housing with differential, ball bearing for input shaft and selector shaft
 Removing and installing ball bearing for input shaft, transmission cover, bearing housing and selector
shaft --> Ball bearing for input shaft, transmission cover, bearing housing and selector shaft,
removing and installing, assembly overview
 Removing and installing differential --> Differential, removing and installing
 Servicing transmission housing --> Transmission housing, servicing
2 - Bearing housing with gear assembly
 Removing and installing 3rd to 6th gear --> 3rd to 6th gear assembly overview, removing and
installing
 Removing and installing input shaft, output shaft with selector gear for 1st and 2nd gear, reverse gear
2:31:25 AM Page 157

wheel and reverse selector gear --> Input shaft, output shaft, reverse gear wheel and reverse selector
gear, assembly overview, removing and installing
Ball bearing for input shaft, transmission cover, bearing housing and selector shaft, removing and installing, assembly
overview
Fig. 244: Ball Bearing For Input Shaft, Transmission Cover, Bearing Housing And Selector Shaft,
Removing And Installing, Assembly Overview
1 - Torx bolt, 35Nm
2:31:25 AM Page 158

 3 (Qty.)
2 - Guide sleeve
 With seal
 Removing and installing --> Disassembling and assembling sequence
3 - O-ring
 Always replace
4 - Dished spring
5 - Circlip
 Note thickness
 Re-determining thickness
6 - Ball bearing
7 - Circlip
 Note thickness
 2 (Qty.)
 Apply locking fluid AMV185101A1 when installing
9 - Dowel sleeve
 2 (Qty.)
 Insert in transmission housing
 Remove and install with drift 3121
11 - O-ring
2:31:25 AM Page 159


 Always replace
 Lubricate with gear oil
 With Back-up light switch F4

13 - Bolt, 24 Nm
 3 (Qty.)
14 - Back-up light switch F4 -20 Nm-
15 - Pin
 For selector shaft stop

 Installation position: groove on threaded pin points toward selector shaft cover
16 - Dowel sleeve
 2 (Qty.)
 Insert in bearing housing
18 - Bolt, 35 Nm plus an additional 90° 1 /4 turn
 12 (Qty.)
installing
2:31:25 AM Page 160

 Servicing --> Bearing housing, servicing

3rd to 6th gear assembly overview, removing and installing
NOTE:  3rd to 6th speed selector gears should have an axial play of 0.20to 0.50mm
after installing.
2:31:25 AM Page 161

Fig. 245: 3rd To 6th Gear Assembly Overview

1 - Bearing housing
 With input shaft and output shaft
2 - Oil collector
 With magnet
 Clipped into reverse shaft support.
3 - Circlip
 Install thickest circlip that will still just fit.

 Re-determining thickness --> Disassembling and assembling sequence
2:31:25 AM Page 162

4 - 6th gear wheel
5 - Spacer sleeve
6 - 5th gear wheel
 Installation position: high inside collar faces 4th gear wheel
7 - 4th gear wheel
8 - Circlip

9 - 3rd gear wheel
 Installation position: machined side faces reverse gear synchronizing hub
10 - Thrust washer
 For 3rd speed selector gear
11 - Needle bearing
 For 3rd gear
12 - 3rd speed selector gear
 Insert spring before installing Inserting spring in selector gear

 Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)
 Checking for wear Checking synchro-ring for wear
14 - Circlip
 Mark
15 - Synchronizing hub for 3rd and 4th gear
 Installation position: high inside collar faces 3rd speed selector gear
2:31:25 AM Page 163

16 - Circlip
 Mark position in relation to synchronizing hub prior to removing
18 - Selector fork for 3rd and 4th gear
19 - Pin with clip
 For securing selector fork for 3rd and 4th gear to selector rod
21 - 4th speed selector gear

22 - Needle bearing
 For 4th gear
23 - Thrust washer
 For 4th speed and 5th speed selector gears
24 - Needle bearing inner race
 For 5th gear
25 - Needle bearing
 For 5th gear

2:31:25 AM Page 164

28 - Synchronizing hub for 5th and 6th gear
 For 6th gear
31 - Needle bearing
 For 6th gear

34 - Thrust washer
 For 6th speed selector gear
35 - Inner race
 For needle roller bearing
36 - Multi-point socket head bolt, 150Nm
37 - Selector fork for 5th and 6th gear
38 - Pin with clip
 For securing selector fork for 5th and 6th gear to selector rod
Input shaft, output shaft, reverse gear wheel and reverse selector gear, assembly overview, removing and installing
Sequence for dismantling and assembling --> Disassembling and assembling sequence
2:31:25 AM Page 165

Fig. 246: Input Shaft, Output Shaft, Reverse Gear Wheel And Reverse Selector Gear, Assembly
Overview
1 - Bearing housing
2 - Reverse gear wheel
 With support for reverse shaft

 Assembly overview - reverse gear wheel Assembly overview - reverse gear wheel
3 - Bolt, 30 Nm
 3 (Qty.)
4 - Reverse gear selector fork
2:31:25 AM Page 166

5 - Pin with clip
 For securing reverse gear selector fork to selector rod
6 - Reverse gear locking collar

 Installation position: taper faces reverse gear synchro-ring
7 - Reverse gear synchronizing hub
 Installation position: high inside collar faces 3rd gear wheel
8 - Synchronizing ring for reverse gear
9 - Reverse selector gear

10 - Needle bearing
 With tapered roller bearing and selector gears for 1st and 2nd speed
 Disassembling and assembling --> Pinion shaft, disassembling and assembling
12 - Input shaft
 Disassembling and assembling --> Input shaft, disassembling and assembling
Assembly overview - reverse gear wheel
2:31:25 AM Page 167

Fig. 247: Assembly Overview - Reverse Gear Wheel

1. Thrust washer
2. Needle bearing
3. Reverse gear wheel
Installation position: collar points toward bearing housing
4 - Reverse shaft support
Disassembling and assembling sequence
Removing and installing ball bearing for input shaft, selector shaft, transmission cover and bearing housing with
input shaft and pinion shaft.
2:31:25 AM Page 168

Fig. 248: Identifying Special Tools - Transmission Disassembling And Assembling Sequence (1 Of 5)
 Drift sleeve VW 244 B

 Tube 60 mm dia. VW 415 A

 Thrust pad con. VW 433
2:31:25 AM Page 169

 Sleeve VW 519
 Press tool 40 - 21
 Sleeve 40 - 103
2:31:25 AM Page 170


 Mandrel 2064
 Door hinge alignment tool (M8 and M10) 3114/2

 Fitting tool T10246
2:31:25 AM Page 171

 Repair press V.A.G 1290 A


 Adapter V.A.G 1582/12
 - 2 - Puller Kukko 18/2
2:31:25 AM Page 172

 Removal plate T40086

 Holding plate T40088/1
 - 1 - Two-arm puller Kukko 20/10
 - 2 - Puller hook, length 200 mm

 Feeler gauge
 2 bolts M8 (length 70 mm) with washers
2:31:25 AM Page 173

 Assembly sleeve 01E311120

 Locking fluid AMV185101A1
Disassembling transmission
Fig. 253: Transmission Mounted On Assembly Stand

 Mount transmission on assembly stand.

 Drain transmission oil.

 Remove clutch release lever - A - together with release bearing.

 Remove guide sleeve - B -
 Remove dished spring - C -.
 Remove circlip - D - in front of ball bearing for input shaft.
NOTE:  If the input shaft or transmission housing is not to be replaced, note the
2:31:25 AM Page 174

thickness of the circlip.
Fig. 255: Pulling Ball Bearing For Input Shaft Out Of Transmission Housing
 Pull ball bearing for input shaft out of transmission housing.
 Remove circlip - arrow - behind ball bearing for input shaft.
2:31:25 AM Page 175

Fig. 257: Selector Shaft Cover Bolts

 Remove bolts - arrows - and selector shaft cover - A -.
Fig. 258: Selector Shaft Locking Bolts

 Remove two locking bolts - 1 - for selector shaft.
 Push selector shaft - 2 - into transmission as far as it will go, simultaneously removing pin - 3 -.
 Remove selector shaft.
2:31:25 AM Page 176

Fig. 259: Locating Selector Rods

 Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g.
reverse gear and 1st gear).
Fig. 260: Transmission Cover Securing Bolts

 Remove securing bolts for transmission cover - arrows -.
Fig. 261: Transmission Cover, Bearing Housing And Transmission Housing
2:31:25 AM Page 177

 Carefully remove transmission cover - A - toward rear. The bearing housing - B - remains installed to
transmission housing - C -.
Fig. 262: Securing Bearing Housing To Transmission Housing With Two Bolts M8 And Washers
 Secure bearing housing to transmission housing - arrows - with two bolts M8 (length approx. 70 mm)
and washers.
 Tighten 2 bolts - arrows - to max. 5 Nm.
 Detach oil collector - A -.
Fig. 263: Removing/Installing Multi-Point Socket Head Bolt For Input Shaft
 Check that the 2 gears are still engaged and then unscrew and remove multi-point socket head bolt - 1 -
for input shaft.
2:31:25 AM Page 178

Fig. 264: Detaching 6th Speed Selector Gear With Inner Race For Roller Bearing And Thrust Washer
 Detach 6th speed selector gear with inner race for roller bearing and thrust washer.
NOTE:  Check the gear teeth on the selector gears and gear wheels for damage
after pulling them off.
 Remove synchro-ring and needle bearing for 6th speed selector gear.
Fig. 265: Removing 6th Gear Wheel

 Remove 6th gear wheel.
 Remove spacer sleeve from output shaft.
2:31:25 AM Page 179

Fig. 266: Identifying Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip,
Selector Rod, Selector Fork And Locking Collar
 Pull out pin with clip - A - for securing selector fork for 5th and 6th gear from selector rod - B -.
 Mark installation position of locking collar in relation to synchronizing hub - arrow -.
 Move selector fork - C - downward and detach with locking collar - D -.
Fig. 267: Removing 5th Speed Selector Gear Together With Needle Bearing Inner Race For 6th Gear
And Synchronizing Hub For 5th And 6th Gear
 Remove 5th speed selector gear together with needle bearing inner race for 6th gear and synchronizing
hub for 5th and 6th gear.
A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm
NOTE:  Counter-hold two-arm puller using e.g. open end wrench - B -.

 If the needle bearing inner race for 6th gear is in contact with press tool
VW 433, insert locking pin 2064 into hole in input shaft to pull off the
components all the way.
2:31:26 AM Page 180

Fig. 268: Remove 4th And 5th Gear Wheels Together

 Remove 4th and 5th gear wheels together.
A - Puller, e.g. Kukko 18/2
NOTE:  Counter-hold puller - A - using e.g. transmission bracket 2004.
Fig. 269: Removing 4th Speed Selector Gear With Needle Bearing Inner Race For 5th Gear And Thrust
Washer
 Remove 4th speed selector gear with needle bearing inner race for 5th gear and thrust washer.
 Counter-hold two-arm puller using e.g. open end wrench - B -.

2:31:26 AM Page 181

Fig. 270: Pulling Pin With Clip Securing Selector Fork For 3rd And 4th Gear Out From Selector Rod
 Pull pin with clip - A - securing selector fork for 3rd and 4th gear out from selector rod - B -.
 Detach selector fork - C - with locking collar - D -.

 Remove circlip for 3rd gear and 4th gear synchronizing hub and note thickness of circlip.
Fig. 271: Pulling Off 3rd Speed Selector Gear With Synchronizing Hub For 3rd And 4th Gear
 Pull off 3rd speed selector gear with synchronizing hub for 3rd and 4th gear.
NOTE:  Counter-hold puller - A - using e.g. transmission bracket 2004 to prevent

plate T40086 from making contact with 3rd gear wheel or selector rod for
5th and 6th gear.
 Remove circlip for 3rd speed selector gear needle bearing and detach 3rd gear needle bearing.
2:31:26 AM Page 182

Fig. 272: Pulling Off Thrust Washer For 3rd Speed Selector Gear
 Pull off thrust washer - B - for 3rd speed selector gear.
Fig. 273: Removing Circlip For 3rd Gear Wheel

 Remove circlip for 3rd gear wheel and note thickness of circlip.
 Pull off 3rd gear wheel.
2:31:26 AM Page 183

Fig. 274: Reverse Shaft Support Bolts, Bearing Housing And Bolts
 Remove bolts - arrows - for reverse shaft support.

 Remove 2 bolts - A - for bearing housing at transmission housing.
 Remove bearing housing - B - together with shafts.
Fig. 275: Driving Reverse Shaft Support Carefully Out Of Bearing Housing And Removing With Reverse
Gear Wheel
 Insert an internal puller - A - e.g. Kukko 21/2 into bore for reverse shaft support.
 Spread open internal puller far enough for it to make contact with reverse shaft support - B -.
 Drive reverse shaft support carefully out of bearing housing direction of - arrow - and remove with
reverse gear wheel.
2:31:26 AM Page 184

Fig. 276: Pulling Out Input Shaft From Bearing Housing At An Angle From The Front Direction Of
 Pull out input shaft - A - carefully from bearing housing at an angle from the front direction of - arrow -.
Fig. 277: Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod,
Selector Fork And Locking Collar
 Pull pin with clip - A - for securing selector fork for reverse gear out from selector rod - B -.
2:31:26 AM Page 185

Fig. 278: Pressing Off Synchronizing Hub For Reverse Gear From Output Shaft
 Press off synchronizing hub for reverse gear from output shaft.
NOTE:  Place the bearing housing onto thrust plates VW 401 and VW 402 so that
the output shaft and selector rods are not damaged when pressing off the
synchronizing hub.
 Detach reverse selector gear, needle bearing for reverse selector gear and reverse gear synchronizing hub.
 Guide output shaft out of selector fork for 1st and 2nd gear and bearing housing.
Assembling transmission
If the input shaft or the transmission housing have been replaced, you must first re-determine the thickness of
the input shaft circlips --> Determining circlips for input shaft ball bearing.
NOTE:  Lubricate all needle bearings with gear oil before installing.
 Check synchro-rings for wear Checking synchro-ring for wear
 Insert spring in selector gear Inserting spring in selector gear
 Heat gear wheels, needle bearing inner races and synchronizing hubs to
130° C (max.) before pressing on (wear protective gloves).
 Insert output shaft in bearing housing and selector fork for 1st and 2nd gear.
 Place reverse gear selector gear with needle bearing, spring and synchro-ring onto output shaft.
 The lugs on synchro-ring should engage into recesses in selector gear.
2:31:26 AM Page 186

Fig. 279: Pressing On Reverse Gear Synchronizing Hub

 Press on reverse gear synchronizing hub.
 Installation position: high inside collar faces 3rd gear wheel.
 Check axial clearance of reverse selector gear.
Fig. 280: Inserting Input Shaft With Needle Roller Bearing Into Bearing Housing At An Angle Toward
The Rear
 Insert input shaft - A - with needle roller bearing - B - into bearing housing in direction of - arrow - at an
angle toward the rear.
2:31:26 AM Page 187

Fig. 281: Reverse Gear Wheel Bolts

 Install reverse gear wheel and tighten 3 bolts - arrows - for reverse shaft support to 30 Nm.
Assembly overview - reverse gear wheel Assembly overview - reverse gear wheel
 Slide reverse gear selector fork - C - together with locking collar - D - onto selector rod - B - and reverse
gear synchronizing hub.
 The markings on locking collar and synchronizing hub - arrow - must coincide.
 The chamfer on locking collar faces reverse selector gear.
 If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.
2:31:26 AM Page 188

Fig. 283: Plate T40088/1 Placed On Press Table And Bearing Housing Inserted With Shafts And Selector
Rods
 Place plate T40088/1 on press table and insert bearing housing with shafts and selector rods.
Fig. 284: Pressing On 3rd Gear Wheel

 Press on 3rd gear wheel.
 Installation position: machined side faces reverse gear synchronizing hub.
 Insert circlip for 3rd gear wheel.
 When replacing gear wheel or output shaft:
2:31:26 AM Page 189

Re-determine thickness of circlip for 3rd gear wheel:
 Determine thickest circlip that will just fit and install it. For Part No.

1.90 1.98 2.06
1.94 2.02 2.10
Fig. 285: Pressing On Thrust Washer For 3rd Speed Selector Gear Until Limit Stop
 Press on thrust washer - A - for 3rd speed selector gear until limit stop.
Fig. 286: Installing Needle Bearing For 3rd Speed Selector Gear And Circlip For 3rd Gear Needle
Bearing Onto Input Shaft
 Install needle bearing for 3rd speed selector gear - 1 - and circlip - 2 - for 3rd gear needle bearing onto
input shaft.
 Install 3rd speed selector gear with spring and synchro-ring.
2:31:26 AM Page 190

Fig. 287: Pressing On Heated Synchronizing Hub For 3rd And 4th Gear
 Press on heated synchronizing hub for 3rd and 4th gear
 Installation position: high inside collar faces 3rd speed selector gear.

 Insert circlip for synchronizing hub for 3rd and 4th gear.
 When replacing synchronizing hub or input shaft:
Re-determine thickness of circlip for synchronizing hub for 3rd and 4th gear:
2:31:26 AM Page 191

1.90 1.96 2.02

1.93 1.99 2.05
 Check axial clearance of 3rd speed selector gear.
 Slide selector fork for 3rd and 4th gear - C - together with locking collar - D - onto selector rod - B - and
synchronizing hub for 3rd and 4th gear.
NOTE:  Do not insert pin with clip for 5th/6th gear selector fork (diameter 6 mm)
into selector fork for 3rd and 4th gear.
Fig. 290: Installing 4th Speed Selector Gear With Spring, Synchro-Ring, Needle Bearing And Thrust
Washer For 3rd And 4th Gear And Pressing On Heated Inner Race For Needle Bearing For 5th Speed
Selector Gear
2:31:26 AM Page 192

 Install 4th speed selector gear - A - with spring, synchro-ring, needle bearing and thrust washer for 3rd
and 4th gear - B -.
 Press on heated inner race - C - for needle bearing for 5th speed selector gear.
 Check axial clearance of 4th speed selector gear.
Fig. 291: Pressing On 4th Gear Wheel

 Heat 4th gear wheel and press on.
 Installation position: high inside collar faces 5th gear wheel.

2:31:26 AM Page 193

Fig. 293: Pressing On Heated Synchronizing Hub For 5th And 6th Gear
 Place 5th speed selector gear with spring, synchro-ring and needle bearing onto input shaft.
 Install and press on heated synchronizing hub for 5th and 6th gear.
 Slide selector fork for 5th and 6th gear - C - together with locking collar - D - onto synchronizing hub for
5th and 6th gear.
 Move selector fork for 5th and 6th gear - C - into selector rod - B -.
 If holes of selector fork and selector rod coincide, clip in pin with clip - A -.
2:31:26 AM Page 194

Fig. 295: Pressing On Heated Inner Race For Needle Bearing For 5th Speed Selector Gear
 Press on heated inner race for needle bearing for 5th speed selector gear.
Fig. 296: Pressing On 6th Speed Selector Gear

 Install 6th speed selector gear with spring, synchro-ring, needle bearing and thrust washer for 6th gear - A
-.
 Heat inner race - B - for needle roller bearing and press on.
2:31:26 AM Page 195


 Install spacer sleeve - A - onto output shaft.

Fig. 298: Identifying 6th Gear Wheel Circlip

Insert circlip - A - for 6th gear wheel.
Re-determine circlip - A - for 6th gear wheel:

1.90 2.02 2.14
1.93 2.05 2.17
2:31:26 AM Page 196

1.96 2.08 2.20

1.99 2.11
 Remove bearing housing from holding plate T40088/1.
Fig. 299: Bearing Housing Secured To Transmission Housing With Two Bolts M8 And Washers
 Secure bearing housing to transmission housing with two bolts M8 (length approx. 70 mm) - arrows -
and washers.
 Tighten these 2 bolts - arrows - to max. 5 Nm.
NOTE:  Do not install oil collector - A - at this stage.

2:31:26 AM Page 197

 Tighten multi-point socket head bolt - 1 - for input shaft to 150 Nm.
 Remove complete bearing housing from transmission housing.
 Check if the 2 dowel sleeves are installed between transmission housing and bearing housing.
 Apply sealing paste AMV 188 001 01 evenly and not too thickly onto contact surfaces between
transmission housing and bearing housing.
 Install bearing housing onto transmission housing.
 Clip oil collector - A - into reverse shaft support.
NOTE:  Make sure that the bolts - arrows - are removed.
2:31:26 AM Page 198


 Check if the 2 dowel sleeves are installed between bearing housing - B - and transmission cover - A -.
 Apply sealing paste AMV 188 001 02 evenly and not too thickly onto contact surfaces between bearing
housing and transmission cover.
 Insert securing bolts for transmission cover - A - and bearing housing - B - to transmission housing - C -.

 Tighten bolts - arrows - to 35Nmplus an additional 90° 1 /4 turn.
2:31:26 AM Page 199

 Push assembly sleeve 01E311120 - A - onto selector shaft - B -.
NOTE:  To avoid damaging the oil seal - C - , the oil seal and selector shaft must
only be installed using assembly sleeve 01E311120 - A -.
 Move selector rods to neutral.

 Installation position: Chamfer of selector shaft points downward.

 Push selector shaft - 2 - into transmission as far as it will go, simultaneously inserting pin - 3 -.
 Installation position for pin - 3 - : The groove - arrow - on pin points toward selector shaft cover.
 Clean threads of locking bolts - 1 - with a wire brush. Then insert bolts with locking fluid
AMV185101A1 and tighten to 45 Nm.
2:31:26 AM Page 200


 Install cover - A - with new O-ring.

 Clean threads of bolts - arrows - with a wire brush. Then insert bolts with locking fluid AMV185101A1
and tighten to 24 Nm.
 Install rear circlip - arrow - for input shaft ball bearing.

 Then push ball bearing onto input shaft.
The sealed side of ball cage faces transmission housing.
2:31:26 AM Page 201


 Pressing in ball bearing:
First screw door hinge alignment tool (M8 and M10) 3114/2 into tapped hole for ball head stud.
Slide thrust plate T10246/2 onto input shaft.
Position fitting tool T10246/1 behind splines for clutch plate. Tighten bolts - A - only slightly. The bolts locate
in recesses in the thrust plate T10246/2.
Press in ball bearing onto stop by tightening bolts alternately (1/2 turn at a time).

 Install front circlip - D - for input shaft ball bearing.

 Install dished spring - C -.
The curved side faces guide sleeve - B -.
2:31:26 AM Page 202

 Install a shrink hose onto input shaft splines.

 Install guide sleeve - B - for release bearing.
 Remove shrink hose.
 Install clutch release lever - A - with release bearing.

2:31:26 AM Page 203


 Thrust pad VW 512

 Sleeve VW 519


2:31:26 AM Page 204


 - 1 - internal puller Kukko 21/2
Fig. 313: Transmission Cover Remove/Install Components

2:31:26 AM Page 205

2 - Dowel sleeve
 2x
 For centralizing transmission cover on bearing housing
 Drive out and in with drift 3121
3 - Roller bearing
 Bearing for output shaft in transmission cover

 Always replace
 Pulling out Pulling roller bearing for output shaft out of transmission cover
 Pressing in Pressing new roller bearing for output shaft into transmission cover as far as the stop
(press in carefully)
4 - Roller bearing
 Bearing for input shaft in transmission cover

 With lubricating unit
 Always replace
 Pulling out Pulling roller bearing for input shaft out of transmission cover
 Pressing in Pressing new roller bearing for input shaft into transmission cover as far as stop (press
in carefully)
5 - Ball sleeve

 Pulling out Pulling out ball sleeve - C - from transmission cover
 Driving in Driving ball sleeve into transmission cover until flush
6 - Ball sleeve

8 - Retaining plate
 Installation position Securing needle roller bearing and needle bearing in transmission cover.
Pulling roller bearing for output shaft out of transmission cover
2:31:26 AM Page 206

Fig. 314: Pulling Roller Bearing For Output Shaft Out Of Transmission Cover
B - Internal puller 37... 46 mm, e.g. Kukko 21/6
NOTE:  Always replace needle roller bearing after pulling out.
Pressing new roller bearing for output shaft into transmission cover as far as the stop (press in carefully)
Fig. 315: Pressing New Roller Bearing For Output Shaft Into Transmission Cover As Far As The Stop
Support transmission cover with thrust plate VW 447 i directly below bearing mounting.
Pulling out ball sleeve - C - from transmission cover
2:31:26 AM Page 207

Fig. 316: Pulling Out Ball Sleeve From Transmission Cover

B - Internal puller 14.5 to 18.5 mm, e.g. Kukko 21/2
Driving ball sleeve into transmission cover until flush
Fig. 317: Driving Ball Sleeve Into Transmission Cover Until Flush
Install ball sleeve - 1 - and - 2 - so that side with lettering (thicker metal) faces guide pin 10 - 15 or centering
mandrel 3176.
NOTE:  Due to the housing depth use centering mandrel 3176 for driving in ball
sleeve - 2 -.
Pulling roller bearing for input shaft out of transmission cover
2:31:26 AM Page 208

Fig. 318: Pulling Roller Bearing For Input Shaft Out Of Transmission Cover
Shorten (cut off) lubricating unit in needle roller bearing in order to insert internal puller - B -.
Pressing new roller bearing for input shaft into transmission cover as far as stop (press in carefully)
Fig. 319: Pressing New Roller Bearing For Input Shaft Into Transmission Cover As Far As Stop
Securing needle roller bearing and needle bearing in transmission cover.
2:31:26 AM Page 209

Fig. 320: Securing Needle Roller Bearing And Needle Bearing In Transmission Cover
 Insert retaining plate - 2 - with high shoulder - arrow - facing needle bearing - 1 - into transmission
cover.
 Tighten hex socket head bolt - 3 - to 24 Nm.
BEARING HOUSING, SERVICING
Bearing housing, servicing
2:31:26 AM Page 210

Fig. 321: Identifying Special Tools - Bearing Housing, Servicing (1 Of 2)


 Installing sleeve VW 455

 Tube 42 mm dia. VW 516
2:31:26 AM Page 211


 Thrust pad 3074
 Drift T40085
2:31:26 AM Page 212

Fig. 323: Bearing Housing Remove/Install Components

1 - Bearing housing
 Re-determine shim "S4 " when replacing --> Re-determining shim "S4" when replacing bearing
housing
2 - Outer race
 For needle roller bearing on input shaft

 Driving out Driving outer race for needle roller bearing out of bearing housing
 Pressing in Pressing outer race for needle roller bearing into bearing housing until limit stop
3 - Shim "S4 "
2:31:27 AM Page 213

 Table of adjustments --> Table of adjustments

 Re-determine when replacing bearing housing --> Re-determining shim "S4" when replacing bearing
housing
 For output shaft
 Only replace together with selector fork for 1st and 2nd gear (secured together by means of a pin)
7 - Ball sleeve
 (Front) for reverse gear selector rod

 Pulling out Pulling front ball sleeve out of reverse gear selector rod
 Pressing in Pressing front ball sleeve into reverse gear selector rod until limit stop.
8 - Ball sleeve
 (Rear) for reverse gear selector rod

 Pulling out Pulling out rear ball sleeve for reverse gear selector rod
 Pressing in Pressing in rear ball sleeve - A - for reverse gear selector rod
 Remove burrs and scoring after removing from bearing housing
11 - Ball sleeve

 Pull out with internal puller Kukko 21/2
 Drive in until flush using guide pin 10 - 15
12 - Locking bushing

 Removing and installing Removing and installing locking bushing for selector rod
2:31:27 AM Page 214


14 - Ball sleeve

 Driving in Driving in ball sleeve for selector rod for 3rd and 4th gear
Driving outer race for needle roller bearing out of bearing housing
Fig. 324: Driving Outer Race For Needle Roller Bearing Out Of Bearing Housing
 Clamp bearing housing in vise, using jaw protectors - C -.

 Drive out outer race - A - using drift - B - by alternately applying drift to bearing housing recesses located
opposite to each other - arrow -.
Pressing outer race for needle roller bearing into bearing housing until limit stop
Fig. 325: Pressing Outer Race For Needle Roller Bearing Into Bearing Housing Until Limit Stop
2:31:27 AM Page 215

Pulling front ball sleeve out of reverse gear selector rod
Fig. 326: Pulling Front Ball Sleeve Out Of Reverse Gear Selector Rod
Pressing front ball sleeve into reverse gear selector rod until limit stop
Fig. 327: Pressing Front Ball Sleeve Into Reverse Gear Selector Rod Until Limit Stop
Install ball sleeve - arrow - so that side with lettering (thicker metal) faces guide pin 10 - 15.
Pulling out rear ball sleeve for reverse gear selector rod
2:31:27 AM Page 216

Fig. 328: Pulling Out Rear Ball Sleeve For Reverse Gear Selector Rod
 Clamp actuating arm of selector rod in vise, using jaw protectors - C -.

 Install thrust tube VW 454 and installing sleeve VW 455 onto selector rod.
B - Internal puller 14.5... 18.5 mm, e.g. Kukko 21/2
Pressing in rear ball sleeve - A - for reverse gear selector rod
Fig. 329: Pressing In Rear Ball Sleeve For Reverse Gear Selector Rod
Driving in ball sleeve for selector rod for 3rd and 4th gear
2:31:27 AM Page 217

Fig. 330: Driving In Ball Sleeve For Selector Rod For 3Rd And 4Th Gear
Install ball sleeve so that side with lettering (thicker metal) faces guide pin 10 - 15.
 Dimension for pressing in - a - = 2.5 mm
Removing and installing locking bushing for selector rod
Fig. 331: Removing And Installing Locking Bushing For Selector Rod
 Remove relevant selector rod (for 3rd and 4th gear or for 5th and 6th gear).
 Bolt bearing housing - B - with transmission cover - A - onto transmission housing prior to driving out
and driving in the locking bushings - C -.
 Drive out old locking bushing inward into bearing housing.

 Drive in new locking bushing until flush.
2:31:27 AM Page 218


 Needle bearing drift VW 295

 Needle bearing drift VW 295 A
 Tube VW 423
 Multi-purpose tool VW 771

2:31:27 AM Page 219


 Installing tool 40 - 503

 Drift T40085
2:31:27 AM Page 220

Fig. 334: Transmission Housing Remove/Install Components

 When replacing: adjust input shaft --> Input shaft, adjusting, adjust output shaft and differential (final
drive gear set) --> Table of adjustments
 Replacing (with transmission removed) --> Selector shaft oil seal, replacing with transmission
removed (transmission remains assembled)
 Replacing (with transmission installed) --> Selector shaft oil seal, replacing with transmission
installed
 Always replace
 Pulling out Pulling out oil seal for selector shaft with transmission disassembled
2:31:27 AM Page 221

 Driving in Driving in seal for selector shaft

 Use assembly sleeve to install (selector shaft remains installed) --> Selector shaft oil seal, replacing
with transmission removed (transmission remains assembled)
3 - Tapered roller bearing outer race (right-side)
 If replaced: adjust differential (crown wheel) --> Crown wheel, adjusting
4 - Shim "S2 "
 Note thickness
5 - Bushing
 Drive in (for example, with press tool VW 408 A when replacing transmission
6 - Magnet
 Clean
7 - Ball head stud, 25 Nm
 Grease with MoS2 grease
9 - Oil seal
 For flange shaft (right-side)

 Removing Removing flange shaft oil seal (right-side)
 Installing Installing flange shaft oil seal (right-side)


2:31:27 AM Page 222

12 - Ball sleeve

13 - Ball sleeve

14 - Shim "S3 "
 Note thickness
16 - Bolt, 24 Nm
17 - Needle bearing
 For input shaft

 Driving out Driving out input shaft needle bearing from transmission housing
 Driving in Pressing in input shaft needle bearing until limit stop
18 - Oil collector
 With magnet
 Installation position in transmission housing Securing input shaft needle bearing
19 - Ball sleeve

 Pulling out Removing selector shaft ball sleeve
 Driving in Driving in ball sleeve for selector shaft
20 - Cap
2:31:27 AM Page 223

21 - Breather pipe
 Drive in onto stop

 Clip in cap for transmission breather
Pulling out oil seal for selector shaft with transmission disassembled

Driving in seal for selector shaft

 Pack space between sealing lip and dust lip half-full with sealing grease G052128A1 .
 Drive oil seal - arrow - into housing as far as it will go.
2:31:27 AM Page 224

 Drive out used locking bushing - A - inward into transmission housing.

 Drive in new locking bushing into transmission housing - B - until flush.
Pulling out ball sleeve - C - from transmission housing.
Fig. 338: Pulling Out Ball Sleeve From Transmission Housing.

Driving out input shaft needle bearing from transmission housing
2:31:27 AM Page 225

Fig. 339: Driving Out Input Shaft Needle Bearing From Transmission Housing
 Remove bolt for securing needle bearing Securing input shaft needle bearing.
 Install adapter VW 295 A with smaller outside diameter into needle bearing.
 Drive out needle bearing with drift VW 295.
Pressing in input shaft needle bearing until limit stop
Fig. 340: Pressing In Input Shaft Needle Bearing Until Limit Stop
 Secure needle bearing after pressing in Securing input shaft needle bearing
Securing input shaft needle bearing
2:31:27 AM Page 226

Fig. 341: Securing Input Shaft Needle Bearing

 Secure input shaft needle bearing with bolt - 2 -.

 Insert oil collector - 1 - into transmission housing.
Removing selector shaft ball sleeve

Driving in ball sleeve for selector shaft
2:31:27 AM Page 227


 Drive in ball sleeve until flush.
SELECTOR SHAFT, SERVICING
Selector shaft with transmission installed, removing and installing

2:31:27 AM Page 228


 Tube VW423


2:31:27 AM Page 229

Fig. 347: Fasteners

Removing


2:31:27 AM Page 230

 Remove front exhaust pipe (right side) -->


2:31:27 AM Page 231


 Disconnect electrical connector - arrow - for back-up light switch F4.


2:31:27 AM Page 232

Fig. 355: Prying Out Seal With A Screwdriver

 Carefully pry out seal with a screwdriver.
Installing
NOTE:  replace seals and O-rings.
 Install selector shaft.
 Installation position: Chamfer of selector shaft - B - points downwards.
2:31:27 AM Page 233

NOTE:  Ignore - item A - and - item C -.

 Installation position: groove - arrow - on pin - 3 - faces toward selector shaft cover.


2:31:27 AM Page 234

NOTE:  Use mounting sleeve 01E311120 - item A - to prevent damaging the seal -
C - when installing.

 Lightly oil outer circumference of seal - arrow -.

2:31:27 AM Page 235


 Install front exhaust pipe align exhaust system so it is free of stress -->
.
Tightening torques
Component Nm
Locking bolts for selector shaft 45
Cover for selector shaft 24
Selector shaft oil seal, replacing with transmission removed (transmission remains assembled)
NOTE:  Removal is also possible with transmission installed in vehicle --> Selector
shaft oil seal, replacing with transmission installed.
2:31:27 AM Page 236


 Tube VW423

 Extractor lever T20143/1

2:31:27 AM Page 237


Removing
 With selector shaft installed
 Carefully pry out oil seal, making sure shaft is not damaged.

 With selector shaft removed
 Carefully pry out oil seal using a screwdriver or oil seal extractor lever VW 681.
Installing
01E311120 - A -.
2:31:27 AM Page 238

 Pack space between sealing lip and dust lip half full with sealing grease G052128A1 .

Selector shaft oil seal, replacing with transmission installed

 Tube VW423
2:31:27 AM Page 239




2:31:27 AM Page 240


Removing

 Remove heat shield for drive shaft (left-side).


2:31:27 AM Page 241


Installing
01E311120 - A -.
2:31:27 AM Page 242


The remaining installation steps are perform in the reverse sequence. Note the following:
 Install front exhaust pipe with catalytic converter and align exhaust system so it is free of stress --> 3.0
Liter 6-Cyl. 5V Engine Mechanical, Engine Code(s): AVK - 26 EXHAUST SYSTEM, EMISSION
CONTROLS .
 Install heat shield for drive axle (left-side).
 Check gear oil level in transmission --> Transmission oil level, checking.
Tightening torques
Component Nm
Back-up light switch F4, removing and installing
2:31:27 AM Page 243



Removing
2:31:27 AM Page 244


 Disconnect electrical connector - arrow - for back-up light switch F4 on transmission (right side).
Fig. 380: Removing Back-Up Light Switch F4 From Selector Shaft Cover
 Remove back-up light switch F4 from selector shaft cover - arrow -.
Installing
 Screw back-up light switch F4 into selector shaft cover - arrow -.
2:31:28 AM Page 245


 Attach electrical connector - arrow - for back-up light switch F4 on transmission (right side).
Component Nm
Back-up light switch F4 20
35 GEARS, SHAFTS
NOTE:  Refer to technical data when installing new gears --> Code letters,
 Lubricate all bearings on input shaft with gear oil before installing.
2:31:28 AM Page 246


1 - Circlip
 Mark
 Installation position Installation position of circlips, - item 1 -
 Determining thickness
2 - Ball bearing
3 - Circlip
 Mark
2:31:28 AM Page 247


5 - Needle bearing
 For input shaft
6 - Bolt, 24 Nm
7 - Input shaft
 Adjusting --> Input shaft, adjusting
8 - Roller bearing
 Disassembling and assembling Detaching needle roller bearing from input shaft and installing needle
roller bearing onto input shaft
 Installation position: collar faces splines for 2nd gear
9 - Outer race
11 - Thrust washer
12 - Needle bearing
 For 3rd gear
13 - Circlip
 Mark
15 - Spring
 Insert in 3rd speed selector gear --> Inserting spring in selector gear
2:31:28 AM Page 248

 Allocation of spring to selector gear
18 - Circlip
 Mark
 Re-determining thickness Determining thickness of circlip for synchronizing hub for 3rd and 4th
gear
20 - Needle bearing
 For 4th gear
22 - Spring
 Insert in 4th speed selector gear --> Inserting spring in selector gear
24 - Thrust washer
 For 5th gear
26 - Needle bearing
2:31:28 AM Page 249

 For 5th gear
28 - Spring
 For 6th gear
33 - Needle bearing
 For 6th gear
35 - Spring
 Insert in 6th speed selector gear Inserting spring in selector gear

37 - Thrust washer
38 - Inner race
2:31:28 AM Page 250

42 - Roller bearing

 Always replace
Input shaft, Disassembling and assembling
NOTE:  Removing and installing 3rd to 6th speed selector gears is described in
chapter on disassembling and assembling transmission --> Disassembling
and assembling sequence.
 Feeler gauge
Detaching needle roller bearing from input shaft and installing needle roller bearing onto input shaft
Fig. 384: Detaching Needle Roller Bearing From Input Shaft And Installing Needle Roller Bearing Onto
Input Shaft
2:31:28 AM Page 251

Removing needle roller bearing:
 Bend open needle roller bearing at separating point - arrow B - far enough for it to be detached from
input shaft (do not bend open more than necessary).
Installing needle roller bearing:
 The shoulder - arrow A - faces toward splines for 2nd gear.
 Only bend open needle roller bearing at separating point - arrow B - far enough for it to be guided over
input shaft and onto its seat - arrow C -.
Inserting spring in selector gear

The bent end of spring - arrow - must be hooked into hole in selector gear.

2:31:28 AM Page 252

 Press synchro-ring into locking collar and measure gap - a - at positions - A - , - B - and - C - using feeler
gauge.
 Add measured values and divide by 3.
 The determined value should not exceed 0.45 mm.
Fig. 387: Installation Position Of Circlips

 The circlips - 1 - and - 2 - secure input shaft ball bearing.
Determining thickness --> Determining circlips for input shaft ball bearing.
 The circlip - 3 - secures needle bearing for 3rd speed selector gear and 3rd and 4th gear synchronizing
hub.
Thickness: 2.00 mm.
 The circlip - 4 - secures 3rd and 4th gear synchronizing hub.
Determining thickness Determining thickness of circlip for synchronizing hub for 3rd and 4th gear.
Determining thickness of circlip for synchronizing hub for 3rd and 4th gear
2:31:28 AM Page 253


 Press synchronizing hub onto stop.

1.90 1.96 2.02
1.93 1.99 2.05
Determining circlips for input shaft ball bearing
It is necessary to readjust input shaft when:
or the
 Input shaft
are replaced.
2:31:28 AM Page 254


Fig. 391: Fitting Tool T10246
2:31:28 AM Page 255


 Digital depth gauge e.g. VAS 6087
Determining thickness for circlip behind input shaft ball bearing
 Install provisional circlip - arrow - in rear groove on input shaft.


Screw pin (M8 and M10) 3114/2 into tapped hole for ball head stud.
2:31:28 AM Page 256

Position fitting tool T10246/1 behind splines for clutch plate. Tighten bolts - a - only slightly. The bolts locate
in recesses in thrust plate T10246/2.
Fig. 394: Dished Spring, Guide Sleeve And Bolt

 Install dished spring - 1 -.
The convex side faces guide sleeve - 2 -.

 Bolt guide sleeve to transmission housing - 2 - with bolts - 3 -.
 Turn transmission housing so joint flange for bearing housing points upward.
 The contact surface must be cleaned to remove sealing paste .
Fig. 395: Measuring From Thrust Washer To Contact Surface Of Housing
2:31:28 AM Page 257

 Place thrust washer - 1 - for 4th and 5th speed selector gears onto input shaft.
 Place a digital depth gauge (e. g. VAS 6087) onto thrust washer and measure distance to contact surface
of housing. The measuring point on housing contact surface must be as close to input shaft as possible.
NOTE:  When measuring, lift the input shaft with e.g. support bridge 30-211A or
the help of a second mechanic until the play in the ball bearing is taken up.
Specification: distance "a" = 164.14 mm
NOTE:  If the measured value exceeds the specification, use a thinner circlip than
the circlip installed so that the specification is attained.
 If the measured value is below the specification, use a thicker circlip than
 Determine the circlip thickness to meet the specification as exactly as
possible (164.14 mm).

1.54 2.08 2.62
1.63 2.17 2.71
1.72 2.26 2.80
1.81 2.35 2.89
1.90 2.44
1.99 2.53
 Select circlip from table.

2:31:28 AM Page 258

Checking adjustment and checking distance "a"
 Determined circlip is installed.
The distance "a" should be 164.14mm +- 0.04 mm if the correct circlip has been selected.
Determining thickness for circlip in front of the input shaft ball bearing
 Drive rear circlip (as determined) and ball bearing onto input shaft using drift sleeve 30 - 100.
 Determine thickest circlip which will still fit.

 Refer to table The following circlips are available: to determine correct circlip.
PINION SHAFT (OUTPUT SHAFT)
Pinion shaft, assembly overview
NOTE:  Refer to technical data --> Code letters, allocation, transmission ratios,
capacities when installing new gear wheels or the final drive gear set.
 Refer to technical data when installing new gear wheels
 Lubricate all needle bearings on output shaft with gear oil before
installing.
 Adjustment work is required when replacing the parts marked with 1) .
Table of adjustments --> Table of adjustments
2:31:28 AM Page 259

Fig. 398: Pinion Shaft, Assembly Overview

 Servicing --> Transmission housing, servicing
2 - Shim "S3"
3 - Tapered roller bearing outer race 1)
 Pulling out Pulling tapered roller bearing outer race out of transmission housing
 Pressing in Heating transmission housing in order to install tapered roller bearing outer race and
2:31:28 AM Page 260

4 - Pinion shaft (output shaft) 1)
 Is mated with crown wheel, always replace together as a set

 Adjusting crown wheel and pinion shaft --> --> Pinion shaft and crown wheel, adjusting
5 - Tapered roller bearing inner race1)
 Will be damaged during removal

 Replace
 Pressing off Pressing off tapered roller bearing inner race
 Pressing on Pressing on tapered roller bearing inner race
6 - Circlip
 Re-determine thickness if taper roller bearing is replaced Determining thickness of circlip
7 - Needle bearing
 For 1st gear
8 - 1st speed selector gear
 Check axial clearance after installing using feeler gauge Checking axial play of 1st speed selector gear
(0.20 to 0.50 mm)
9 - Inner ring for 1st gear
 Installation position Installation position of synchronizing rings for 1st and 2nd gear:
 Checking for wear Checking 1st gear inner ring for wear
 Replace if scored or if there are visible traces of wear
 Checking for wear Checking 1st and 2nd gear intermediate ring for wear
11 - Synchro-ring for 1st gear
2:31:28 AM Page 261


 Assembling locking collar/synchronizing hub Assembling 1st and 2nd gear locking
collar/synchronizing hub
13 - Locking piece
 Install locking pieces (3 Qty.) Assembling 1st and 2nd gear locking collar/synchronizing hub
14 - Synchronizing hub for 1st and 2nd gear
 Installation position: high inside collar faces 2nd speed selector gear
 Pressing off Pressing off 1st and 2nd gear synchronizing hub
 Pressing on Pressing on 1st and 2nd gear synchronizing hub
15 - Circlip
 Mark
 Re-determine thickness when replacing 1st and 2nd gear synchronizing hub or pinion shaft Determining
thickness of circlip
16 - Needle bearing
 For 2nd gear
17 - Synchro-ring for 2nd gear
19 - Inner ring for 2nd gear
2:31:28 AM Page 262

20 - 2nd speed selector gear
 Check axial clearance after installing using feeler gauge Checking axial play of 2nd speed selector gear
(0.20 to 0.50 mm)
21 - Circlip
 Mark
 Pressing off Pressing off tapered roller bearing inner race with 2nd speed selector gear
23 - Circlip
 Mark
24 - Thrust washer
 For reverse selector gear

 Pressing off Pressing off thrust washer for reverse selector gear
 Pressing on Pressing on thrust washer for reverse selector gear
 Pulling out Pulling tapered roller bearing outer race out of bearing housing
 Pressing in Pressing tapered roller bearing outer race into bearing housing
26 - Shim "S4 "
27 - Bearing housing 1)
28 - Needle bearing
2:31:28 AM Page 263

30 - Spring
 Insert into reverse selector gear Inserting spring in selector gear


34 - 3rd gear wheel
35 - Circlip
 Mark
 Re-determine thickness when replacing 3rd gear wheel, reverse gear synchronizing hub or pinion shaft
36 - 4th gear wheel
37 - 5th gear wheel
38 - Spacer sleeve
39 - 6th gear wheel
40 - Circlip
 Mark
2:31:28 AM Page 264

 Re-determine thickness when replacing gear wheels for 4th to 6th gear, the spacer sleeve or pinion shaft
41 - Needle bearing
 Bearing for pinion shaft in transmission cover


2:31:28 AM Page 265

gauge.
The determined value should not exceed 0.45 mm.
Pinion shaft, disassembling and assembling
NOTE:  Removing and installing gear wheels for 3rd to 6th gear and reverse
selector gear is described in chapter on disassembling and assembling
transmission --> Disassembling and assembling sequence.
Fig. 401: Identifying Special Tools - Pinion Shaft, Disassembling And Assembling (1 Of 3)
2:31:28 AM Page 266


 Tube VW 415 A
 Tube VW 519
2:31:28 AM Page 267

 Thrust pad 3062
 Press tool 3118

 Slotted nut wrench 3155
 Press support-RI wheel brgs. 3144

 Assembly tool 3253
2:31:28 AM Page 268

 Hot air blower V.A.G 1416

 - 3 - Splitter Kukko 17/2
 Feeler gauge
Pulling tapered roller bearing outer race out of transmission housing
Fig. 404: Pulling Tapered Roller Bearing Outer Race Out Of Transmission Housing
 Removing differential --> Differential, removing and installing.

 Install thrust piece 2050 with large diameter pointing toward outer race.
 Install threaded spindle and thrust pad of assembly tool 3253 with thrust plate VW 401 onto transmission
housing.
The outer race will be pulled out of transmission housing when nut is tightened.
Heating transmission housing in order to install tapered roller bearing outer race
2:31:28 AM Page 269

 Heat transmission housing in area of bearing seat for approx. 15 minutes, to approx. 100° C, with hot air
blower V.A.G 1416.
Fig. 406: Pressing Tapered Roller Bearing Outer Race Into Transmission Housing
 Insert outer race only after heating transmission housing and push into position under Workshop press
Pulling tapered roller bearing outer race out of bearing housing
Fig. 407: Pulling Tapered Roller Bearing Outer Race Out Of Bearing Housing
Pressing tapered roller bearing outer race into bearing housing
2:31:28 AM Page 270

Fig. 408: Pressing In Tapered Roller Bearing Outer Race For Pinion Shaft With Shim Into Bearing
Housing
Support bearing housing with press support-RI wheel brgs. 3144 directly below bearing mounting.
 Press in outer race until limit stop.
Pressing off thrust washer for reverse selector gear
Fig. 409: Pressing Off Thrust Washer For Reverse Selector Gear
A - Splitter 22 to 115 mm, e.g. Kukko 17/2
NOTE:  Install splitter - A - below thrust washer, and not below circlip.
 Remove circlip below thrust washer.
Pressing off tapered roller bearing inner race with 2nd speed selector gear
2:31:28 AM Page 271

Fig. 410: Pressing Off Tapered Roller Bearing Inner Race With 2Nd Speed Selector Gear
CAUTION: When pressing off, make sure that only the gear teeth of the selector gear
and not the gear shift splines contact the splitter - A -. Otherwise the gear
shift splines will be damaged.
 Remove circlip for tapered roller bearing inner race.
Pressing off 1st and 2nd gear synchronizing hub
2:31:28 AM Page 272

Fig. 411: Pressing Off 1st And 2nd Gear Synchronizing Hub

 Press synchronizing hub off with 1st speed selector gear
Pressing off tapered roller bearing inner race
Fig. 412: Pressing Off Tapered Roller Bearing Inner Race


 The outer race of tapered roller bearing - arrow - must be installed prior to pressing off inner race.
Pressing on tapered roller bearing inner race
2:31:28 AM Page 273


 Heat inner race to approx. 100° C and press on.

 Determine thickness of required circlip Determining thickness of circlip and install circlip.

NOTE:  The thickness of the circlips for the synchronizing hubs and individual
gear wheels must also be determined as shown for the tapered roller
bearing.
Overview for installation position of circlips Installation position of circlips
2:31:28 AM Page 274


The required circlips for inner races of tapered roller bearings, the synchronizing hubs and individual gear
wheels should be selected as shown in Determining thickness of circlip
 Circlip - 1 - secures tapered roller bearing inner race.

2.50 2.56 2.62
2.53 2.59 2.65
 Circlip - 2 - secures 1st and 2nd gear synchronizing hub.
Identification: blue color

1.90 2.02 2.14
1.93 2.05 2.17
1.96 2.08
1.99 2.11

3.50
2:31:29 AM Page 275

 Circlip - 4 - secures thrust washer for reverse selector gear.

3.50
 Circlip - 5 - secures 3rd gear wheel.

1.90 1.98 2.06
1.94 2.02 2.10
 Circlip - 6 - secures 6th gear wheel.

1.90 2.02 2.14
1.93 2.05 2.17
1.96 2.08 2.20
1.99 2.11
 Determine circlips according to table.
Installation position of synchronizing rings for 1st and 2nd gear:
Fig. 416: Installation Position Of Synchronizer Rings For 1St And 2Nd Gear
NOTE:  If components are not being replaced, make sure they are re-installed on
the same gear.
 Install inner ring - 2 - onto selector gear - 1 -.

 Install intermediate ring - 3 -. Lug - B - must be inserted into recess - A -.
 Synchro-ring - 4 - installed. Guide lugs - C - through recess - arrow -.
2:31:29 AM Page 276

Checking 1st gear inner ring for wear
Fig. 417: Checking Inner Race Of 1st Gear For Wear

 Check outer contact surface - arrow - for scoring or visible traces of wear and replace if necessary.
 Press inner ring onto chamfer on selector gear and measure gap - a - using a feeler gauge.
Gap - a - As-new installation value Wear limit

Inner ring for 1st gear 1.2 to 2.0 mm 0.6 mm
Checking 1st and 2nd gear intermediate ring for wear

 Check inner contact surface of synchro-ring for scoring or visible traces of wear and replace if necessary.
 Press inner ring, intermediate ring and synchro-ring onto chamfer on selector gear and measure gap - a -
using a feeler gauge.

1st and 2nd gear 1.4 to 2.0 mm 0.8 mm
2:31:29 AM Page 277

Pressing on 1st and 2nd gear synchronizing hub
Fig. 419: Pressing On 1st And 2nd Gear Synchronizing Hub

High inside collar faces 2nd gear.
 The lugs of 1st gear synchro-ring and recesses on synchronizing hub must align - arrow - when pressing
on.
Assembling 1st and 2nd gear locking collar/synchronizing hub
Fig. 420: Assembly Of Operating Sleeve/Synchronizers For 1st And 2nd Gear
 Install locking pieces - arrows A - into mounted synchronizing hub - 1 -.
2:31:29 AM Page 278

 Install locking collar - 2 - onto synchronizing hub so that the wide splines of locking collar and
synchronizing hub - arrow B - coincide.
 Install circlip for 1st and 2nd gear synchronizing hub.
 Install 2nd speed selector gear with needle bearing and synchro-rings.

 Install circlip for tapered roller bearing inner race onto pinion shaft.
 Shoulder of tube VW 415 A faces inner race - arrow -.
Then check axial play of 1st speed and 2nd speed selector gears Checking axial play of 1st speed selector
gear and Checking axial play of 2nd speed selector gear.
Checking axial play of 1st speed selector gear
2:31:29 AM Page 279

Fig. 422: Checking Axial Play Of 1st Speed Selector Gear

 Press 1st speed selector gear - 2 - in direction of - arrow A - as far as stop.

 Measure distance between 1st speed selector gear - 2 - and synchro-ring - 3 - using a feeler gauge - 1 -.
Example: 2.55 mm
 Press 1st speed selector gear - 2 - in direction of 2nd speed selector gear - 4 -.
 Measure distance again between 1st speed selector gear - 2 - and synchro-ring - 3 - using a feeler gauge -
1 -.
Example: 2.15 mm
 The difference between two measured values must be between 0.20to 0.50mm.
Checking axial play of 2nd speed selector gear
Fig. 423: Checking Axial Play Of 2nd Speed Selector Gear

 Check axial play between 2nd speed selector gear - 2 - and inner race of tapered roller bearing - 3 - using
a feeler gauge - 1 -.
2:31:29 AM Page 280

 The play must be 0.20 to 0.50 mm.
Pressing on thrust washer for reverse selector gear
Fig. 424: Pressing On Thrust Washer For Reverse Selector Gear

 Install circlip - B - onto output shaft.

 Press on thrust washer - A - until it makes contact with circlip.
39 FINAL DRIVE - DIFFERENTIAL

FLANGE SHAFT OIL SEAL (LEFT-SIDE), REPLACING
Flange shaft oil seal (left-side), replacing
2:31:29 AM Page 281

Fig. 425: Identifying Special Tools - Flange Shaft Oil Seal, Replacing
 Drift VW295
 Drift 2062
 Puller T10037
 Torque wrench V.A.G1331

Removing
2:31:29 AM Page 282

Observe general repair instructions --> General repair instructions.


 If installed, remove sound insulation - arrows - in wheel housing (left-side).
2:31:29 AM Page 283


 If installed, remove heat shield - arrows - for drive shaft (left-side).

 Remove drive axle - 1 - from flange shaft and tie as far as possible to front, taking care not to damage
surface protection.
Fig. 429: Removing Flange Shaft Using Puller T10037

 Place drip tray V.A.G1306 underneath.

2:31:29 AM Page 284


 Pry out flange shaft oil seal.
Installing

 Drive in new flange shaft oil seal using driver 2062; keep seal straight when installing.
 Insertion depth: 5.50 ± 0.15 mm below top of cover.
2:31:29 AM Page 285


NOTE:  Inspect polygon bearings for visible damage - 2 -.

 If the polygon bearings - 2 - do not run smoothly with the flange shaft
removed, this does not necessarily indicate that the bearings are faulty. A
test for noisy bearings can only be performed with the bearings installed.
 The polygon bearings can only be replaced together with the flange shaft.
 Always replace circlip for flange shaft - 5 -.
 Clamp flange shaft in vise, using jaw protectors. Use new circlip - A - to press old circlip out of groove in
flange shaft.
2:31:29 AM Page 286

 Drive flange shaft in with needle bearing drift VW295.

 If applicable, bolt on heat shield for drive axle (left-side).
 Fill transmission with oil and check oil level --> Transmission oil level, checking.
 Install sound insulation.
Tightening torque
Component Nm
Heat shield above drive axle to transmission 23
Flange shaft oil seal (right-side), replacing
2:31:29 AM Page 287

 Drift VW295
 Drift 2062
 Puller T10037

Removing
 Loosen bolt for right-side drive axle / wheel hub.


2:31:29 AM Page 288


 If installed, remove sound insulation - arrows - in wheel housing (right-side).

 Remove heat shield - arrows - for drive axle (right-side).

 Remove drive axle (right-side) --> 40 - FRONT SUSPENSION .
2:31:29 AM Page 289

Fig. 438: Removing Flange Shaft By Securing Puller T10037 To Transmission Housing

 Remove flange shaft (right-side); by securing puller T10037 to transmission housing - arrow -.
Fig. 439: Prying Out Flange Shaft Oil Seal Using An Assembly Lever
 Pry out flange shaft oil seal - arrow - using an assembly lever.
Fig. 440: Driving In New Flange Shaft Oil Seal Using Fitting Drift 2062
2:31:29 AM Page 290

Installing

 Drive in new flange shaft oil seal using fitting drift 2062; keep seal straight when installing.


2:31:29 AM Page 291

flange shaft.
 Drive flange shaft in with drift VW295.
 Install drive axle --> 40 - FRONT SUSPENSION .
 Bolt on heat shield for drive axle (right-side).
Tightening torque
Component Nm
Heat shield above drive shaft to transmission 23
2:31:29 AM Page 292


 Slide hammer-complete set VW771

 Socket (27 mm) 3257
NOTE:  Removing and installing is possible with the transmission installed.

 The differential can be removed and installed without removing the
selector mechanism, input shaft, pinion shaft and bearing housing. These
components must be removed if the differential needs to be adjusted.
 Inspect polygon bearings for visible damage.
2:31:29 AM Page 293

 If the polygon bearings do not run smoothly with the flange shaft removed,
this does not necessarily indicate that the bearings are faulty. A test for
noisy bearings can only be performed with the bearings installed.
 A spacer ring is installed between the polygon bearing and the differential
sun wheel on flange shafts with 30 mm spline diameter Flange shaft
assembly, - Item4 -.
Fig. 444: Differential Remove/Install Components

2:31:29 AM Page 294

2 - Oil seal
 Removing (left-side) Removing flange shaft oil seal (left-side)

 Installing (left-side) Installing flange shaft oil seal (left-side)
 Removing (right-side) Removing flange shaft oil seal (right-side)
 Installing (right-side) Installing flange shaft oil seal (right-side)
3 - Circlip
 Replace
 Removing and installing Removing and installing circlip
4 - Spacer ring
 Is only installed on flange shafts with a spline diameter of 30 mm

 Remove with Internal puller 30 to 37 mm, e.g. Kukko 21/5
 Installing Installing spacer ring
5 - Flange shaft
 Removing (left-side) Removing flange shaft (left-side)

 Removing (right-side) Remove right flange shaft
 Drive in with drift VW295.
 Flange shaft assembly Flange shaft assembly
6 - Differential with crown wheel 1)
7 - O-ring
 Always replace
9 - TORX bolt, 20 Nm plus an additional 90°1 / 4 turn
Removing flange shaft (left-side)
2:31:29 AM Page 295


 Remove flange shaft (left-side); by securing puller T10037 to cover for final drive - arrow -.
Remove right flange shaft
2:31:29 AM Page 296


flange shaft.

 Drive new spacer ring in onto stop; do not tilt ring when doing this.
Flange shaft assembly
2:31:29 AM Page 297


1. Flange shaft
3. Spacer ring
4. Spacer ring - installed on shafts with 30mm spline diameter
5. Circlip
NOTE:  The needle bearing (polygon bearing) does not turn easily when the flange
shaft is removed. This does not indicate that the bearing is defective.
Removing flange shaft oil seal (left-side)

 Pry out flange shaft oil seal using an assembly lever.
Installing flange shaft oil seal (left-side)
2:31:29 AM Page 298

 Lightly oil outer circumference of new seal.


 Pack space between sealing lip and dust lip half-full with sealing grease G052128A1 .
Removing flange shaft oil seal (right-side)
Installing flange shaft oil seal (right-side)
2:31:29 AM Page 299



2:31:29 AM Page 300



 Press tool VW408A
 Thrust pad VW447H

2:31:29 AM Page 301


 Drift VW 295
 Thrust pieces for pinion shaft bearing VW 470
 Sleeve 30 - 14
 Thrust pad 3005

 Tube 3296
2:31:29 AM Page 302




Removing and installing differential --> Differential, removing and installing.
2:31:29 AM Page 303

NOTE:  Always replace both tapered roller bearings together.


2 - Shim "S2 "
 Note thickness
2:31:30 AM Page 304

3 - Outer race for tapered roller bearing (right-side)1)
 Pulling out Pulling tapered roller bearing outer race (right-side) out of transmission housing
 Driving in Driving outer race for tapered roller bearing (right-side) into transmission housing
4 - Inner race for tapered roller bearing (right-side)1)
 Pulling off Pulling off inner race for tapered roller bearing (right-side)
 Pressing on Pressing on tapered roller bearing inner race (left and right)
5 - Crown wheel 1)
 Is paired with pinion shaft (final drive set)

 Select correct version according to transmission code letters
 Drive off housing using a punch Driving crown wheel off cage
 Installing onto differential cage HEATING CROWN WHEEL TO APPROX. 100° C and installing
6 - Differential cage1)
7 - Bolt, 30 Nm plus an additional 90°1 / 4 turn
 Replace
 Lightly tighten bolts then tighten in diagonal sequence to correct torque
8 - Inner race for tapered roller bearing (left-side)1)
 Pulling off Pulling off inner race for tapered roller bearing (left-side)
9 - Outer race for tapered roller bearing (left-side)1)
 Pulling out Pulling tapered roller bearing outer race (left-side) out of cover for final drive
 Pressing in Pressing tapered roller bearing outer race (left-side) into cover for final drive.
10 - Shim "S1 "
 Note thickness
 With O-ring
2:31:30 AM Page 305

13 - Sun wheel
 Installing Installing differential bevel gears
14 - Differential pinion pin
15 - Spring pin
 For securing differential pinion pin

 Drive out from differential cage with drift
 Pressing in value: 1.5 mm above differential cage
16 - Planet pinion
Pulling tapered roller bearing outer race (right-side) out of transmission housing
Fig. 458: Pulling Tapered Roller Bearing Outer Race (Right-Side) Out Of Transmission Housing
Driving outer race for tapered roller bearing (right-side) into transmission housing
2:31:30 AM Page 306

Fig. 459: Driving Outer Race For Tapered Roller Bearing With Shim Into Transmission Housing
Pulling off inner race for tapered roller bearing (right-side)
Fig. 460: Pulling Off Inner Race For Tapered Roller Bearing (Right-Side)
 Before setting up puller, place thrust pad VW 447 H on differential cage.
Pressing on tapered roller bearing inner race (left and right)
2:31:30 AM Page 307


NOTE:  Use the same tools for pressing on tapered roller bearing inner race on left
side and right side.
CAUTION: Wear protective gloves.
 Heat inner race to approx. 100° C, fit in position and press home.
Pulling off inner race for tapered roller bearing (left-side)
Fig. 462: Pulling Off Inner Race For Tapered Roller Bearing (Left-Side)
2:31:30 AM Page 308

Pulling tapered roller bearing outer race (left-side) out of cover for final drive
Fig. 463: Pulling Tapered Roller Bearing Outer Race (Left-Side) Out Of Cover For Final Drive
B - Internal puller 56...70 mm, e.g. Kukko 21/8
Pressing tapered roller bearing outer race (left-side) into cover for final drive.
Driving crown wheel off cage
2:31:30 AM Page 309


Heating crown wheel to approx. 100° C and installing

 When installing crown wheel, use centralizing pins - A - (shop-made tool) to locate.
 Allow to cool slightly before screwing in new securing bolts. Then tighten to specified torque.
Installing differential bevel gears
2:31:30 AM Page 310


 Lubricate one-piece thrust washer with gear oil and install.

 Insert sun wheels.
 Insert planet pinions offset 180° and rotate into position - arrow -.
 Drive differential pinion pin into final position and secure.
PINION SHAFT AND CROWN WHEEL, ADJUSTING
Pinion shaft and crown wheel, adjusting
NOTE:  Careful adjustment of the crown wheel and pinion shaft is essential to
ensure that the final drive gives long service and runs silently. For this
reason, the pinion shaft and crown wheel are matched together during
manufacturing, and checked to ensure a good mesh pattern and quiet
running in both directions of rotation. The position of quietest running is
found by moving the pinion shaft in an axial direction and at the same time
lifting the crown wheel out of the zero-play mesh position by the amount
necessary to maintain the backlash within the specified tolerance.
 The deviation (tolerance) "r" in relation to the master gauge "Ro" is
measured for the final drive sets supplied as replacement parts and
marked on the outer circumference of the crown wheel. The final drive set
(pinion shaft and crown wheel) may only be replaced together as a
matched pair.
 Observe the general repair instructions for tapered roller bearings and
shims.
Final drive gear set, adjustment and marking
2:31:30 AM Page 311

Fig. 468: Final Drive Gear Set, Adjustment And Marking

1 - "43185" number of matched pair of gears
2 - Deviation (tolerance) "r" is based on the master gauge used on the test machine in production. The
dimension "r" is always given in 1/100mm. For example: "29" indicates r = 0.29 mm
Ro - Length of test machine master gauge
Ro - Crown wheel diameter 188 mm = 59.65 mm
R - Actual distance between crown wheel axis and face of pinion shaft in position of quietest running for this
gear set.
Vo - Hypoid offset
2:31:30 AM Page 312

Position of shims
NOTE:  Table of adjustments when replacing individual components of final drive -

->--> Table of adjustments.
Fig. 469: Position Of Shims

S1 - Shim for crown wheel in cover for final drive
S2 - Adjustment shim for crown wheel in transmission housing
S3 - Adjustment shim for pinion shaft in transmission housing
S4 - Shim for pinion shaft in bearing housing
2:31:30 AM Page 313

Table of adjustments
NOTE:  If repairs have been perform to the transmission, it is only necessary to

adjust the pinion shaft, crown wheel or final drive set if components have
been replaced which have a direct effect on the adjustment of the final
drive. Refer to the following table to avoid unnecessary adjustment work:
Components requiring
Crown wheel Pinion shaft Pinion shaft Backlash
adjustment:
("S3 " + "S4 ") via
("S1 " + "S2 ") Shim "S4 " only 0.12 -
deviation (tolerance) 0.28
"r"
--> Crown --> Re-determining shim "S4"
--> Pinion shaft,
wheel, when replacing bearing
adjusting
adjusting housing
Component replaced
Transmission housing
X X X
* See note
Bearing housing X X
Differential cage X X
Tapered roller bearing
X X
for pinion shaft
X X
for differential
Final drive gear set *
X X
See note
*Pinion shaft and crown wheel; only replace together.
*If the transmission housing is replaced the input shaft must also be adjusted --> Input shaft, adjusting.
Adjusting gear set, recommended sequence
2:31:30 AM Page 314

Fig. 470: Adjusting Gear Set

The following work sequence is recommended to save time when crown wheel and pinion shaft have to be
adjusted:
 Determine total shim thickness "Stotal " (S3 plus S4 ) for the specified preload on pinion shaft tapered
roller bearings.
 Distribute total shim thickness "Stotal " (S3 plus S4 ) so that dimension from center of crown wheel to end
face of pinion shaft corresponds to installation dimension "R" determined during production.
 Determine total shim thickness "Stotal " (S1 plus S2 ) for the specified preload on differential tapered
roller bearings.
 Distribute total shim thickness "Stotal " (S1 plus S2 ) so that the specified backlash between crown wheel
and pinion shaft is obtained.
Pinion shaft, adjusting
Repairs after which the pinion shaft must be adjusted --> Table of adjustments.
2:31:30 AM Page 315

Fig. 471: Identifying Special Tools - Pinion Shaft, Adjusting (1 Of 2)

 Removal tool VW 296

 Universal measuring tool VW385
 Dial gauge holder VW387

2:31:30 AM Page 316



 Assembly tool VW792
 Thrust pad 3062

2:31:30 AM Page 317

Fig. 473: Identifying Press Tool 3345

 Press tool 3345


 Dial gauge
 Dial gauge extension, 30 mm
Determining total shim thickness "Stotal" for shims "S3" plus "S4"
(Setting preload of tapered roller bearings for pinion shaft)
2:31:30 AM Page 318

Fig. 475: Pressing Tapered Roller Bearing Outer Race For Pinion Shaft Into Transmission Housing
Without Shims
 Press tapered roller bearing outer race for pinion shaft into transmission housing without shims.
Housing
 Press in tapered roller bearing outer race for pinion shaft with shim "S4 *" (thickness 1.01 mm) into
bearing housing.
NOTE:  For measurement purposes a shim "S4 " with a thickness of 1.01 mm is
inserted provisionally. This is referred to in the following as "S4 *". "S4 *"
is exchanged with the final shim "S4 " after determining measured value
"e".
2:31:30 AM Page 319

Fig. 477: Securing Transmission Housing Onto Transmission Support VW 353 With Bolts
 Secure transmission housing onto transmission support VW 353 with bolts - arrows -.
Fig. 478: Tapered Roller Bearing Inner Race, Selector Gears And Locking Collar For 1st And 2nd Gears
And Tapered Roller Bearing Inner Race
 Press tapered roller bearing inner race - 1 - onto pinion shaft and secure Pressing on tapered roller
bearing inner race.
 Install selector gears and locking collar for 1st and 2nd gears - 2 - --> Pinion shaft, disassembling and
assembling.
 Press tapered roller bearing inner race - 3 - onto pinion shaft Pressing on tapered roller bearing inner
race.
2:31:30 AM Page 320

 Install bearing housing and transmission cover with 4 dowel sleeves and tighten bolts to 35Nm.
 Turn transmission so that the transmission cover points downward.
 Press down on face of pinion shaft with removal tool VW 296 until tapered bearing outer race contacts
bearing housing.
 Maintain pressure and rotate pinion shaft 5 turns in both directions to seat taper roller bearing.
 Attach dial gauge (3 mm measuring range) with dial gauge extension to transmission housing.
 Preload dial gauge to 1 mm and set to "0".
The dial gauge extension must contact machined surface on the face of pinion.
2:31:30 AM Page 321

 Turn transmission so that the transmission cover points upward.

 Rotate pinion shaft 5 turns in each direction so that the tapered roller bearing seats properly. Otherwise
the result of the measurement will be incorrect.
 Read off play on dial gauge and note reading.
 Measurement in example: 0.46 mm
NOTE:  If the measuring procedure needs to be repeated, the pinion shaft must
first be rotated 5 turns in each direction again so that the tapered roller
bearing seats properly. Preload dial gauge to 1 mm and set to "0" again.
Formula: "Stotal " = "S4 *" + measured value + bearing preload
Example:
Inserted shim "S4 *" 1.01 mm
+ Measured value (example) 0.46 mm
+ Bearing preload (constant value) 0.12 mm
= Total shim thickness "Stotal " for "S3 " plus "S4 " 1.59 mm
Determining thickness of shim "S3 *"
Formula: "S3 *" = "Stotal " - "S4 *"
Example:
Total shim thickness "Stotal " for "S3 " plus "S4 " 1.59 mm
- Inserted shim "S4 *" 1.01 mm
= Thickness of shim "S3 *" 0.58 mm
2:31:30 AM Page 322

 Pull tapered roller bearing outer race out of transmission housing Pulling tapered roller bearing outer
race out of transmission housing
 Install shim "S3 *" in transmission housing and install outer race again.
 Insert completely assembled pinion shaft into transmission housing again.
 Install bearing housing and transmission cover with the 4 dowel sleeves and tighten bolts to 35Nm.
 Turn pinion shaft 5 turns in each direction so that taper roller bearings seat properly.
Fig. 482: Identifying Assembly Device VW 792, M12 Nut, VW 387 And Transmission Cover
 Install assembly device VW 792 on transmission housing; when doing so, insert a M12 nut - A - between
assembly device VW 792 and transmission housing.
 Install universal dial gauge bracket VW 387 with dial gauge and 30 mm extension.
 Apply dial gauge extension exactly at center of intersection of ribs on transmission cover - arrow -.
 Set dial gauge (3 mm measuring range) to "0" with 1 mm preload.
 Loosen transmission cover bolts and turn pinion shaft several times.
 If correct shims have been selected the dial gauge will now indicate the following value:
 0.06 to 0.12 mm
 Tighten transmission cover bolts again to 35 Nm.

 Take down measuring tools.
2:31:30 AM Page 323

Determining dimension "e"
NOTE:  Measurement "e" is required to determine the final shim thickness of "S3 "
and "S4 ".

 Set adjustment rings of universal measuring tool VW385/1 to the following values:
Fig. 484: Universal Measuring Tool VW385/1

 Assemble universal measuring tool VW385/1 as illustrated:
 Dial gauge extension - VW 385/15 - , 6.5 mm long

 Master gauge VW385/30
 Set master gauge VW385/30 to Ro = 59.65 mm and install onto measuring tool.
2:31:30 AM Page 324

Fig. 485: Measuring Plate End Placed On Face Of Pinion Shaft

 Place end measuring plate on face of pinion shaft.
NOTE:  Make sure plate contact surface fits exactly and is free of oil.

 Remove master gauge and insert measuring tool into housing.
 The dial gauge faces toward final drive cover
2:31:30 AM Page 325

 Install cover for final drive and tighten 4 bolts to 20 Nm.

 Using adjustable ring, pull 2nd centering pad VW385/36 out as far as possible so that the measuring tool
can still just be turned by hand.
 Turn measuring tool until dial gauge point touches the end measuring plate on pinion shaft head, then
 Measurement in following example: "e" = 0.17 mm (in red scale)
NOTE:  Then (after removing universal measuring tool), check once again that the
dial gauge indicates "0" with 2mm preload when master gauge VW385/30
is in place.
Determining thickness of shim "S3"
 The deviation (tolerance) "r" in relation to the master gauge "Ro" is measured for the final drive sets
supplied as replacement parts and marked on the outer circumference of the crown wheel.
 Subtract value "e" if measurement is obtained on red scale.
 Add value "e" if measurement is obtained on black scale.
Formula:
"S3 " = "S3 *" + "r" + "e" ("e" on black scale)
"S3 " = "S3 *" + "r" - "e" ("e" on red scale)
Example:
2:31:30 AM Page 326

+ Deviation "r" 0.29 mm

- Determined value "e" (in red scale) 0.17 mm
= Thickness of shim "S3 " 0.70 mm
 Determine shim(s) according to table.
Available shims for "S3 "

0.53 0.85 1.17
0.57 0.89 1.21
0.61 0.93 1.25
0.65 0.97 1.29
0.69 1.01 1.33
0.73 1.05 1.37
0.77 1.09 1.41
0.81 1.13
*The exact shim thickness required can be obtained by using the shim tolerance variations. Install two shims if
necessary.
Formula: "S4 " = "Stotal " - "S3 "
Example:
- Thickness of shim "S3 " 0.70 mm
Shims available for "S4 "

0.33 0.73 1.13
0.37 0.77 1.17
0.41 0.81 1.21
0.45 0.85 1.25
0.49 0.89 1.29
0.53 0.93 1.33
2:31:30 AM Page 327

0.57 0.91 1.37

0.61 1.01 1.41
0.65 1.05 1.45
0.69 1.09 1.49
necessary.
Checking adjustment
Checking deviation (tolerance) "r "
 Install pinion shaft with appropriate measured shims "S3 " and "S4 ".
 Insert universal measuring tool and check adjustment.

 Read off dial gauge counter-clockwise (red scale).
 If shims have been correctly selected, the deviation "r" (marked on outer circumference of crown wheel)
should be indicated within a tolerance of ± 0.04 mm.
Re-determining shim "S4" when replacing bearing housing
2:31:30 AM Page 328

Fig. 489: Identifying Dial Gauge Holder VW 387

 Universal dial gauge bracket VW387
Fig. 490: Installation Arbor VW 792


 Dial gauge
 Straightedge
 Clean housing flange.
2:31:30 AM Page 329

Fig. 491: Measuring Difference Between Depth On Old And New Bearing Housing With A Digital Depth
Gauge
 Place straightedge (e.g. 19.50 mm wide - 1 - onto housing flange.

 Measure difference between depth - a - on old and new bearing housing with a digital depth gauge (e.g.
VAS 6087).
Example:
Depth - a - of previous bearing housing (with straightedge width) 26.30 mm

Depth - a - of new bearing housing (with straightedge width) 26.45 mm
 If new bearing housing is deeper, install a thicker "S4 " shim.

 If previous bearing housing is deeper, install a thinner "S4 " shim.
Example:
Previous shim "S4 " 0.95 mm

= New shim "S4 " 1.10 mm
Shims available.
 Press tapered roller bearing outer race with shim "S4 " into bearing housing Pressing tapered roller
bearing outer race into bearing housing
 Install bearing housing and transmission cover and tighten bolts to 35Nm.
2:31:30 AM Page 330

 Install assembly device VW 792 on transmission housing; when doing so, insert an M12 nut - A -
between assembly device VW 792 and transmission housing.
 Attach universal dial gauge bracket VW 387 with dial gauge and 30 mm extension.
NOTE:  Attach dial gauge extension exactly at the center of the webbing
intersection on the transmission cover - arrow -.

 0.06 to 0.12 mm
If this reading is not obtained, the adjustment must be corrected.
Crown wheel, adjusting
2:31:30 AM Page 331

Fig. 493: Identifying Special Tools - Crown Wheel, Adjusting (1 Of 2)

 Drift VW 295
 Dial gauge extension VW382/10
 End measuring plate VW385/17
 Adjustable measuring lever VW 388

2:31:31 AM Page 332



 Crown wheel adjusting tool VW 521
 Tube 30 - 14

 Dial gauge
2:31:31 AM Page 333

It is necessary to readjust crown wheel when the following components have been replaced:
Transmission housing, final drive cover, taper roller bearings for differential, differential cage or the final drive
gear set
(adjustment of pre-load of taper roller bearings for differential)
 Pinion shaft removed
 Remove flange shaft oil seals

 Remove tapered roller bearing outer races for differential and remove shims --> Differential,
 Drive outer race for tapered roller bearing (right-side) with shim "S2 " into transmission housing. For
measurement purposes use a 1.30 mm thick "S2 *" shim (or 2 shims of 0.65 mm).
NOTE:  For measurement purposes a 1.30mm thick shim "S2 " is inserted
provisionally. This is referred to in the following as "S2 *". "S2 *" is
exchanged with the final shim "S2 " after determining backlash.
2:31:31 AM Page 334

 Press tapered roller bearing outer race (left-side) without shim "S1 " into cover for final drive.
 Install differential in transmission housing. The crown wheel is positioned on left-hand side (same side as
cover for final drive).
 Install cover for final drive with 4 bolts (20 Nm).
 Turn transmission so that cover for final drive points upward.
 Turn differential 5 turns in both directions so that the tapered roller bearings settle.
 Place measuring plate VW385/17 on differential.
 Set up measuring tool using 30 mm extension.
2:31:31 AM Page 335

 Set dial gauge (3 mm measuring range) - A - to "0" with 2mm preload.
NOTE:  Tip of dial gauge must be located at center of differential.
 Raise differential without turning, read clearance off dial gauge and write down.
 Measurement in following example: 0.62 mm
Fig. 498: Special Tools VW521/4 And VW521/12 Secured On Right Of Differential
NOTE:  Secure special tools VW521/4 and VW521/12 on right of differential

(transmission side) to lift differential.
 If the measurement has to be repeated, the differential must again first be
turned 5 turns in each direction to settle the tapered roller bearings.
Example:
Inserted shim(s) "S2 *" 1.30 mm
NOTE:  Provisional shim "S1 *" is replaced with final shim "S1 " after determining
backlash.
 Total shim thickness "Stotal " remains unchanged.
2:31:31 AM Page 336

Example:
- Inserted shim(s) "S2 *" 1.30 mm
Measuring backlash
 Install pinion shaft with shims "S3 " and "S4 ".
 Install differential with crown wheel: S1 is installed on cover side, S2 in transmission housing.
 Insert crown wheel adjusting tool VW521/4 and VW521/12.
 Turn differential 5 turns in both directions so that the taper roller bearings seat properly.

 Secure universal dial gauge bracket VW 387 to housing.

 Install dial gauge with dial gauge extension VW382/10 (6mm flat).
 Adjust measuring lever VW388 to distance "a" = 79 mm (for diameter 188 mm crown wheel).
 Measure play between teeth faces (backlash) as follows:
 Turn crown wheel until it makes contact with the face of one tooth (end of backlash travel).
2:31:31 AM Page 337


 Turn back crown wheel until it makes contact with opposite tooth face (backlash).
 Take backlash reading and note down measured value.
 Turn crown wheel through 90° and repeat measurements a further 3 times.
 Add the four measured values together and divide by four.
Example:
= Sum of measured values 1.16 mm
 Result: the average backlash is 1.16 mm : 4 = 0.29 mm
NOTE:  If the individual measurements differ from each other by more than 0.06
mm, the installation of the crown wheel or the final drive gear set itself is
not correct. Check installation; replace final drive gear set if necessary.
Formula: "S2 " = "S2 *" - measured backlash + specified backlash
Example:
- Measured average backlash 0.29 mm
+ Specified backlash (constant value) 0.20 mm

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
2:31:31 AM Page 338

0.57 0.73
necessary.
Example:

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
necessary.
Adjustment, checking
2:31:31 AM Page 339


 After installing shims "S1 " and "S2 ", turn differential 5turns in both directions so that the tapered roller
bearings settle.
 Specification: 0.12 to0.28 mm
NOTE:  Adjustment must be repeated if backlash is outside tolerance. The total

shim thickness "Stotal " must remain unchanged.
 Deviation between individual measured values must not exceed 0.06 mm.
2:31:31 AM Page 340

Installation position of selector mechanism
Fig. 102: Installation Position Of Selector Mechanism, Gear Selection Movement And Gate Selection
Movement
1 - Selector rod
2:36:22 AM
2:36:30 Page 1
2 - Push rod
3 - Connecting rod
Selector mechanism components, assembly overview
Part I
G052142A2 .
Fig. 103: Shift Mechanism Remove/Install Components -- Part I

2:36:22 AM Page 2
1 - Ball
2 - Rubber ring
3 - Ball guide
4 - Rubber ring
5 - Washer
6 - Circlip
7 - Spring
8 - Spacer sleeve
9 - Washer
10 - Circlip
11 - Sound insulation
 - Arrow - marked on sound insulation points in direction of travel
 With cover
 Removing and installing --> Gear lever knob with boot, removing and installing
13 - Nut -10 Nm-
14 - Ball housing
16 - Gear lever
17 - Bolt
18 - Nut, 10 Nm
2:36:22 AM Page 3
21 - Nut, 10 Nm
 Self-locking
 Replace
22 - Bushing
Part II
G052142A2 .
Fig. 104: Shift Mechanism Remove/Install Components -- Part II
2:36:22 AM Page 4
1 - Boot
 Secure to selector rod with commercially available instant adhesive
2 - Washer
3 - Ball socket
4 - Cap nut, 23 Nm
5 - Ball stud
6 - Ball socket
7 - Connecting rod
8 - Bushing
9 - Bushing
10 - Bolt, 23 Nm
11 - Sleeve
12 - Retaining clip
13 - Bolt, 40 Nm
14 - Push rod
 With bushing, bolt and washers
16 - Washer
18 - Clamping ring for boot
19 - Boot
2:36:22 AM Page 5
21 - Clamp
22 - Selector rod
24 - Cap nut, 10 Nm
 Self-locking
 Replace
Gear lever knob with boot, removing and installing

2:36:22 AM Page 6
Removing
 Open ashtray.
Gear lever knob with clip:

2:36:22 AM Page 7

Gear lever knob with locking mechanism:
 Release connecting element - 1 - in direction of - arrow - and pull gear lever knob off upward together
Installing
2:36:22 AM Page 8
Removing
2:36:22 AM Page 9

Fig. 113: Fasteners

2:36:22 AM Page 10

Fig. 115: Cross Member Bolts

Remove tunnel cross piece (rear) - arrows -.
2:36:22 AM Page 11


 Remove rear section of exhaust system -->
 A second technician is required for removing the rear section of the
exhaust system.
Fig. 117: Rear Section Of Exhaust System And Front Cross Member
 Disconnect exhaust system at clamp - 2 -.
2:36:22 AM Page 12
 Remove tunnel cross piece (front) - 1 - - arrows -.

 Remove heat shield for exhaust system - 4 - from below selector mechanism.
Wood
 Remove universal transmission mounting V.A.G1359/2 from engine/transmission jack V.A.G 1383 A
and place a wooden block - arrow - on press tool instead.
 Support tunnel cross member (rear) using engine/transmission jack V.A.G 1383 A.
 Remove bolts - 1 - and - 2 - , then bolts - 3 - and - 4 -.
 Carefully lower tunnel cross member (rear) using engine/transmission jack V.A.G 1383 A until distance
between cross member (rear) and body reaches dimension "x".
2:36:22 AM Page 13
 Dimension x = 60 mm


 Detach push rod - 1 - ; to do so, unscrew hex socket head bolt.
2:36:22 AM Page 14

 Remove selector mechanism to rear.
Installing

.
 Adjust selector mechanism --> Selector mechanism, adjusting.
Tightening torques
Component Nm
Tunnel cross member (rear) to body 60
sound insulation to selector mechanism 10
2:36:22 AM Page 15
Selector mechanism, adjusting
The following are requirements for correct gear lever alignment:
 Gear selector linkage must be in proper condition and undamaged.

 Selector mechanism must move freely.
Procedure
2:36:22 AM Page 16

 Measure distance - a - between two studs in selector mechanism.
 Specification: distance a = 85 mm


2:36:22 AM Page 17


Align gear lever
 Position bottom of gear lever in center of ball guide.
 Distance between ball guide and bottom of gear lever - arrows - must be equal at all points.
2:36:22 AM Page 18

 Align gear lever so that it points slightly (1.5°) to right (as seen in direction of travel).

 Tighten bolt for push rod - arrow - to 23Nm.
tightened.
 The gear lever should rest in the 3rd/4th gear gate when transmission is in neutral.

2:36:22 AM Page 19
 The gear lever should return by itself from reverse gear gate to 3rd / 4th gear gate.
If gear lever sticks or bauks repeatedly when engaging a gear, perform adjustment procedure again.
 Install trim parts and gear lever knob --> Gear lever knob with boot, removing and installing.
 Transmission, installing in vehicles with 4-cylinder or 6-cylinder engine --> Transmission, installing in
vehicles with 4-cylinder or 6-cylinder engine.
2:36:22 AM Page 20



2:36:22 AM Page 21


Procedure


Cabriolet
.
2:36:22 AM Page 22


 To avoid damaging edges of fenders with engine support bridge 10-222 A, insert wing compensation
plates T40045 on both sides between fender mounting flange and body panel underneath.
2:36:22 AM Page 23
Fig. 136: Fasteners

2:36:22 AM Page 24

NOTE:  - Item 3 - and - item B - can be disregarded.

2:36:22 AM Page 25

 Unbolt heat shield - arrow - for drive axle (right side) from transmission.

 Separate exhaust system at clamp - arrow - and slide clamp to rear.
2:36:22 AM Page 26
Fig. 141: Retaining Bracket For Front Exhaust Pipe, Bolt And Nut
 Remove bolt - 1 - and nut - 2 - and detach retaining bracket for front exhaust pipe.

Cabriolet:
NOTE:  On Audi Cabriolet vehicles the following steps are required in order to
remove the three bottom engine/transmission bolts:
 Unbolt torque reaction support - arrows -.
2:36:22 AM Page 27
 Remove nuts - 1 - on left and right sides, and swivel stabilizer bar - 2 - downward.
 Remove nut - 3 - on left and right engine mountings until bottom of nut is flush with end of stud - arrow
-.
 Use engine support bridge 10-222 A to lift engine just enough for nuts - 3 - to make contact with bottom
surface of left and right consoles.

 Remove three lower engine/transmission securing bolts - arrow -.
Cabriolet:
2:36:23 AM Page 28



 Drill a hole of 10.2mmdiameter - arrow - in supporting elements of transmission support 3282.
2:36:23 AM Page 29
 To remove manual transmission 01X, set up transmission support 3282 with adjustment plate 3282/43
NOTE:  The support elements 3282/49 - arrows A - and 3282/52 - arrows B - are


2:36:23 AM Page 30


 Remove bolts - 1 - and bolts - 2 -.
2:36:23 AM Page 31
 Remove nuts - arrows - and detach tunnel cross member.

 Lower transmission slightly using engine/transmission jack V.A.G 1383 A.

 Disconnect electrical connector - arrow - for back-up light switch F4 and move electrical wire clear.

 Remove push rod - 1 - by using an 8 mm hex key when removing bolt.
2:36:23 AM Page 32


 Remove upper engine/transmission securing bolts - arrows 1 - and - arrows 2 -. Please note that
retaining brackets for wires/lines and coolant pipe may be secured on bolts - arrows2 - (important for
installation).
 If installed, remove retaining clips/cable ties together with Lambda probe wiring from transmission.
2:36:23 AM Page 33

 Press transmission off dowel sleeves and lower carefully with engine/transmission jack V.A.G 1383 A
NOTE:  When lowering transmission, make sure hydraulic line to slave cylinder is
not damaged.

 Lower transmission completely with engine/transmission jack V.A.G 1383 A.
2:36:23 AM Page 34
drive axles.

2:36:23 AM Page 35



2:36:23 AM Page 36
Fig. 160: Engine Sling 2024 A

 Engine sling 2024 A

Procedure

Cabriolet
2:36:23 AM Page 37



2:36:23 AM Page 38


 Unfasten coolant expansion tank - arrow -.

coolant expansion tank. Move coolant expansion tank (with coolant hoses - 1to 3 - attached) clear to one
side.
2:36:23 AM Page 39

 Remove bolts - arrows - from solenoid valve mounting plate - 3 -.

 Disconnect air intake hose - 1 - from mass air flow sensor.
 Pull hose - 4 - for crankcase breather system off air duct - 2 -.
2:36:23 AM Page 40
 Loosen bolt - arrow - and disconnect air duct - 2 - from throttle valve module.
 If installed, disconnect hose - 1 - from air duct.
NOTE:  In the illustration, the air duct is shown from the rear and with the engine
removed.
 Remove engine/transmission securing bolts which are accessible from above.

 Disconnect connectors - 1 to 4 - from retainer at left of bulkhead.

 Move oxygen sensor wires clear.
 Remove retainer for connectors.

2:36:23 AM Page 41
 Remove nut - 1 - (access from above), connecting left front exhaust pipe with exhaust manifold.

 To avoid damaging edges of fenders use Engine support bridge 10-222 A, insert insert pad for front
 Set up Engine support bridge 10-222 A on fender mounting flanges.
2:36:23 AM Page 42

 Remove eye of lifting tackle 2024A.

 Re-insert pin - 1 - in middle hole on lifting tackle and secure it with split pin.
 Hook pin on lifting tackle 2024A onto spindle on Engine support bridge 10-222 A.
 Hook lifting tackle 2024A into lifting eyes at front and rear of engine.
 Slightly pretension engine with spindle of Engine support bridge.
Fig. 174: Fasteners

auxiliary/additional heater to sound insulation.
2:36:23 AM Page 43


2:36:23 AM Page 44

 Remove heat shield - arrow - for drive axles (left and right).

 If installed, remove tunnel cross member (front) - 1 to 4 -.
2:36:23 AM Page 45


 Remove bracket for exhaust pipe (front right) from transmission.
 Remove nuts - 1 - at bottom of engine mountings (left and right).
2:36:23 AM Page 46
 If installed, unclip operating rod for Left Front Level Control System Sensor G78 from lower transverse
link - arrow -.

 Before loosening subframe, use testing mandrel 3393 to check whether holes - 1 - and - 2 - are aligned.
If holes are not aligned, a wheel alignment has to be performed after installing the subframe.
2:36:23 AM Page 47

2:36:23 AM Page 48
 Temporarily secure subframe again.
Temporary tightening torque:
1 - approx. 100 Nm
2 - approx. 70 Nm
3 - approx. 70 Nm

 Remove drive axles - 1 - from flange shafts and tie up to side.
NOTE:  Do not damage surface coating on drive axles.
 Support transmission with engine/transmission jack V.A.G 1383 A.

 Remove two nuts - 4 - and detach tunnel cross member.
2:36:23 AM Page 49

 Disconnect push rod - 1 - ; by removing hex socket-head bolt.

 Disconnect connector - arrow - for back-up light switch on right side of transmission.
2:36:23 AM Page 50
 Open cable ties - arrows A and B - , unclip oxygen sensor wiring at side - arrows C - and move wiring
clear.


2:36:23 AM Page 51
 If installed, remove engine speed (RPM) sensor G28 from left side of transmission - arrow - and lay
aside.
 Remove upper engine/transmission securing bolts as well as those on the side, except for bolts marked
with - arrow A - and - arrow B -.
2:36:23 AM Page 52
 To remove manual transmission 01X set up transmission support 3282 with adjustment plate 3282 /43
NOTE:  The adjustment plate 3282/49 - arrows A - and 3282/52 - arrows B - are



2:36:23 AM Page 53

 Press transmission off dowel sleeves and lower carefully using engine/transmission jack V.A.G 1383 A
NOTE:  When lowering transmission, ensure hydraulic line to slave cylinder is not
damaged.

2:36:23 AM Page 54

drive axles.

 If installing a new transmission instead of the one removed, the transmission mounting has to be
transferred to new transmission - arrows -.
Transmission, installing in vehicles with 4-cylinder or 6-cylinder engine
Installation is perform in reverse sequence; note the following:
 Use a thread tap to remove any remaining locking fluid from all threaded holes which will accommodate
self-locking bolts.
 Always replace self-locking bolts and nuts.
apply only a very thin coating of grease for clutch plate splines G000100 to splines. Do not grease
guide sleeve.
It should be possible to push the clutch plate back and forth slightly on the input shaft.
2:36:23 AM Page 55


 Check that dowel sleeves for centralizing engine/transmission are in cylinder block, install if necessary.
 Before installing transmission, tie electrical wires and brackets off to one side so that they are not trapped
between engine and the transmission.
2:36:23 AM Page 56
 Lightly lubricate surface where operating rod and clutch release lever make contact - arrow B - using
 Raise transmission far enough to be able to install slave cylinder with bracket for hose/line assembly.

 Secure slave cylinder with new bolt - arrow -.

 Insert transmission, making sure there is sufficient clearance to drive axles.
2:36:23 AM Page 57
 Install engine/transmission securing bolts - arrow A - and - arrow B -.


2:36:23 AM Page 58

 Carefully lower transmission a short distance using engine/transmission jack V.A.G 1383 A.
 If possible, tighten upper engine/transmission securing bolts - arrows1 - and - arrows2 -.
 If installed, secure all electrical wiring to transmission again - arrows A to C -.
2:36:23 AM Page 59
 If installed, install engine speed (RPM) sensor G28 on left side of transmission.

 Install push rod - 1 - ; by tightening hex socket-head bolt.

2:36:23 AM Page 60

 Connect electrical connector - arrow - for reversing light switch on transmission (right side).

 Lift transmission again using engine/transmission jack V.A.G 1383 A.

 Attach tunnel cross member to body with new bolts - 2 - and - 3 - (tighten hand-tight only).
 Secure tunnel cross member to transmission mounting - 4 - --> 40 - FRONT SUSPENSION .
 Bolt drive axles - 1 - to flange shafts --> 40 - FRONT SUSPENSION .
2:36:23 AM Page 61
 Weight of engine is supported with engine support bridge Fig. 172.

 Tighten three lower engine/transmission securing bolts at bottom - arrows -.
2:36:23 AM Page 62
 Replace front subframe bolts - 1 - , - 2 - and - 3 - on both sides of vehicle.
Before tightening subframe, it must be aligned with body using testing mandrel 3393.
 Hole - 1 - and hole - 2 - of subframe and hole - 3 - of aluminum bracket must be flush on both sides.
NOTE:  This alignment can only replace a subsequent wheel alignment if holes - 1
- and - 2 - coincided before the repair work was perform.
2:36:23 AM Page 63
Cabriolet vehicles with 4-cylinder engine:
 Lift engine slightly using spindles.

 Tighten bottom engine/transmission securing bolts - arrows -.

2:36:23 AM Page 64

 Secure torque reaction support - arrows -.
 Tighten nuts - 1 - for engine mountings -->

 10 ENGINE - ASSEMBLY for AVK
 10 - ENGINE - ASSEMBLY for BPG

 Install exhaust system and align stress free -->
.
 Check selector mechanism setting and adjust if necessary --> Selector mechanism, adjusting.
2:36:23 AM Page 65
 Check fluid level in transmission --> Transmission oil level, checking.

.
 Wheel alignment is not necessary if subframe was located in relation to body using testing mandrel 3393
prior to disassembling and assembly of subframe (before tightening bolts).
 Wheel alignment must, however, be perform if the subframe was not located in relation to body using
testing mandrel 3393 or if it was not possible to fully insert two pins into holes.
Tightening torques


Engine/transmission attachment (2.0 ltr. engine)
Item Bolt Nm
2:36:23 AM Page 66
4, 6 M12x90 65
5 * See note M12x110 65
8, 9, 10 M10x45 45
11 * See note M12x110 65
*With bracket for wiring harness
*With nut

Engine/transmission attachment (6-cylinder 3.0 ltr. engine)
Item Bolt Nm
1, 10, 11 M10x60 45
2 * See note M10x150 65
3 * See note M12x130 65
4 M12x85 65
5, 6 M12x90 65
7 M12x100 65
8 M12x95 65
2:36:23 AM Page 67
Component Nm
Slave cylinder to transmission 23 * See note
Transmission selector lever to transmission 23
*replace bolt
Transporting the transmission

2:36:23 AM Page 68
Fig. 223: Transmission Lift Hook T40013

Procedure
 Fasten hook of workshop crane in 4th notch - arrow - on lifting tackle.
 Lift transmission with workshop crane and transmission lift hook T40013.
2:36:24 AM Page 69


Removing
2:36:24 AM Page 70

Between
 Use engine/transmission jack V.A.G 1383 A to lift transmission up slightly. Insert a wooden block - 1 -
between transmission and transmission jack.


 Remove two nuts - 1 - and push tunnel cross member backward slightly.
2:36:24 AM Page 71

 Remove transmission mounting - arrows -.

Installing
Installation is in reverse sequence. Note the following:
 Secure transmission mounting to transmission - arrows - (tightening torque: 23 Nm).
2:36:24 AM Page 72


 Lift transmission far enough to be able to screw in bolts - 2 -.

 Tighten bolts - 2 - and then bolts - 1 - --> 40 - FRONT SUSPENSION .
NOTE:  Replace bolts - 1 - and - 2 -.
 Install exhaust system so it is free of stress -->

Tightening torques
Component Nm
2:36:24 AM Page 73



Procedure
2:36:24 AM Page 74
 To check gear oil level, remove oil filler plug - arrow -.

Oil level is correct when transmission is filled up to edge of housing - arrow -.
 Top off with gear oil if necessary. Specification --> Code letters, allocation, transmission ratios,
capacities.
 Install oil filler plug and tighten.

Note the following when filling with new oil:
 Remove oil filler plug - arrow -.
2:36:24 AM Page 75

 Fill with gear oil up to edge of housing - arrow -.

 Start engine, engage a gear and allow transmission to turn for approx. 2 minutes.
 Switch off engine and remove oil filler plug.
Once more, fill with gear oil up to edge of housing - arrow -.
 Screw in oil filler plug and tighten.
Tightening torque
Component Nm
Oil filler plug 45
TRANSMISSION, MOUNTING ON ASSEMBLY STAND
Transmission, mounting on assembly stand
2:36:24 AM Page 76
Fig. 239: Identifying Special Tools - Transmission, Mounting On Assembly Stand

 Support clamp VW313

 Engine/transmission support VW540
 Workshop crane VAS6100
2:36:24 AM Page 77
Procedure
 Fasten hook of workshop crane VAS6100 in 4th notch - arrow - on transmission lift hook T40013.
 Lift transmission with workshop crane VAS6100 and transmission lift hook T40013.
Fig. 241: Holding Fixture VW 540 Secured To Transmission And Installed Into Support Clamp VW313
 Secure holding fixture VW 540 to transmission and install into support clamp VW313.
Transmission, overview
2:36:24 AM Page 78

1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - 6th gear
7 - Reverse gear
2:36:24 AM Page 79
12 - Ball bearing
 For input shaft
14 - Differential
Assembly overview
2:36:24 AM Page 80
Fig. 243: Transmission Overview

1 - Transmission housing with differential, ball bearing for input shaft and selector shaft
 Removing and installing ball bearing for input shaft, transmission cover, bearing housing and selector
shaft --> Ball bearing for input shaft, transmission cover, bearing housing and selector shaft,
removing and installing, assembly overview
2 - Bearing housing with gear assembly
installing
2:36:24 AM Page 81
Ball bearing for input shaft, transmission cover, bearing housing and selector shaft, removing and installing, assembly
overview
Fig. 244: Ball Bearing For Input Shaft, Transmission Cover, Bearing Housing And Selector Shaft,
Removing And Installing, Assembly Overview
1 - Torx bolt, 35Nm
2:36:24 AM Page 82
 3 (Qty.)
2 - Guide sleeve
 With seal
3 - O-ring
 Always replace
4 - Dished spring
5 - Circlip
 Note thickness
6 - Ball bearing
7 - Circlip
 Note thickness
 2 (Qty.)
9 - Dowel sleeve
 2 (Qty.)
11 - O-ring
2:36:24 AM Page 83

 Always replace
 With Back-up light switch F4

13 - Bolt, 24 Nm
 3 (Qty.)
14 - Back-up light switch F4 -20 Nm-
15 - Pin
 For selector shaft stop

 Installation position: groove on threaded pin points toward selector shaft cover
16 - Dowel sleeve
 2 (Qty.)
 Insert in bearing housing
 12 (Qty.)
installing
2:36:24 AM Page 84
 Servicing --> Bearing housing, servicing

3rd to 6th gear assembly overview, removing and installing
NOTE:  3rd to 6th speed selector gears should have an axial play of 0.20to 0.50mm
after installing.
2:36:24 AM Page 85
Fig. 245: 3rd To 6th Gear Assembly Overview

1 - Bearing housing
 With input shaft and output shaft
2 - Oil collector
 With magnet
 Clipped into reverse shaft support.
3 - Circlip

2:36:24 AM Page 86
4 - 6th gear wheel
5 - Spacer sleeve
6 - 5th gear wheel
7 - 4th gear wheel
8 - Circlip

9 - 3rd gear wheel
10 - Thrust washer
11 - Needle bearing
 For 3rd gear

14 - Circlip
 Mark
2:36:24 AM Page 87
16 - Circlip
18 - Selector fork for 3rd and 4th gear
19 - Pin with clip
 For securing selector fork for 3rd and 4th gear to selector rod

22 - Needle bearing
 For 4th gear
23 - Thrust washer
 For 5th gear
25 - Needle bearing
 For 5th gear

2:36:24 AM Page 88
 For 6th gear
31 - Needle bearing
 For 6th gear

34 - Thrust washer
35 - Inner race
37 - Selector fork for 5th and 6th gear
38 - Pin with clip
 For securing selector fork for 5th and 6th gear to selector rod
Input shaft, output shaft, reverse gear wheel and reverse selector gear, assembly overview, removing and installing
Sequence for dismantling and assembling --> Disassembling and assembling sequence
2:36:24 AM Page 89
Fig. 246: Input Shaft, Output Shaft, Reverse Gear Wheel And Reverse Selector Gear, Assembly
Overview
1 - Bearing housing
2 - Reverse gear wheel
 With support for reverse shaft

 Assembly overview - reverse gear wheel Assembly overview - reverse gear wheel
3 - Bolt, 30 Nm
 3 (Qty.)
4 - Reverse gear selector fork
2:36:24 AM Page 90
5 - Pin with clip
 For securing reverse gear selector fork to selector rod


10 - Needle bearing
 With tapered roller bearing and selector gears for 1st and 2nd speed
 Disassembling and assembling --> Pinion shaft, disassembling and assembling
12 - Input shaft
 Disassembling and assembling --> Input shaft, disassembling and assembling
Assembly overview - reverse gear wheel
2:36:24 AM Page 91
Fig. 247: Assembly Overview - Reverse Gear Wheel

1. Thrust washer
2. Needle bearing
3. Reverse gear wheel
Installation position: collar points toward bearing housing
4 - Reverse shaft support
Disassembling and assembling sequence
Removing and installing ball bearing for input shaft, selector shaft, transmission cover and bearing housing with
input shaft and pinion shaft.
2:36:24 AM Page 92
 Drift sleeve VW 244 B

 Tube 60 mm dia. VW 415 A

 Thrust pad con. VW 433
2:36:24 AM Page 93
 Sleeve VW 519
 Sleeve 40 - 103
2:36:24 AM Page 94

 Mandrel 2064

2:36:24 AM Page 95
 Repair press V.A.G 1290 A


 - 2 - Puller Kukko 18/2
2:36:24 AM Page 96
 Removal plate T40086

 Holding plate T40088/1
 - 1 - Two-arm puller Kukko 20/10

 Feeler gauge
 2 bolts M8 (length 70 mm) with washers
2:36:24 AM Page 97
 Assembly sleeve 01E311120

 Locking fluid AMV185101A1
Disassembling transmission
Fig. 253: Transmission Mounted On Assembly Stand

 Mount transmission on assembly stand.

 Drain transmission oil.

 Remove clutch release lever - A - together with release bearing.

 Remove guide sleeve - B -
 Remove dished spring - C -.
 Remove circlip - D - in front of ball bearing for input shaft.
2:36:24 AM Page 98
Fig. 255: Pulling Ball Bearing For Input Shaft Out Of Transmission Housing
 Pull ball bearing for input shaft out of transmission housing.
 Remove circlip - arrow - behind ball bearing for input shaft.
2:36:24 AM Page 99


 Remove selector shaft.
2:36:24 AM Page 100



 Remove securing bolts for transmission cover - arrows -.
2:36:24 AM Page 101

 Carefully remove transmission cover - A - toward rear. The bearing housing - B - remains installed to
transmission housing - C -.
Fig. 262: Securing Bearing Housing To Transmission Housing With Two Bolts M8 And Washers
 Secure bearing housing to transmission housing - arrows - with two bolts M8 (length approx. 70 mm)
and washers.
 Tighten 2 bolts - arrows - to max. 5 Nm.
 Detach oil collector - A -.
 Check that the 2 gears are still engaged and then unscrew and remove multi-point socket head bolt - 1 -
for input shaft.
2:36:24 AM Page 102

Fig. 264: Detaching 6th Speed Selector Gear With Inner Race For Roller Bearing And Thrust Washer
 Detach 6th speed selector gear with inner race for roller bearing and thrust washer.
NOTE:  Check the gear teeth on the selector gears and gear wheels for damage
after pulling them off.
Fig. 265: Removing 6th Gear Wheel

 Remove 6th gear wheel.
 Remove spacer sleeve from output shaft.
2:36:24 AM Page 103

 Pull out pin with clip - A - for securing selector fork for 5th and 6th gear from selector rod - B -.
 Move selector fork - C - downward and detach with locking collar - D -.
Fig. 267: Removing 5th Speed Selector Gear Together With Needle Bearing Inner Race For 6th Gear
And Synchronizing Hub For 5th And 6th Gear
 Remove 5th speed selector gear together with needle bearing inner race for 6th gear and synchronizing
hub for 5th and 6th gear.
NOTE:  Counter-hold two-arm puller using e.g. open end wrench - B -.

 If the needle bearing inner race for 6th gear is in contact with press tool
VW 433, insert locking pin 2064 into hole in input shaft to pull off the
components all the way.
2:36:24 AM Page 104

Fig. 268: Remove 4th And 5th Gear Wheels Together

 Remove 4th and 5th gear wheels together.
NOTE:  Counter-hold puller - A - using e.g. transmission bracket 2004.
Fig. 269: Removing 4th Speed Selector Gear With Needle Bearing Inner Race For 5th Gear And Thrust
Washer
 Remove 4th speed selector gear with needle bearing inner race for 5th gear and thrust washer.
 Counter-hold two-arm puller using e.g. open end wrench - B -.

2:36:24 AM Page 105

 Pull pin with clip - A - securing selector fork for 3rd and 4th gear out from selector rod - B -.

 Remove circlip for 3rd gear and 4th gear synchronizing hub and note thickness of circlip.
Fig. 271: Pulling Off 3rd Speed Selector Gear With Synchronizing Hub For 3rd And 4th Gear
 Pull off 3rd speed selector gear with synchronizing hub for 3rd and 4th gear.
NOTE:  Counter-hold puller - A - using e.g. transmission bracket 2004 to prevent

plate T40086 from making contact with 3rd gear wheel or selector rod for
5th and 6th gear.
 Remove circlip for 3rd speed selector gear needle bearing and detach 3rd gear needle bearing.
2:36:24 AM Page 106

Fig. 272: Pulling Off Thrust Washer For 3rd Speed Selector Gear
 Pull off thrust washer - B - for 3rd speed selector gear.
Fig. 273: Removing Circlip For 3rd Gear Wheel

 Remove circlip for 3rd gear wheel and note thickness of circlip.
 Pull off 3rd gear wheel.
2:36:24 AM Page 107

Fig. 274: Reverse Shaft Support Bolts, Bearing Housing And Bolts
 Remove bolts - arrows - for reverse shaft support.

 Remove 2 bolts - A - for bearing housing at transmission housing.
 Remove bearing housing - B - together with shafts.
Fig. 275: Driving Reverse Shaft Support Carefully Out Of Bearing Housing And Removing With Reverse
Gear Wheel
 Insert an internal puller - A - e.g. Kukko 21/2 into bore for reverse shaft support.
 Spread open internal puller far enough for it to make contact with reverse shaft support - B -.
 Drive reverse shaft support carefully out of bearing housing direction of - arrow - and remove with
reverse gear wheel.
2:36:24 AM Page 108

Fig. 276: Pulling Out Input Shaft From Bearing Housing At An Angle From The Front Direction Of
 Pull out input shaft - A - carefully from bearing housing at an angle from the front direction of - arrow -.
 Pull pin with clip - A - for securing selector fork for reverse gear out from selector rod - B -.
2:36:25 AM Page 109

Fig. 278: Pressing Off Synchronizing Hub For Reverse Gear From Output Shaft
 Press off synchronizing hub for reverse gear from output shaft.
NOTE:  Place the bearing housing onto thrust plates VW 401 and VW 402 so that
the output shaft and selector rods are not damaged when pressing off the
synchronizing hub.
 Detach reverse selector gear, needle bearing for reverse selector gear and reverse gear synchronizing hub.
 Guide output shaft out of selector fork for 1st and 2nd gear and bearing housing.
Assembling transmission
If the input shaft or the transmission housing have been replaced, you must first re-determine the thickness of
the input shaft circlips --> Determining circlips for input shaft ball bearing.
NOTE:  Lubricate all needle bearings with gear oil before installing.
 Check synchro-rings for wear Checking synchro-ring for wear
 Insert spring in selector gear Inserting spring in selector gear
 Heat gear wheels, needle bearing inner races and synchronizing hubs to
130° C (max.) before pressing on (wear protective gloves).
 Insert output shaft in bearing housing and selector fork for 1st and 2nd gear.
 Place reverse gear selector gear with needle bearing, spring and synchro-ring onto output shaft.
2:36:25 AM Page 110

Fig. 279: Pressing On Reverse Gear Synchronizing Hub

 Press on reverse gear synchronizing hub.
 Installation position: high inside collar faces 3rd gear wheel.
 Check axial clearance of reverse selector gear.
Fig. 280: Inserting Input Shaft With Needle Roller Bearing Into Bearing Housing At An Angle Toward
The Rear
 Insert input shaft - A - with needle roller bearing - B - into bearing housing in direction of - arrow - at an
angle toward the rear.
2:36:25 AM Page 111

Fig. 281: Reverse Gear Wheel Bolts

 Install reverse gear wheel and tighten 3 bolts - arrows - for reverse shaft support to 30 Nm.
Assembly overview - reverse gear wheel Assembly overview - reverse gear wheel
 Slide reverse gear selector fork - C - together with locking collar - D - onto selector rod - B - and reverse
gear synchronizing hub.
 The chamfer on locking collar faces reverse selector gear.
2:36:25 AM Page 112

Fig. 283: Plate T40088/1 Placed On Press Table And Bearing Housing Inserted With Shafts And Selector
Rods
 Place plate T40088/1 on press table and insert bearing housing with shafts and selector rods.
Fig. 284: Pressing On 3rd Gear Wheel

 Press on 3rd gear wheel.
 Installation position: machined side faces reverse gear synchronizing hub.
 Insert circlip for 3rd gear wheel.
2:36:25 AM Page 113

Re-determine thickness of circlip for 3rd gear wheel:

1.90 1.98 2.06
1.94 2.02 2.10
Fig. 285: Pressing On Thrust Washer For 3rd Speed Selector Gear Until Limit Stop
 Press on thrust washer - A - for 3rd speed selector gear until limit stop.
Fig. 286: Installing Needle Bearing For 3rd Speed Selector Gear And Circlip For 3rd Gear Needle
Bearing Onto Input Shaft
 Install needle bearing for 3rd speed selector gear - 1 - and circlip - 2 - for 3rd gear needle bearing onto
input shaft.
 Install 3rd speed selector gear with spring and synchro-ring.
2:36:25 AM Page 114

Fig. 287: Pressing On Heated Synchronizing Hub For 3rd And 4th Gear
 Press on heated synchronizing hub for 3rd and 4th gear
 Installation position: high inside collar faces 3rd speed selector gear.

 Insert circlip for synchronizing hub for 3rd and 4th gear.
 When replacing synchronizing hub or input shaft:
Re-determine thickness of circlip for synchronizing hub for 3rd and 4th gear:
2:36:25 AM Page 115

1.90 1.96 2.02

1.93 1.99 2.05
 Check axial clearance of 3rd speed selector gear.
 Slide selector fork for 3rd and 4th gear - C - together with locking collar - D - onto selector rod - B - and
synchronizing hub for 3rd and 4th gear.
NOTE:  Do not insert pin with clip for 5th/6th gear selector fork (diameter 6 mm)
into selector fork for 3rd and 4th gear.
Fig. 290: Installing 4th Speed Selector Gear With Spring, Synchro-Ring, Needle Bearing And Thrust
Washer For 3rd And 4th Gear And Pressing On Heated Inner Race For Needle Bearing For 5th Speed
Selector Gear
2:36:25 AM Page 116

 Install 4th speed selector gear - A - with spring, synchro-ring, needle bearing and thrust washer for 3rd
and 4th gear - B -.
 Press on heated inner race - C - for needle bearing for 5th speed selector gear.


2:36:25 AM Page 117

Fig. 293: Pressing On Heated Synchronizing Hub For 5th And 6th Gear
 Place 5th speed selector gear with spring, synchro-ring and needle bearing onto input shaft.
 Install and press on heated synchronizing hub for 5th and 6th gear.
 Slide selector fork for 5th and 6th gear - C - together with locking collar - D - onto synchronizing hub for
5th and 6th gear.
 Move selector fork for 5th and 6th gear - C - into selector rod - B -.
 If holes of selector fork and selector rod coincide, clip in pin with clip - A -.
2:36:25 AM Page 118

Fig. 295: Pressing On Heated Inner Race For Needle Bearing For 5th Speed Selector Gear
 Press on heated inner race for needle bearing for 5th speed selector gear.
Fig. 296: Pressing On 6th Speed Selector Gear

 Install 6th speed selector gear with spring, synchro-ring, needle bearing and thrust washer for 6th gear - A
-.
 Heat inner race - B - for needle roller bearing and press on.
2:36:25 AM Page 119


 Install spacer sleeve - A - onto output shaft.

Fig. 298: Identifying 6th Gear Wheel Circlip

Insert circlip - A - for 6th gear wheel.
Re-determine circlip - A - for 6th gear wheel:

1.90 2.02 2.14
1.93 2.05 2.17
2:36:25 AM Page 120

1.96 2.08 2.20

1.99 2.11
 Remove bearing housing from holding plate T40088/1.
 Secure bearing housing to transmission housing with two bolts M8 (length approx. 70 mm) - arrows -
and washers.
 Tighten these 2 bolts - arrows - to max. 5 Nm.
NOTE:  Do not install oil collector - A - at this stage.

2:36:25 AM Page 121

 Tighten multi-point socket head bolt - 1 - for input shaft to 150 Nm.
 Remove complete bearing housing from transmission housing.
 Check if the 2 dowel sleeves are installed between transmission housing and bearing housing.
 Apply sealing paste AMV 188 001 01 evenly and not too thickly onto contact surfaces between
transmission housing and bearing housing.
 Install bearing housing onto transmission housing.
 Clip oil collector - A - into reverse shaft support.
NOTE:  Make sure that the bolts - arrows - are removed.
2:36:25 AM Page 122


 Check if the 2 dowel sleeves are installed between bearing housing - B - and transmission cover - A -.
 Apply sealing paste AMV 188 001 02 evenly and not too thickly onto contact surfaces between bearing
housing and transmission cover.
 Insert securing bolts for transmission cover - A - and bearing housing - B - to transmission housing - C -.

 Tighten bolts - arrows - to 35Nmplus an additional 90° 1 /4 turn.
2:36:25 AM Page 123

 Push assembly sleeve 01E311120 - A - onto selector shaft - B -.
NOTE:  To avoid damaging the oil seal - C - , the oil seal and selector shaft must
only be installed using assembly sleeve 01E311120 - A -.
 Move selector rods to neutral.

 Installation position: Chamfer of selector shaft points downward.

 Installation position for pin - 3 - : The groove - arrow - on pin points toward selector shaft cover.
2:36:25 AM Page 124



 Install rear circlip - arrow - for input shaft ball bearing.

 Then push ball bearing onto input shaft.
2:36:25 AM Page 125


First screw door hinge alignment tool (M8 and M10) 3114/2 into tapped hole for ball head stud.
Position fitting tool T10246/1 behind splines for clutch plate. Tighten bolts - A - only slightly. The bolts locate
in recesses in the thrust plate T10246/2.

 Install front circlip - D - for input shaft ball bearing.

 Install dished spring - C -.
The curved side faces guide sleeve - B -.
2:36:25 AM Page 126


 Install guide sleeve - B - for release bearing.
 Remove shrink hose.
 Install clutch release lever - A - with release bearing.

2:36:25 AM Page 127


 Thrust pad VW 512

 Sleeve VW 519


2:36:25 AM Page 128


 - 1 - internal puller Kukko 21/2
Fig. 313: Transmission Cover Remove/Install Components

2:36:25 AM Page 129

2 - Dowel sleeve
 2x
 For centralizing transmission cover on bearing housing
 Drive out and in with drift 3121
3 - Roller bearing
 Bearing for output shaft in transmission cover

 Always replace
 Pulling out Pulling roller bearing for output shaft out of transmission cover
 Pressing in Pressing new roller bearing for output shaft into transmission cover as far as the stop
(press in carefully)
4 - Roller bearing

 Always replace
 Pulling out Pulling roller bearing for input shaft out of transmission cover
 Pressing in Pressing new roller bearing for input shaft into transmission cover as far as stop (press
in carefully)
5 - Ball sleeve

6 - Ball sleeve

8 - Retaining plate
 Installation position Securing needle roller bearing and needle bearing in transmission cover.
Pulling roller bearing for output shaft out of transmission cover
2:36:25 AM Page 130

Fig. 314: Pulling Roller Bearing For Output Shaft Out Of Transmission Cover
Pressing new roller bearing for output shaft into transmission cover as far as the stop (press in carefully)
Fig. 315: Pressing New Roller Bearing For Output Shaft Into Transmission Cover As Far As The Stop
Pulling out ball sleeve - C - from transmission cover
2:36:25 AM Page 131

Fig. 316: Pulling Out Ball Sleeve From Transmission Cover

Driving ball sleeve into transmission cover until flush
Fig. 317: Driving Ball Sleeve Into Transmission Cover Until Flush
Install ball sleeve - 1 - and - 2 - so that side with lettering (thicker metal) faces guide pin 10 - 15 or centering
mandrel 3176.
NOTE:  Due to the housing depth use centering mandrel 3176 for driving in ball
sleeve - 2 -.
Pulling roller bearing for input shaft out of transmission cover
2:36:25 AM Page 132

Fig. 318: Pulling Roller Bearing For Input Shaft Out Of Transmission Cover
Shorten (cut off) lubricating unit in needle roller bearing in order to insert internal puller - B -.
Pressing new roller bearing for input shaft into transmission cover as far as stop (press in carefully)
Fig. 319: Pressing New Roller Bearing For Input Shaft Into Transmission Cover As Far As Stop
Securing needle roller bearing and needle bearing in transmission cover.
2:36:25 AM Page 133

Fig. 320: Securing Needle Roller Bearing And Needle Bearing In Transmission Cover
 Insert retaining plate - 2 - with high shoulder - arrow - facing needle bearing - 1 - into transmission
cover.
 Tighten hex socket head bolt - 3 - to 24 Nm.
BEARING HOUSING, SERVICING
Bearing housing, servicing
2:36:25 AM Page 134



 Installing sleeve VW 455

 Tube 42 mm dia. VW 516
2:36:25 AM Page 135


 Thrust pad 3074
 Drift T40085
2:36:25 AM Page 136

Fig. 323: Bearing Housing Remove/Install Components

1 - Bearing housing
 Re-determine shim "S4 " when replacing --> Re-determining shim "S4" when replacing bearing
housing
2 - Outer race
 For needle roller bearing on input shaft

 Driving out Driving outer race for needle roller bearing out of bearing housing
 Pressing in Pressing outer race for needle roller bearing into bearing housing until limit stop
3 - Shim "S4 "
2:36:25 AM Page 137


 Re-determine when replacing bearing housing --> Re-determining shim "S4" when replacing bearing
housing
 Only replace together with selector fork for 1st and 2nd gear (secured together by means of a pin)
7 - Ball sleeve
 (Front) for reverse gear selector rod

 Pressing in Pressing front ball sleeve into reverse gear selector rod until limit stop.
8 - Ball sleeve
 (Rear) for reverse gear selector rod

 Pulling out Pulling out rear ball sleeve for reverse gear selector rod
 Pressing in Pressing in rear ball sleeve - A - for reverse gear selector rod
 Remove burrs and scoring after removing from bearing housing
11 - Ball sleeve


2:36:25 AM Page 138


14 - Ball sleeve

 Driving in Driving in ball sleeve for selector rod for 3rd and 4th gear
Driving outer race for needle roller bearing out of bearing housing
Fig. 324: Driving Outer Race For Needle Roller Bearing Out Of Bearing Housing
 Clamp bearing housing in vise, using jaw protectors - C -.

 Drive out outer race - A - using drift - B - by alternately applying drift to bearing housing recesses located
opposite to each other - arrow -.
Pressing outer race for needle roller bearing into bearing housing until limit stop
Fig. 325: Pressing Outer Race For Needle Roller Bearing Into Bearing Housing Until Limit Stop
2:36:25 AM Page 139

Pulling front ball sleeve out of reverse gear selector rod
Fig. 326: Pulling Front Ball Sleeve Out Of Reverse Gear Selector Rod
Pressing front ball sleeve into reverse gear selector rod until limit stop
Fig. 327: Pressing Front Ball Sleeve Into Reverse Gear Selector Rod Until Limit Stop
Install ball sleeve - arrow - so that side with lettering (thicker metal) faces guide pin 10 - 15.
Pulling out rear ball sleeve for reverse gear selector rod
2:36:25 AM Page 140

Fig. 328: Pulling Out Rear Ball Sleeve For Reverse Gear Selector Rod
 Clamp actuating arm of selector rod in vise, using jaw protectors - C -.

 Install thrust tube VW 454 and installing sleeve VW 455 onto selector rod.
Pressing in rear ball sleeve - A - for reverse gear selector rod
Fig. 329: Pressing In Rear Ball Sleeve For Reverse Gear Selector Rod
Driving in ball sleeve for selector rod for 3rd and 4th gear
2:36:25 AM Page 141

Fig. 330: Driving In Ball Sleeve For Selector Rod For 3Rd And 4Th Gear
 Dimension for pressing in - a - = 2.5 mm
 Remove relevant selector rod (for 3rd and 4th gear or for 5th and 6th gear).
 Bolt bearing housing - B - with transmission cover - A - onto transmission housing prior to driving out
and driving in the locking bushings - C -.
 Drive out old locking bushing inward into bearing housing.

 Drive in new locking bushing until flush.
2:36:25 AM Page 142



 Needle bearing drift VW 295 A
 Tube VW 423
 Multi-purpose tool VW 771

2:36:25 AM Page 143


 Installing tool 40 - 503

 Drift T40085
2:36:25 AM Page 144

Fig. 334: Transmission Housing Remove/Install Components

 When replacing: adjust input shaft --> Input shaft, adjusting, adjust output shaft and differential (final
drive gear set) --> Table of adjustments
 Replacing (with transmission removed) --> Selector shaft oil seal, replacing with transmission
removed (transmission remains assembled)
 Replacing (with transmission installed) --> Selector shaft oil seal, replacing with transmission
installed
 Always replace
 Pulling out Pulling out oil seal for selector shaft with transmission disassembled
2:36:25 AM Page 145

 Driving in Driving in seal for selector shaft

 Use assembly sleeve to install (selector shaft remains installed) --> Selector shaft oil seal, replacing
with transmission removed (transmission remains assembled)
3 - Tapered roller bearing outer race (right-side)
 If replaced: adjust differential (crown wheel) --> Crown wheel, adjusting
4 - Shim "S2 "
 Note thickness
5 - Bushing
 Drive in (for example, with press tool VW 408 A when replacing transmission
6 - Magnet
 Clean
7 - Ball head stud, 25 Nm
 Grease with MoS2 grease
9 - Oil seal
 For flange shaft (right-side)

 Removing Removing flange shaft oil seal (right-side)
 Installing Installing flange shaft oil seal (right-side)


2:36:26 AM Page 146

12 - Ball sleeve

13 - Ball sleeve

14 - Shim "S3 "
 Note thickness
16 - Bolt, 24 Nm
17 - Needle bearing
 For input shaft

 Driving out Driving out input shaft needle bearing from transmission housing
 Driving in Pressing in input shaft needle bearing until limit stop
18 - Oil collector
 With magnet
 Installation position in transmission housing Securing input shaft needle bearing
19 - Ball sleeve

 Pulling out Removing selector shaft ball sleeve
 Driving in Driving in ball sleeve for selector shaft
20 - Cap
2:36:26 AM Page 147

21 - Breather pipe
 Drive in onto stop

 Clip in cap for transmission breather
Pulling out oil seal for selector shaft with transmission disassembled

Driving in seal for selector shaft

2:36:26 AM Page 148

 Drive out used locking bushing - A - inward into transmission housing.

 Drive in new locking bushing into transmission housing - B - until flush.
Pulling out ball sleeve - C - from transmission housing.
Fig. 338: Pulling Out Ball Sleeve From Transmission Housing.

Driving out input shaft needle bearing from transmission housing
2:36:26 AM Page 149

Fig. 339: Driving Out Input Shaft Needle Bearing From Transmission Housing
 Remove bolt for securing needle bearing Securing input shaft needle bearing.
 Install adapter VW 295 A with smaller outside diameter into needle bearing.
 Drive out needle bearing with drift VW 295.
Pressing in input shaft needle bearing until limit stop
Fig. 340: Pressing In Input Shaft Needle Bearing Until Limit Stop
 Secure needle bearing after pressing in Securing input shaft needle bearing
Securing input shaft needle bearing
2:36:26 AM Page 150

Fig. 341: Securing Input Shaft Needle Bearing

 Secure input shaft needle bearing with bolt - 2 -.

 Insert oil collector - 1 - into transmission housing.
Removing selector shaft ball sleeve

Driving in ball sleeve for selector shaft
2:36:26 AM Page 151


 Drive in ball sleeve until flush.
SELECTOR SHAFT, SERVICING
Selector shaft with transmission installed, removing and installing

2:36:26 AM Page 152


 Tube VW423


2:36:26 AM Page 153

Fig. 347: Fasteners

Removing


2:36:26 AM Page 154

 Remove front exhaust pipe (right side) -->


2:36:26 AM Page 155


 Disconnect electrical connector - arrow - for back-up light switch F4.


2:36:26 AM Page 156


 Carefully pry out seal with a screwdriver.
Installing
NOTE:  replace seals and O-rings.
 Install selector shaft.
 Installation position: Chamfer of selector shaft - B - points downwards.
2:36:26 AM Page 157

NOTE:  Ignore - item A - and - item C -.

 Installation position: groove - arrow - on pin - 3 - faces toward selector shaft cover.


2:36:26 AM Page 158

NOTE:  Use mounting sleeve 01E311120 - item A - to prevent damaging the seal -
C - when installing.

 Lightly oil outer circumference of seal - arrow -.

2:36:26 AM Page 159


 Install front exhaust pipe align exhaust system so it is free of stress -->
.
Tightening torques
Component Nm
Locking bolts for selector shaft 45
Cover for selector shaft 24
Selector shaft oil seal, replacing with transmission removed (transmission remains assembled)
NOTE:  Removal is also possible with transmission installed in vehicle --> Selector
shaft oil seal, replacing with transmission installed.
2:36:26 AM Page 160


 Tube VW423


2:36:26 AM Page 161


Removing
 With selector shaft installed

 With selector shaft removed
 Carefully pry out oil seal using a screwdriver or oil seal extractor lever VW 681.
Installing
01E311120 - A -.
2:36:26 AM Page 162


Selector shaft oil seal, replacing with transmission installed

 Tube VW423
2:36:26 AM Page 163




2:36:26 AM Page 164


Removing

 Remove heat shield for drive shaft (left-side).


2:36:26 AM Page 165


Installing
01E311120 - A -.
2:36:26 AM Page 166


The remaining installation steps are perform in the reverse sequence. Note the following:
 Install front exhaust pipe with catalytic converter and align exhaust system so it is free of stress --> 3.0
Liter 6-Cyl. 5V Engine Mechanical, Engine Code(s): AVK - 26 EXHAUST SYSTEM, EMISSION
CONTROLS .
 Install heat shield for drive axle (left-side).
 Check gear oil level in transmission --> Transmission oil level, checking.
Tightening torques
Component Nm
Back-up light switch F4, removing and installing
2:36:26 AM Page 167



Removing
2:36:26 AM Page 168


 Disconnect electrical connector - arrow - for back-up light switch F4 on transmission (right side).
 Remove back-up light switch F4 from selector shaft cover - arrow -.
Installing
 Screw back-up light switch F4 into selector shaft cover - arrow -.
2:36:26 AM Page 169


 Attach electrical connector - arrow - for back-up light switch F4 on transmission (right side).
Component Nm
Back-up light switch F4 20
2:36:26 AM Page 170

35 GEARS, SHAFTS
NOTE:  Refer to technical data when installing new gears --> Code letters,
 Lubricate all bearings on input shaft with gear oil before installing.

1 - Circlip
2:37:16 AM
2:37:20 Page 1
 Mark
2 - Ball bearing
3 - Circlip
 Mark
5 - Needle bearing
 For input shaft
6 - Bolt, 24 Nm
7 - Input shaft
 Adjusting --> Input shaft, adjusting
8 - Roller bearing
 Disassembling and assembling Detaching needle roller bearing from input shaft and installing needle
roller bearing onto input shaft
 Installation position: collar faces splines for 2nd gear
9 - Outer race
11 - Thrust washer
12 - Needle bearing
 For 3rd gear
2:37:16 AM Page 2
13 - Circlip
 Mark
15 - Spring
 Insert in 3rd speed selector gear --> Inserting spring in selector gear
18 - Circlip
 Mark
 Re-determining thickness Determining thickness of circlip for synchronizing hub for 3rd and 4th
gear
20 - Needle bearing
 For 4th gear
22 - Spring
2:37:17 AM Page 3
24 - Thrust washer
 For 5th gear
26 - Needle bearing
 For 5th gear
28 - Spring
 For 6th gear
33 - Needle bearing
 For 6th gear
35 - Spring
 Insert in 6th speed selector gear Inserting spring in selector gear

2:37:17 AM Page 4
37 - Thrust washer
38 - Inner race
42 - Roller bearing

 Always replace
Input shaft, Disassembling and assembling
NOTE:  Removing and installing 3rd to 6th speed selector gears is described in
chapter on disassembling and assembling transmission --> Disassembling
and assembling sequence.
 Feeler gauge
Detaching needle roller bearing from input shaft and installing needle roller bearing onto input shaft
2:37:17 AM Page 5
Fig. 384: Detaching Needle Roller Bearing From Input Shaft And Installing Needle Roller Bearing Onto
Input Shaft
Removing needle roller bearing:
 Bend open needle roller bearing at separating point - arrow B - far enough for it to be detached from
input shaft (do not bend open more than necessary).
Installing needle roller bearing:
 The shoulder - arrow A - faces toward splines for 2nd gear.
 Only bend open needle roller bearing at separating point - arrow B - far enough for it to be guided over
input shaft and onto its seat - arrow C -.
2:37:17 AM Page 6


gauge.
 The determined value should not exceed 0.45 mm.
2:37:17 AM Page 7

 The circlips - 1 - and - 2 - secure input shaft ball bearing.
Determining thickness --> Determining circlips for input shaft ball bearing.
 The circlip - 3 - secures needle bearing for 3rd speed selector gear and 3rd and 4th gear synchronizing
hub.
Thickness: 2.00 mm.
 The circlip - 4 - secures 3rd and 4th gear synchronizing hub.
Determining thickness Determining thickness of circlip for synchronizing hub for 3rd and 4th gear.
Determining thickness of circlip for synchronizing hub for 3rd and 4th gear
2:37:17 AM Page 8

 Press synchronizing hub onto stop.

1.90 1.96 2.02
1.93 1.99 2.05
Determining circlips for input shaft ball bearing
It is necessary to readjust input shaft when:
or the
 Input shaft
are replaced.
2:37:17 AM Page 9

Fig. 391: Fitting Tool T10246
2:37:17 AM Page 10

 Digital depth gauge e.g. VAS 6087
Determining thickness for circlip behind input shaft ball bearing
 Install provisional circlip - arrow - in rear groove on input shaft.


Screw pin (M8 and M10) 3114/2 into tapped hole for ball head stud.
2:37:17 AM Page 11
Position fitting tool T10246/1 behind splines for clutch plate. Tighten bolts - a - only slightly. The bolts locate
in recesses in thrust plate T10246/2.
Fig. 394: Dished Spring, Guide Sleeve And Bolt

 Install dished spring - 1 -.
The convex side faces guide sleeve - 2 -.

 Bolt guide sleeve to transmission housing - 2 - with bolts - 3 -.
 Turn transmission housing so joint flange for bearing housing points upward.
 The contact surface must be cleaned to remove sealing paste .
2:37:17 AM Page 12
 Place thrust washer - 1 - for 4th and 5th speed selector gears onto input shaft.
 Place a digital depth gauge (e. g. VAS 6087) onto thrust washer and measure distance to contact surface
of housing. The measuring point on housing contact surface must be as close to input shaft as possible.
NOTE:  When measuring, lift the input shaft with e.g. support bridge 30-211A or
the help of a second mechanic until the play in the ball bearing is taken up.
Specification: distance "a" = 164.14 mm
NOTE:  If the measured value exceeds the specification, use a thinner circlip than
 If the measured value is below the specification, use a thicker circlip than
 Determine the circlip thickness to meet the specification as exactly as
possible (164.14 mm).

1.54 2.08 2.62
1.63 2.17 2.71
1.72 2.26 2.80
1.81 2.35 2.89
1.90 2.44
1.99 2.53
 Select circlip from table.

2:37:17 AM Page 13
Checking adjustment and checking distance "a"
 Determined circlip is installed.
The distance "a" should be 164.14mm +- 0.04 mm if the correct circlip has been selected.
Determining thickness for circlip in front of the input shaft ball bearing
 Drive rear circlip (as determined) and ball bearing onto input shaft using drift sleeve 30 - 100.
 Determine thickest circlip which will still fit.

 Refer to table The following circlips are available: to determine correct circlip.
PINION SHAFT (OUTPUT SHAFT)
Pinion shaft, assembly overview
NOTE:  Refer to technical data --> Code letters, allocation, transmission ratios,
capacities when installing new gear wheels or the final drive gear set.
 Refer to technical data when installing new gear wheels
 Lubricate all needle bearings on output shaft with gear oil before
installing.
2:37:17 AM Page 14
Fig. 398: Pinion Shaft, Assembly Overview

 Servicing --> Transmission housing, servicing
2 - Shim "S3"
 Pulling out Pulling tapered roller bearing outer race out of transmission housing
 Pressing in Heating transmission housing in order to install tapered roller bearing outer race and
2:37:17 AM Page 15
4 - Pinion shaft (output shaft) 1)
 Is mated with crown wheel, always replace together as a set

 Adjusting crown wheel and pinion shaft --> --> Pinion shaft and crown wheel, adjusting
 Will be damaged during removal

 Replace
 Pressing off Pressing off tapered roller bearing inner race
6 - Circlip
 Re-determine thickness if taper roller bearing is replaced Determining thickness of circlip
7 - Needle bearing
 For 1st gear
8 - 1st speed selector gear
 Check axial clearance after installing using feeler gauge Checking axial play of 1st speed selector gear
(0.20 to 0.50 mm)
9 - Inner ring for 1st gear
 Checking for wear Checking 1st gear inner ring for wear
11 - Synchro-ring for 1st gear
2:37:17 AM Page 16

13 - Locking piece
 Install locking pieces (3 Qty.) Assembling 1st and 2nd gear locking collar/synchronizing hub
14 - Synchronizing hub for 1st and 2nd gear
 Installation position: high inside collar faces 2nd speed selector gear
 Pressing off Pressing off 1st and 2nd gear synchronizing hub
 Pressing on Pressing on 1st and 2nd gear synchronizing hub
15 - Circlip
 Mark
 Re-determine thickness when replacing 1st and 2nd gear synchronizing hub or pinion shaft Determining
thickness of circlip
16 - Needle bearing
 For 2nd gear
17 - Synchro-ring for 2nd gear
19 - Inner ring for 2nd gear
2:37:17 AM Page 17
20 - 2nd speed selector gear
 Check axial clearance after installing using feeler gauge Checking axial play of 2nd speed selector gear
(0.20 to 0.50 mm)
21 - Circlip
 Mark
 Pressing off Pressing off tapered roller bearing inner race with 2nd speed selector gear
23 - Circlip
 Mark
24 - Thrust washer

 Pressing off Pressing off thrust washer for reverse selector gear
 Pressing on Pressing on thrust washer for reverse selector gear
 Pulling out Pulling tapered roller bearing outer race out of bearing housing
 Pressing in Pressing tapered roller bearing outer race into bearing housing
26 - Shim "S4 "
27 - Bearing housing 1)
28 - Needle bearing
2:37:17 AM Page 18
30 - Spring
 Insert into reverse selector gear Inserting spring in selector gear


34 - 3rd gear wheel
35 - Circlip
 Mark
 Re-determine thickness when replacing 3rd gear wheel, reverse gear synchronizing hub or pinion shaft
36 - 4th gear wheel
37 - 5th gear wheel
38 - Spacer sleeve
39 - 6th gear wheel
40 - Circlip
 Mark
2:37:17 AM Page 19
 Re-determine thickness when replacing gear wheels for 4th to 6th gear, the spacer sleeve or pinion shaft
41 - Needle bearing
 Bearing for pinion shaft in transmission cover


2:37:17 AM Page 20
gauge.
The determined value should not exceed 0.45 mm.
Pinion shaft, disassembling and assembling
NOTE:  Removing and installing gear wheels for 3rd to 6th gear and reverse
selector gear is described in chapter on disassembling and assembling
transmission --> Disassembling and assembling sequence.
2:37:17 AM Page 21

 Tube VW 415 A
 Tube VW 519
2:37:17 AM Page 22
 Thrust pad 3062
 Press tool 3118

 Slotted nut wrench 3155

 Assembly tool 3253
2:37:17 AM Page 23
 Hot air blower V.A.G 1416

 - 3 - Splitter Kukko 17/2
 Feeler gauge
Pulling tapered roller bearing outer race out of transmission housing
Fig. 404: Pulling Tapered Roller Bearing Outer Race Out Of Transmission Housing
 Removing differential --> Differential, removing and installing.

 Install thrust piece 2050 with large diameter pointing toward outer race.
 Install threaded spindle and thrust pad of assembly tool 3253 with thrust plate VW 401 onto transmission
housing.
The outer race will be pulled out of transmission housing when nut is tightened.
Heating transmission housing in order to install tapered roller bearing outer race
2:37:17 AM Page 24
 Heat transmission housing in area of bearing seat for approx. 15 minutes, to approx. 100° C, with hot air
blower V.A.G 1416.
Fig. 406: Pressing Tapered Roller Bearing Outer Race Into Transmission Housing
 Insert outer race only after heating transmission housing and push into position under Workshop press
Pulling tapered roller bearing outer race out of bearing housing
Fig. 407: Pulling Tapered Roller Bearing Outer Race Out Of Bearing Housing
Pressing tapered roller bearing outer race into bearing housing
2:37:17 AM Page 25
Housing
Support bearing housing with press support-RI wheel brgs. 3144 directly below bearing mounting.
 Press in outer race until limit stop.
Pressing off thrust washer for reverse selector gear
Fig. 409: Pressing Off Thrust Washer For Reverse Selector Gear
NOTE:  Install splitter - A - below thrust washer, and not below circlip.
 Remove circlip below thrust washer.
Pressing off tapered roller bearing inner race with 2nd speed selector gear
2:37:17 AM Page 26
Fig. 410: Pressing Off Tapered Roller Bearing Inner Race With 2Nd Speed Selector Gear
CAUTION: When pressing off, make sure that only the gear teeth of the selector gear
and not the gear shift splines contact the splitter - A -. Otherwise the gear
shift splines will be damaged.
 Remove circlip for tapered roller bearing inner race.
Pressing off 1st and 2nd gear synchronizing hub
2:37:17 AM Page 27
Fig. 411: Pressing Off 1st And 2nd Gear Synchronizing Hub

 Press synchronizing hub off with 1st speed selector gear
Pressing off tapered roller bearing inner race
Fig. 412: Pressing Off Tapered Roller Bearing Inner Race


 The outer race of tapered roller bearing - arrow - must be installed prior to pressing off inner race.
2:37:17 AM Page 28

 Heat inner race to approx. 100° C and press on.

 Determine thickness of required circlip Determining thickness of circlip and install circlip.

NOTE:  The thickness of the circlips for the synchronizing hubs and individual
gear wheels must also be determined as shown for the tapered roller
bearing.
Overview for installation position of circlips Installation position of circlips
2:37:17 AM Page 29

The required circlips for inner races of tapered roller bearings, the synchronizing hubs and individual gear
wheels should be selected as shown in Determining thickness of circlip

2.50 2.56 2.62
2.53 2.59 2.65
 Circlip - 2 - secures 1st and 2nd gear synchronizing hub.
Identification: blue color

1.90 2.02 2.14
1.93 2.05 2.17
1.96 2.08
1.99 2.11

3.50
2:37:17 AM Page 30
 Circlip - 4 - secures thrust washer for reverse selector gear.

3.50
 Circlip - 5 - secures 3rd gear wheel.

1.90 1.98 2.06
1.94 2.02 2.10
 Circlip - 6 - secures 6th gear wheel.

1.90 2.02 2.14
1.93 2.05 2.17
1.96 2.08 2.20
1.99 2.11
 Determine circlips according to table.
Installation position of synchronizing rings for 1st and 2nd gear:
Fig. 416: Installation Position Of Synchronizer Rings For 1St And 2Nd Gear
NOTE:  If components are not being replaced, make sure they are re-installed on
the same gear.
 Install inner ring - 2 - onto selector gear - 1 -.

 Install intermediate ring - 3 -. Lug - B - must be inserted into recess - A -.
 Synchro-ring - 4 - installed. Guide lugs - C - through recess - arrow -.
2:37:17 AM Page 31
Checking 1st gear inner ring for wear
Fig. 417: Checking Inner Race Of 1st Gear For Wear

 Check outer contact surface - arrow - for scoring or visible traces of wear and replace if necessary.
 Press inner ring onto chamfer on selector gear and measure gap - a - using a feeler gauge.

Inner ring for 1st gear 1.2 to 2.0 mm 0.6 mm
Checking 1st and 2nd gear intermediate ring for wear

 Check inner contact surface of synchro-ring for scoring or visible traces of wear and replace if necessary.
 Press inner ring, intermediate ring and synchro-ring onto chamfer on selector gear and measure gap - a -
using a feeler gauge.

1st and 2nd gear 1.4 to 2.0 mm 0.8 mm
2:37:17 AM Page 32
Pressing on 1st and 2nd gear synchronizing hub
Fig. 419: Pressing On 1st And 2nd Gear Synchronizing Hub

High inside collar faces 2nd gear.
 The lugs of 1st gear synchro-ring and recesses on synchronizing hub must align - arrow - when pressing
on.
Assembling 1st and 2nd gear locking collar/synchronizing hub
Fig. 420: Assembly Of Operating Sleeve/Synchronizers For 1st And 2nd Gear
 Install locking pieces - arrows A - into mounted synchronizing hub - 1 -.
2:37:17 AM Page 33
 Install locking collar - 2 - onto synchronizing hub so that the wide splines of locking collar and
synchronizing hub - arrow B - coincide.
 Install circlip for 1st and 2nd gear synchronizing hub.
 Install 2nd speed selector gear with needle bearing and synchro-rings.

 Install circlip for tapered roller bearing inner race onto pinion shaft.
 Shoulder of tube VW 415 A faces inner race - arrow -.
Then check axial play of 1st speed and 2nd speed selector gears Checking axial play of 1st speed selector
gear and Checking axial play of 2nd speed selector gear.
Checking axial play of 1st speed selector gear
2:37:17 AM Page 34
Fig. 422: Checking Axial Play Of 1st Speed Selector Gear

 Press 1st speed selector gear - 2 - in direction of - arrow A - as far as stop.

 Measure distance between 1st speed selector gear - 2 - and synchro-ring - 3 - using a feeler gauge - 1 -.
Example: 2.55 mm
 Press 1st speed selector gear - 2 - in direction of 2nd speed selector gear - 4 -.
 Measure distance again between 1st speed selector gear - 2 - and synchro-ring - 3 - using a feeler gauge -
1 -.
Example: 2.15 mm
 The difference between two measured values must be between 0.20to 0.50mm.
Checking axial play of 2nd speed selector gear
Fig. 423: Checking Axial Play Of 2nd Speed Selector Gear

 Check axial play between 2nd speed selector gear - 2 - and inner race of tapered roller bearing - 3 - using
a feeler gauge - 1 -.
2:37:17 AM Page 35
 The play must be 0.20 to 0.50 mm.
Pressing on thrust washer for reverse selector gear
Fig. 424: Pressing On Thrust Washer For Reverse Selector Gear

 Install circlip - B - onto output shaft.

 Press on thrust washer - A - until it makes contact with circlip.
2:37:17 AM Page 36
39 FINAL DRIVE - DIFFERENTIAL

FLANGE SHAFT OIL SEAL (LEFT-SIDE), REPLACING
 Drift VW295
 Drift 2062
 Puller T10037
2:38:00 AM
2:38:05 Page 1

Removing


2:38:00 AM Page 2

 If installed, remove heat shield - arrows - for drive shaft (left-side).

surface protection.


2:38:00 AM Page 3

Installing

2:38:00 AM Page 4


flange shaft.
2:38:00 AM Page 5

Tightening torque
Component Nm
2:38:00 AM Page 6
 Drift VW295
 Drift 2062
 Puller T10037

Removing


2:38:00 AM Page 7



2:38:00 AM Page 8

2:38:00 AM Page 9
Installing

 Drive in new flange shaft oil seal using fitting drift 2062; keep seal straight when installing.


2:38:00 AM Page 10
flange shaft.
 Drive flange shaft in with drift VW295.
 Install drive axle --> 40 - FRONT SUSPENSION .
Tightening torque
Component Nm
2:38:00 AM Page 11


 Socket (27 mm) 3257

selector mechanism, input shaft, pinion shaft and bearing housing. These
components must be removed if the differential needs to be adjusted.
2:38:00 AM Page 12

2:38:00 AM Page 13
2 - Oil seal

3 - Circlip
 Replace
4 - Spacer ring

5 - Flange shaft

6 - Differential with crown wheel 1)
7 - O-ring
 Always replace
9 - TORX bolt, 20 Nm plus an additional 90°1 / 4 turn
2:38:00 AM Page 14

 Remove flange shaft (left-side); by securing puller T10037 to cover for final drive - arrow -.
2:38:00 AM Page 15

flange shaft.

 Drive new spacer ring in onto stop; do not tilt ring when doing this.
2:38:01 AM Page 16

1. Flange shaft
3. Spacer ring
5. Circlip
shaft is removed. This does not indicate that the bearing is defective.

2:38:01 AM Page 17


2:38:01 AM Page 18


2:38:01 AM Page 19



2:38:01 AM Page 20

 Drift VW 295
 Thrust pieces for pinion shaft bearing VW 470
 Sleeve 30 - 14
 Thrust pad 3005

 Tube 3296
2:38:01 AM Page 21



2:38:01 AM Page 22


2 - Shim "S2 "
 Note thickness
2:38:01 AM Page 23
5 - Crown wheel 1)

 Drive off housing using a punch Driving crown wheel off cage
 Installing onto differential cage HEATING CROWN WHEEL TO APPROX. 100° C and installing
7 - Bolt, 30 Nm plus an additional 90°1 / 4 turn
 Replace
10 - Shim "S1 "
 Note thickness
 With O-ring
2:38:01 AM Page 24
13 - Sun wheel
15 - Spring pin

16 - Planet pinion
2:38:01 AM Page 25
2:38:01 AM Page 26

 Heat inner race to approx. 100° C, fit in position and press home.
2:38:01 AM Page 27
B - Internal puller 56...70 mm, e.g. Kukko 21/8
Driving crown wheel off cage
2:38:01 AM Page 28

Heating crown wheel to approx. 100° C and installing

 When installing crown wheel, use centralizing pins - A - (shop-made tool) to locate.
2:38:01 AM Page 29


PINION SHAFT AND CROWN WHEEL, ADJUSTING
Pinion shaft and crown wheel, adjusting
NOTE:  Careful adjustment of the crown wheel and pinion shaft is essential to
ensure that the final drive gives long service and runs silently. For this
reason, the pinion shaft and crown wheel are matched together during
manufacturing, and checked to ensure a good mesh pattern and quiet
running in both directions of rotation. The position of quietest running is
found by moving the pinion shaft in an axial direction and at the same time
lifting the crown wheel out of the zero-play mesh position by the amount
necessary to maintain the backlash within the specified tolerance.
marked on the outer circumference of the crown wheel. The final drive set
(pinion shaft and crown wheel) may only be replaced together as a
matched pair.
shims.
2:38:01 AM Page 30

Ro - Crown wheel diameter 188 mm = 59.65 mm
R - Actual distance between crown wheel axis and face of pinion shaft in position of quietest running for this
gear set.
Vo - Hypoid offset
2:38:01 AM Page 31
Position of shims

->--> Table of adjustments.

S1 - Shim for crown wheel in cover for final drive
S2 - Adjustment shim for crown wheel in transmission housing
2:38:01 AM Page 32
NOTE:  If repairs have been perform to the transmission, it is only necessary to

adjust the pinion shaft, crown wheel or final drive set if components have
Crown wheel Pinion shaft Pinion shaft Backlash
adjustment:
("S3 " + "S4 ") via
("S1 " + "S2 ") Shim "S4 " only 0.12 -
deviation (tolerance) 0.28
"r"
--> Crown --> Re-determining shim "S4"
--> Pinion shaft,
wheel, when replacing bearing
adjusting
adjusting housing
Component replaced
Transmission housing
X X X
* See note
Bearing housing X X
X X
for pinion shaft
X X
for differential
Final drive gear set *
X X
See note
*Pinion shaft and crown wheel; only replace together.
Adjusting gear set, recommended sequence
2:38:01 AM Page 33

The following work sequence is recommended to save time when crown wheel and pinion shaft have to be
adjusted:
roller bearings.
 Distribute total shim thickness "Stotal " (S3 plus S4 ) so that dimension from center of crown wheel to end
roller bearings.
 Distribute total shim thickness "Stotal " (S1 plus S2 ) so that the specified backlash between crown wheel
and pinion shaft is obtained.
2:38:01 AM Page 34



2:38:01 AM Page 35


 Thrust pad 3062

2:38:01 AM Page 36

 Press tool 3345


 Dial gauge
(Setting preload of tapered roller bearings for pinion shaft)
2:38:01 AM Page 37
Without Shims
 Press tapered roller bearing outer race for pinion shaft into transmission housing without shims.
Housing
 Press in tapered roller bearing outer race for pinion shaft with shim "S4 *" (thickness 1.01 mm) into
bearing housing.
"e".
2:38:01 AM Page 38
Fig. 478: Tapered Roller Bearing Inner Race, Selector Gears And Locking Collar For 1st And 2nd Gears
And Tapered Roller Bearing Inner Race
 Press tapered roller bearing inner race - 1 - onto pinion shaft and secure Pressing on tapered roller
bearing inner race.
 Install selector gears and locking collar for 1st and 2nd gears - 2 - --> Pinion shaft, disassembling and
assembling.
 Press tapered roller bearing inner race - 3 - onto pinion shaft Pressing on tapered roller bearing inner
race.
2:38:01 AM Page 39
 Install bearing housing and transmission cover with 4 dowel sleeves and tighten bolts to 35Nm.
bearing housing.
 Maintain pressure and rotate pinion shaft 5 turns in both directions to seat taper roller bearing.
 Attach dial gauge (3 mm measuring range) with dial gauge extension to transmission housing.
The dial gauge extension must contact machined surface on the face of pinion.
2:38:01 AM Page 40

 Rotate pinion shaft 5 turns in each direction so that the tapered roller bearing seats properly. Otherwise
the result of the measurement will be incorrect.
NOTE:  If the measuring procedure needs to be repeated, the pinion shaft must
first be rotated 5 turns in each direction again so that the tapered roller
bearing seats properly. Preload dial gauge to 1 mm and set to "0" again.
Example:
Example:
2:38:01 AM Page 41
 Pull tapered roller bearing outer race out of transmission housing Pulling tapered roller bearing outer
race out of transmission housing
 Install shim "S3 *" in transmission housing and install outer race again.
 Install bearing housing and transmission cover with the 4 dowel sleeves and tighten bolts to 35Nm.
 Install assembly device VW 792 on transmission housing; when doing so, insert a M12 nut - A - between
assembly device VW 792 and transmission housing.
 Install universal dial gauge bracket VW 387 with dial gauge and 30 mm extension.
 Apply dial gauge extension exactly at center of intersection of ribs on transmission cover - arrow -.
 0.06 to 0.12 mm

2:38:01 AM Page 42
and "S4 ".

 Set adjustment rings of universal measuring tool VW385/1 to the following values:


 Master gauge VW385/30
 Set master gauge VW385/30 to Ro = 59.65 mm and install onto measuring tool.
2:38:01 AM Page 43


2:38:01 AM Page 44

is in place.
supplied as replacement parts and marked on the outer circumference of the crown wheel.
Formula:
Example:
2:38:01 AM Page 45


0.53 0.85 1.17
0.57 0.89 1.21
0.61 0.93 1.25
0.65 0.97 1.29
0.69 1.01 1.33
0.73 1.05 1.37
0.77 1.09 1.41
0.81 1.13
necessary.
Example:

0.33 0.73 1.13
0.37 0.77 1.17
0.41 0.81 1.21
0.45 0.85 1.25
0.49 0.89 1.29
0.53 0.93 1.33
2:38:01 AM Page 46
0.57 0.91 1.37

0.61 1.01 1.41
0.65 1.05 1.45
0.69 1.09 1.49
necessary.
Checking adjustment
 Install pinion shaft with appropriate measured shims "S3 " and "S4 ".

 If shims have been correctly selected, the deviation "r" (marked on outer circumference of crown wheel)
2:38:01 AM Page 47



 Dial gauge
 Straightedge
2:38:01 AM Page 48
Gauge

VAS 6087).
Example:


Example:

Shims available.
bearing outer race into bearing housing
2:38:01 AM Page 49
 Install assembly device VW 792 on transmission housing; when doing so, insert an M12 nut - A -
between assembly device VW 792 and transmission housing.
 Attach universal dial gauge bracket VW 387 with dial gauge and 30 mm extension.
NOTE:  Attach dial gauge extension exactly at the center of the webbing
intersection on the transmission cover - arrow -.

 0.06 to 0.12 mm
Crown wheel, adjusting
2:38:01 AM Page 50

 Drift VW 295
 Dial gauge extension VW382/10
 End measuring plate VW385/17
 Adjustable measuring lever VW 388

2:38:01 AM Page 51


 Crown wheel adjusting tool VW 521
 Tube 30 - 14

 Dial gauge
2:38:01 AM Page 52
It is necessary to readjust crown wheel when the following components have been replaced:
gear set

 Remove tapered roller bearing outer races for differential and remove shims --> Differential,
2:38:01 AM Page 53
 Install differential in transmission housing. The crown wheel is positioned on left-hand side (same side as
2:38:01 AM Page 54

Example:
backlash.
2:38:01 AM Page 55
Example:
Measuring backlash
 Install differential with crown wheel: S1 is installed on cover side, S2 in transmission housing.
 Insert crown wheel adjusting tool VW521/4 and VW521/12.


 Adjust measuring lever VW388 to distance "a" = 79 mm (for diameter 188 mm crown wheel).
 Turn crown wheel until it makes contact with the face of one tooth (end of backlash travel).
2:38:01 AM Page 56

 Turn back crown wheel until it makes contact with opposite tooth face (backlash).
 Take backlash reading and note down measured value.
 Turn crown wheel through 90° and repeat measurements a further 3 times.
Example:
mm, the installation of the crown wheel or the final drive gear set itself is
not correct. Check installation; replace final drive gear set if necessary.
Example:

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
2:38:02 AM Page 57
0.57 0.73
necessary.
Example:

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
necessary.
Adjustment, checking
2:38:02 AM Page 58

 After installing shims "S1 " and "S2 ", turn differential 5turns in both directions so that the tapered roller
bearings settle.
 Specification: 0.12 to0.28 mm

2:38:02 AM Page 59

FLANGE SHAFT OIL SEAL, REPLACING
Fig. 465: Identifying Special Tools -- Flange Shaft Oil Seal, Replacing
 Needle bearing drift VW295

 Driver 2062
 Puller T10037
2:51:35 AM
2:51:41 Page 1

Removing
Observe the general repair instructions --> General repair instructions.


2:51:35 AM Page 2


surface protection.

 Remove flange shaft (left-side) by securing puller T10037 to cover for final drive - arrow -.
2:51:35 AM Page 3

Installing
 Drive new oil seal for flange shaft using driver 2062; keep seal straight when installing.
2:51:35 AM Page 4


flange shaft.
2:51:35 AM Page 5
 Knock flange shaft in with needle bearing drift VW295.

 Bolt drive axle to flange shaft --> 40 - FRONT SUSPENSION
 Fill transmission with oil and check oil level --> Transmission oil level, checking .
Tightening torque
Component Nm
Fig. 474: Identifying Special Tools -- Flange Shaft Oil Seal, Replacing
2:51:35 AM Page 6
 Needle bearing drift VW295

 Driver 2062
 Puller T10037

Removing
 With transmission is installed
Observe the general repair instructions --> General repair instructions.


2:51:36 AM Page 7



2:51:36 AM Page 8
2:51:36 AM Page 9
Installing

 Drive new oil seal for flange shaft using driver 2062; keep seal straight when installing.


2:51:36 AM Page 10
flange shaft.
 Knock flange shaft in using needle bearing drift VW295.
 Install drive axle--> 40 - FRONT SUSPENSION .
 Fill transmission with oil and check oil level--> Transmission oil level, checking .
Tightening torque
Component Nm
2:51:36 AM Page 11


 Socket (27 mm) 3257

selector mechanism, input shaft, pinion shaft/hollow shaft or bearing
housing. These components must be removed if the differential needs to
be adjusted.
2:51:36 AM Page 12


2:51:36 AM Page 13
2 - Oil seal

3 - Circlip
 Replace
4 - Spacer ring

5 - Flange shaft

6 - Differential with ring gear1)
7 - O-ring
 Always replace
9 - TORX bolt, 20 Nm plus an additional 90° 1 /4 turn
2:51:36 AM Page 14

 Remove flange shaft (left-side) by securing puller T10037 to cover for final drive - arrow -.
 Remove flange shaft (right-side) by securing puller T10037 to transmission housing - arrow -.
2:51:36 AM Page 15

flange shaft.

 Drive new spacer ring in onto stop; do not cant ring when doing this.
2:51:36 AM Page 16

1. Flange shaft
3. Spacer ring
5. Circlip
shaft is removed. This does not indicate that the bearing is faulty.

2:51:36 AM Page 17

 Drive new flange shaft oil seal using driver 2062; keep seal straight when installing.

 Knock flange shaft in with needle bearing drift VW295.
2:51:36 AM Page 18

 Drive new flange shaft oil seal using fitting drift 2062; keep seal straight when installing.
2:51:36 AM Page 19


 Punch VW407
 Punch VW408A

2:51:36 AM Page 20


 Thrust ring VW 470
 Sleeve 30 - 14
 Thrust pad 3005

 Tube 3296
2:51:36 AM Page 21



2:51:36 AM Page 22


2 - Shim "S2 "
 Note thickness
2:51:36 AM Page 23
5 - Ring gear1)

 Drive off housing using a punch Driving ring gear off cage
 installing onto differential cage HEATING RING GEAR TO APPROX. 100° C and installing
 Replace
10 - Shim "S1 "
 Note thickness
 With O-ring
2:51:36 AM Page 24
13 - Sun wheel
15 - Spring pin

16 - Planetary pinion
2:51:36 AM Page 25
 Before setting up the puller, place thrust pad VW 447 H on differential cage.
2:51:36 AM Page 26

 Heat inner race to approx. 100° C, install in position and press home.
2:51:36 AM Page 27
 Before setting up the puller, place thrust pad VW 447 H on differential cage.
Driving ring gear off cage
2:51:36 AM Page 28

Heating ring gear to approx. 100° C and installing

 When installing ring gear, use centralizing pins - A - (shop-made tool) to locate.
2:51:36 AM Page 29


PINION SHAFT AND RING GEAR, ADJUSTING
Pinion shaft and ring gear, adjusting
NOTE:  Careful adjustment of the ring gear and pinion shaft is essential to ensure
that the final drive gives long service and runs silently. For this reason, the
pinion shaft and ring gear are matched together during manufacture, and
checked to ensure a good mesh pattern and quiet running in both
directions of rotation. The position of quietest running is found by moving
the pinion shaft in an axial direction and at the same time lifting the ring
gear out of the zero-play mesh position by the amount necessary to
maintain the backlash within the specified tolerance.
marked on the outer circumference of the ring gear. The final drive set
(pinion shaft and ring gear) may only be replaced together as a matched
pair.
shims.
2:51:36 AM Page 30

 In some cases identification number of matched pair only has four digits
R - Actual distance between ring gear axis and face of pinion shaft in position of quietest running for this gear
set.
2:51:36 AM Page 31
Vo - Hypoid offset
Position of shims

-> Table of adjustments.

S1 - Shim for ring gear in cover for final drive
2:51:36 AM Page 32
NOTE:  If repairs have been performed to the transmission, it is only necessary to

adjust the pinion shaft, ring gear or final drive set if components have
Ring gear Pinion shaft Pinion shaft Backlash
adjustment:
("S3 " + "S4 ") via
("S1 " + "S2 ") deviation (tolerance) Shim "S4 " only 0.12 -
0.28
"r"
--> Re-determining shim
--> Ring gear, --> Pinion shaft,
"S4" when replacing
adjusting adjusting
bearing housing
Component replaced
Transmission housing *
X X X
See note
Bearing housing X X
Tapered roller bearings
for pinion shaft/hollow X X
shaft
Tapered roller bearing for
X X
differential
Final drive gear set * See
X X X
note
*Pinion shaft and ring gear; only replace together.
Recommended sequence for adjusting gear set
2:51:36 AM Page 33

The following work sequence is recommended to save time when the ring gear and pinion shaft have to be
adjusted:
roller bearings.
 Distribute total shim thickness "Stotal " (S3 plus S4 ) so that dimension from center of ring gear to end
roller bearings.
 Distribute total shim thickness "Stotal " (S1 plus S2 ) so that the specified backlash between ring gear and
pinion shaft is obtained.
(Adjusting pinion shaft with hollow shaft)
2:51:36 AM Page 34
Fig. 511: Identifying Special Tools -- Pinion Shaft, Adjusting (1 Of 2)



2:51:36 AM Page 35
Fig. 512: Identifying Special Tools -- Pinion Shaft, Adjusting (2 Of 2)

 Punch VW407
 Installation arbor VW792
 Thrust pad 3062

 Press Support-R Wheel Brgs. 3144
2:51:36 AM Page 36

 Press tool 3345


 Dial gauge
 Hose clip
(Adjustment of pre-load of tapered roller bearings for pinion shaft with hollow shaft)
2:51:36 AM Page 37
Fig. 515: Double Tapered Roller Bearing Inner Race, Large Needle Bearing, Hollow Shaft And Small
Needle Bearing
 Press double tapered roller bearing inner race - 1 - onto pinion shaft and secure Pressing on double
tapered roller bearing inner race.
 Install large needle bearing - 2 -.
 Install pinion shaft in hollow shaft - 3 -.
 Reassemble hollow shaft with selector gears and tapered roller bearing inner race.
 Install small needle bearing - 4 -.
Without Shims
2:51:36 AM Page 38
 Press double tapered roller bearing outer race for pinion shaft into transmission housing without shims.
Housing
 Press in tapered roller bearing outer race for pinion shaft/hollow shaft with shim "S4 *" (thickness 1.01
mm) into bearing housing.
"e".
 Install fully assembled pinion shaft with hollow shaft into transmission housing.
2:51:36 AM Page 39
bearing housing.
 While still maintaining pressure, rotate pinion shaft 5turns in each direction in relation to the hollow shaft
to settle the double tapered roller bearing.
 Rotate pinion shaft together with the hollow shaft 5turns in each direction to settle the hollow shaft
tapered roller bearing.
 Turn pinion shaft with hollow shaft five turns in both directions so that the double tapered roller bearing
settles. Otherwise the result of the measurement will be incorrect.
Fig. 520: Pinion Shaft Clamped Onto Hollow Shaft With A Hose Clip
 Set up measuring tool.

 Clamp pinion shaft onto hollow shaft with a hose clip - arrow -.
2:51:36 AM Page 40
Fig. 521: Moving Pinion Shaft With Hollow Shaft Up And Down
 Then move pinion shaft - A - with hollow shaft up and down in direction of - arrow -.
NOTE:  If the measurement has to be repeated, pinion shaft with hollow shaft must
first be rotated another 5turns in each direction to settle the double
tapered roller bearing. Preload dial gauge to 1 mm and set to "0" again.
Example:
Example:
 Remove double tapered roller bearing outer race, install shim "S3 *" in transmission housing and install
2:51:36 AM Page 41
outer race again.

 Re-install fully assembled pinion shaft with hollow shaft into transmission housing.
 To settle the tapered roller bearings: rotate pinion shaft together with hollow shaft 5turns in each
direction, then rotate pinion shaft separately in relation to hollow shaft 5turns in each direction.
Fig. 522: Determining Thickness Of Shim S3

 Set up measuring tools using dial gauge extension 30 mm - A - ; place nut M12 between VW 792 and
transmission housing when securing bolt - arrow - to transmission housing.
NOTE:  Place dial gauge extension - A - onto web in transmission cover.

 0.09 to 0.18 mm

 To settle tapered roller bearings: rotate pinion shaft together with hollow shaft 5turns in each direction,
then rotate pinion shaft separately in relation to hollow shaft 5turns in each direction.
2:51:36 AM Page 42
and "S4 ".

 Set adjustment rings of measuring bar VW385/1 to the following values:


 Master gauge-adjustable VW385/30
 Set master gauge-adjustable VW385/30 to Ro = 59.65 mm and install onto measuring tool.
2:51:36 AM Page 43

Fig. 526: Identifying Gauge Extension Installed

 Install gauge extension - A - (length = 6.5mm).

2:51:36 AM Page 44
is in place.
supplied as replacement parts and marked on the outer circumference of the ring gear.
Formula:
Example:
2:51:36 AM Page 45


0.53 0.85 1.17
0.57 0.89 1.21
0.61 0.93 1.25
0.65 0.97 1.29
0.69 1.01 1.33
0.73 1.05 1.37
0.77 1.09 1.41
0.81 1.13
necessary.
Example:

0.33 0.73 1.13
0.37 0.77 1.17
0.41 0.81 1.21
0.45 0.85 1.25
0.49 0.89 1.29
0.53 0.93 1.33
0.57 0.91 1.37
2:51:36 AM Page 46
0.61 1.01 1.41

0.65 1.05 1.45
0.69 1.09 1.49
necessary.
Checking adjustment
 Install pinion shaft and hollow shaft with determined shims "S3 " and "S4 ".
 Turn hollow shaft against pinion shaft five turns in both directions so that the double tapered roller
bearing settles.
 Turn pinion shaft with hollow shaft five turns in both directions so that the tapered roller bearings settle.

 If shims have been correctly selected, the deviation "r" (marked on outer circumference of ring gear)
2:51:36 AM Page 47


 Installation arbor VW792

 Digital depth gauge (e..g. VAS 6087)
 Dial gauge
 Straightedge
2:51:36 AM Page 48
Gauge

VAS 6087).
Example:


Example:

Shims available.
bearing outer race into bearing housing.
 Re-install fully assembled pinion shaft with hollow shaft into transmission housing.
 To settle tapered roller bearings: rotate pinion shaft together with hollow shaft 5turns in each direction,
then rotate pinion shaft separately in relation to hollow shaft 5 turns in each direction.
2:51:36 AM Page 49
Fig. 532: Determining Thickness Of Shim S3

 Set up measuring tools using dial gauge extension 30 mm - A - ; place nut M12 between VW 792 and
transmission housing when securing bolt - arrow - to transmission housing.
NOTE:  Place dial gauge extension - A - onto web in transmission cover.

 0.09 to 0.18 mm
2:51:37 AM Page 50
Fig. 533: Identifying Special Tools -- Crown Wheel, Adjusting (1 Of 2)


 Extension pin 6 mm VW382/10
 Magnetic plate 50 mm dia. VW385/17
 Measuring lever VW 388

2:51:37 AM Page 51
Fig. 534: Identifying Special Tools -- Crown Wheel, Adjusting (2 Of 2)

 Punch VW408A
 Ring gear adjusting tool VW 521
 Tube 30 - 14
 Thrust pad 3005

 Dial gauge
2:51:37 AM Page 52
It is necessary to readjust the ring gear when the following components have been replaced:
gear set

 Remove tapered roller bearing outer races for differential and take out shims --> Differential,
2:51:37 AM Page 53
 Install differential in transmission housing. The ring gear is positioned on the left-hand side (same side as
2:51:37 AM Page 54

Example:
backlash.
2:51:37 AM Page 55
Example:
Measuring backlash
 Install differential with ring gear: S1 is installed on cover side, S2 in transmission housing.
 Insert ring gear adjusting tool VW521/4 and VW521/12.


 Adjust measuring lever VW388 to distance "a" = 73mm (for 182 mm dia. ring gear).
 Turn ring gear until it makes contact with the face of one tooth (end of backlash travel).
2:51:37 AM Page 56

 Turn back ring gear until it makes contact with opposite tooth face (backlash).
 Take backlash reading and write down measured value.
 Turn ring gear through 90° and repeat measurements another 3 times.
NOTE:  If the pinion shaft rotates during the measurements, counter-hold pinion
shaft to make sure that the measured value of the backlash is correct.
Example:
mm, the installation of the ring gear or the final drive gear set itself is not
correct. Check installation; replace final drive gear set if necessary.
Example:
2:51:37 AM Page 57
0.45 0.61 0.77

0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
necessary.
Example:

0.45 0.61 0.77
0.49 0.65 0.81
0.53 0.69 0.85
0.57 0.73
necessary.
Checking adjustment
2:51:37 AM Page 58

 After installing shims "S1 " and "S2 ", turn differential 5 turns in both directions so that the tapered roller
bearings settle.
 Specification: 0.12to0.28 mm

2:51:37 AM Page 59
TRANSMISSION
6-speed manual transmission 02X, four-wheel drive
00 TECHNICAL DATA
The 6-speed manual transmission 02X all wheel drive is used on the A4 2002 --> in conjunction with the
1.8liter, 2.0liter, 3.0liter. and 3.2liter engines.

 Code letters and date of manufacture - arrow1 - or - arrow 3 -

 Manual transmission 02X - arrow2 -

2:46:42 AM
2:47:15 Page 1
Code letters and date of manufacture of transmission - arrow1 -
Example: GJV 04 04 3
I I I I
I I I I
stickers.
Fig. 3: Code Letters For The Transmission On The Vehicle Data Sticker
Manual transmission 02X - arrow2 -
Code letters, allocation, transmission ratios, capacities
Manual transmission 6-speed 02X all wheel drive

Code letters GJV GJW
to 05.04
Engine 3.0 liter. - 162 kW 1.8 liter. - 120 kW
i = Z2 : Z1 1st gear 33 : 9 = 3.667 33 : 9 = 3.667
2nd gear 39 : 19 = 2.053 39 : 19 = 2.053
3rd gear 37 : 26 = 1.423 37 : 27 = 1.370
4th gear 33 : 31 = 1.065 32 : 31 = 1.032
5th gear 29 : 34 = 0.853 28 : 35 = 0.800
2:46:42 AM Page 2
6th gear 27 : 37 = 0.730 25 : 38 = 0.658

Reverse gear 34 : 10 = 3.400 34 : 10 = 3.400
Capacity 3.5 liters
Clutch plate dia. 240 mm 228 mm
Drive shaft flange dia. 75.5 mm 88 mm
Allocation of rear final driveCode letters ETS ETR, ETQ
Manual transmission 6-speed 02X, all wheel drive

Code letters GVE GYY
to
Engine 2.0 liter. - 147 kW 3.2 liter. -188 kW
i = Z2 : Z1 1st gear 33 : 9 = 3.667 33 : 10 = 3.300
2nd gear 39 : 19 = 2.053 37 : 20 = 1.850
3rd gear 37 : 27 = 1.370 36 : 28 = 1.286
4th gear 32 : 31 = 1.032 31 : 33 = 0.939
5th gear 28 : 35 = 0.800 27 : 36 = 0.750
6th gear 25 : 38 = 0.658 25 : 39 = 0.641
Reverse gear 34 : 10 = 3.400 34 : 10 = 3.400
Capacity 3.5 liters
Drive shaft flange 88 mm 75.5 mm
Allocation of rear final driveCode letters ETS FUB
Rear Final Drive is installed in conjunction with manual transmission 02X (all wheel drive).
NOTE:  For identification of rear final drive --> 00 GENERAL, TECHNICAL DATA .
 For repairs on the drive shaft or the rear final drive --> 39 FINAL DRIVE,
2:46:42 AM Page 3
DIFFERENTIAL .

Location on rear final drive
 Code letters and date of manufacture - arrow1 -

 Rear Final Drive - arrow2 -
Fig. 5: Code Letters And Date Of Manufacture Of Rear Final Drive

Code letters and date of manufacture of rear final drive - arrow1 - :
Example: EUB 04 04 03
I I I I
I I I I
Code letters Day Month Year - 2003 - of manufacture
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Rear Final Drive - arrow2 -
TRANSMISSION LAYOUT
Transmission layout
Identification
2:46:42 AM Page 5

1 - Engine
2 - Clutch
 Diagram of transmission layout --> Transmission, general layout
5 - Differential (front)
6 - Front pinion shaft (output shaft)
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7 - Hollow shaft
9 - Drive shaft
10 - Rear pinion shaft
11 - Differential (rear)
Ratio

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I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
Av - Final drive (front)
Ah - Final drive (rear)
CALCULATING RATIO "I"
Transmission ratio
Ratios Formula
Example:
Calculations:
iG = 25 : 38 = 0.658
iA = 34 : 10 = 3.400
iov = 0.658 x 3.400 = 2.237
2:46:43 AM Page 8
Proper tools and the maximum possible care and cleanliness are essential for successful transmission repairs.
The usual basic safety precautions also naturally apply when performing vehicle repairs.
A number of generally valid instructions which apply to individual repair procedures (as listed at various points
in the article) are summarized here under "Components"--> Components. They apply to the work described in
this article.
Components
Transmission
 Select correct bolts and other components according to transmission code letters --> Code letters,
 When installing a new transmission, check oil level and fill up with oil if necessary --> Transmission oil
level, checking .
 Capacities and specifications --> Code letters, allocation, transmission ratios, capacities
 When installing a new rear final drive unit, check oil level in rear final drive and top off if necessary -->
39 FINAL DRIVE, DIFFERENTIAL .
 Thoroughly clean all joints and surrounding areas before Disassembling.

Sealants

2:46:43 AM Page 9

 Lightly oil O-rings before installing to prevent them from being trapped and damaged when assembling.
Transmission oil level, checking .
Locking elements

 Locking rings/ circlips must be properly seated in the base of the groove.
2:46:43 AM Page 10

 Replace spring pins. Position: the slit - A - should be in line with the line of force - arrow -.
Nuts, bolts
 Loosen nuts and bolts in reverse sequence to the specified tightening sequence.
them straight.

 Clean the threads of bolts which are secured by a locking compound with a wire brush. Then lubricate
bolts with locking compound AMV185101A1 again before installing.
(using a thread tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being
removed.
Shims
2:46:43 AM Page 11
Bearings
 Install new tapered roller bearings as supplied; do not lubricate with oil.
 Lubricate all bearings (except tapered roller bearings) with gear oil before installing in transmission.
 Heat inner races of tapered roller bearings to approx. 100° C before installing. Press in onto stop when
installing so there is no axial clearance.
 Do not interchange the outer or inner races of bearings of the same size (the bearings are paired).
 If required, replace tapered roller bearings on one shaft together and use new bearings from a single
manufacturer.
 Install needle bearings so the lettering (side with thicker metal) faces toward the installing tool.
 Lubricate needle bearing for transmission input shaft in rear of flywheel.
Synchronizer rings
 Do not interchange synchronizer rings. When reusing, always install to the same gear.
Gear wheels and synchronizing hubs
 Before installing, clean and heat on a hotplate to 130° C (maximum).

 Press in onto stop when installing so there is no axial clearance.
 The temperature can be measured with temperature tester V.A.G1558, ignition tester V.A.G 1767 or
diesel tester V.A.G 1743.
Selector gears
 After installing, check 1st to 6th speed selector gears for minimal axial play and freedom of movement.
Clutch actuation
 When removing transmission, remove slave cylinder without disconnecting hydraulic lines.
 Do not depress the clutch pedal after removing the slave cylinder if the hydraulic line is still connected.
Otherwise the piston will be pressed out of the slave cylinder. As a result the slave cylinder will be
destroyed.
(further measures --> Notes on removing and installing master cylinder and slave cylinder).
 Make sure that the pressure plate is kept straight: loosen and tighten bolts in a diagonal sequence and in
several gradual stages (does not apply to SAC pressure plates).
2:46:43 AM Page 12
installing.
 On vehicles with SAC pressure plate an adjuster ring has to be reset when only the clutch

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2005 Audi A4 Quattro

TRANSMISSION 5 Spd. Automatic Transmission 01V

5 Spd. Automatic Transmission 01V

00 - GENERAL, TECHNICAL DATA

Code letter allocation at transmission

Fig. 1: Location Of Code Letters On Transmission

Fig. 2: Location Of Transmission Code Number And Transmission Serial Number

Transmission code number and transmission serial number.

Transmission serial number (arrow 1)

Transmission identification (arrow 2)

Code letter (arrow 3)

NOTES ON 5-SPEED AUTOMATIC TRANSMISSION 01V

Notes on 5-speed automatic transmission 01V

On Board Diagnostic (OBD)

"Guided Fault Finding" is performed using the tester VAS5051.

 It is shifted depending on consumption

Shift point change when driving up- or downhill ranges

CODE LETTERS, ALLOCATION, RATIOS, EQUIPMENT

Code letters, allocation, ratios, equipment

All Wheel Drive (AWD)

Automatic transmission 01V.4 01V.4

*11 mm intermediate plate is installed between engine and transmission.

Transmission Code FEP FEQ

REAR FINAL DRIVE, IDENTIFICATION

Rear final drive, identification

 00 GENERAL, TECHNICAL DATA for REAR FINAL DRIVE

Fig. 3: Locations Of Final Drive Identification

Location on rear final drive

Code letters and date of manufacture (arrow 1)

Rear final drive 01R (arrow 2)

Fig. 4: Final Drive 01R

Rear final drive 01R (arrow 2)

Fig. 5: Locating Code Letters And Date Of Manufacture Of Final Drive

Code letters and date of manufacture of final drive.

Additional information depends on manufacturing.

CODE LETTERS, ALLOCATION, RATIOS

Code letters, allocation, ratios

Rear final drive 01R

Code letters ETQ

ATF is available as a replacement part (is also referred to as VW ATF).

Container size 0.5 L -part number G 052 162 A1

Container size 1.0 L -part number G 052 162 A2

Container size 20 L -part number G 052 162 A6

Container size 0.5 L -part number G 052 145 A1

Container size 1.0 L -part number G 052 145 A2

Container size 0.5 L -part number G 052 145 A1

Container size 1.0 L -part number G 052 145 A2

Rear final drive

 00 GENERAL, TECHNICAL DATA for REAR FINAL DRIVE

ROLL STARTING AND TOWING NOTES

Roll starting and towing notes

Special tools and workshop equipment

 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR

O-rings, gaskets, seals

 Always replace O-rings, gaskets and sealing rings.

Fig. 6: Identifying Space Between Oil Seal Sealing Lips

 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR

Capacities and specifications --> Capacity onward.

 Loosen bolts in reverse order of tightening sequence.

 Always replace self-locking nuts and bolts.

 Do not over-stretch circlips.

 Replace transmission if shift members are burnt.

Guided Troubleshooting, Vehicle On Board Diagnostic (OBD) and Test Instruments

CAUTION: Check installation dimension of torque converter before installing