7 Speed Dual Clutch Gearbox 0bt Repair Manual Eng PDF

Service
Workshop Manual
California 2010 ➤
Caravelle 2010 ➤
Multivan 2010 ➤
Transporter 2010 ➤
7-speed dual clutch gearbox 0BT
Edition 06.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
California 2010 ➤ , Caravelle 2010 ➤ , Multivan 2010 ➤ , Transporter 20 ...
7-speed dual clutch gearbox 0BT - Edition 06.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 Assembly overview - dual clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Electrical and electronic components of the dual clutch gearbox (DSG®) and their
locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2 Removing and installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . 31
2.3 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 Components of dual clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2 Renewing bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Assembly overview - dismantling and assembling selector mechanism . . . . . . . . . . . . . . 40
4.3 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.5 Removing and installing Tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.8 Carrying out emergency release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.1 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2 Renewing sealing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3 Renewing bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1 General notes on removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.2 Converting adapter 10 - 222 A /23 with adapter 10 - 222 A /23-1 . . . . . . . . . . . . . . . . . . . . 60
Contents i
6.3 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.5 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.6 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.7 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.2 Removing and installing bevel box (4-cylinder diesel engines) . . . . . . . . . . . . . . . . . . . . . . 97
7.3 Removing and installing bevel box (4-cylinder petrol engines) . . . . . . . . . . . . . . . . . . . . . . 103
7.4 Checking gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.5 Installing repair kit for stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8 Oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.1 Oil filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.2 Checking and adjusting oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.3 Draining and filling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8.4 Installing oil level pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1 Currently, no repairs can be made to gears and shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . 126
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.1 Assembly overview – seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.2 Renewing seal on left of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.3 Renewing seal on right of gearbox, front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . 130
1.4 Renewing seal on right of gearbox, vehicles with all wheel drive . . . . . . . . . . . . . . . . . . . . 132
1.5 Renewing small stub shaft on bevel box between manual gearbox and bevel box . . . . . . 135
1.6 Renewing large stub shaft on bevel box between manual gearbox and bevel box . . . . . . 138
1.7 Renewing bevel box output flange oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.8 Renewing seal on right of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Volkswagen Technical Site: https://vwts.ru
ii Contents
00 – Technical data
1 Safety information
(VRL011739; Edition 06.2018)
⇒ “1.1 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
1.1 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1.2 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
1. Safety information 1
2 Identification
⇒ “2.1 Gearbox identification”, page 2
2.1 Gearbox identification
LZZ - Gearbox code

A01 - Gearbox version
0310 - Serial number
14 - Factory code
12059 - Production date: 12
May 2009
2 Rep. gr.00 - Technical data

3 Repair instructions
⇒ “3.1 General information”, page 3
⇒ “3.2 Rules for cleanliness”, page 3
⇒ “3.3 General repair instructions”, page 3
⇒ “3.4 Gaskets and seals”, page 4
⇒ “3.5 Nuts and bolts”, page 5
3.1 General information

Gear oil
The “0BT” dual clutch gearbox only has one oil system.
The oil system lubricates the gears, shafts, final drives, clutches
and mechatronic unit for dual clutch gearbox - J743- .
Only use gear oil in accordance with ⇒ Electronic parts cata‐
logue .
Gear oil filter change - »Yes or no?«
• The gear oil filter does not have to be changed as a matter of
course.
Do not change the filter if:
♦ Gear oil cooler or its O-rings were renewed and no coolant
contaminated the oil.
♦ Seals and O-rings of the gearbox were renewed.
♦ The sump or mechatronic unit were renewed.
♦ Service interval was reached.
Filter must be changed if:
♦ Metal particles have been found in the oil.
♦ Clutch is burnt or has a mechanical defect.
3.2 Rules for cleanliness

♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ Seal open lines and connections immediately using clean
plugs or sealing caps from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ Make sure that no dirt can enter an »open« gearbox.
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
♦ If repair work cannot be performed immediately, cover opened
parts carefully.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
3.3 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
3. Repair instructions 3
A number of general notes on the individual repair procedures,

which were otherwise repeated in the relevant sections of the
manual, are summarised here. They apply for this particular work‐
shop manual.
Guided Fault Finding, vehicle self-diagnosis and test instruments
♦ Before performing repairs to the gearbox, determine the cause
of the fault as accurately as possible ⇒ Vehicle diagnostic
tester, Guided Fault Finding , Vehicle Self-Diagnosis
or Test Instruments .
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools" .
Gearbox
Always make sure that no dirt can enter an »open« gearbox. In
particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
3.4 Gaskets and seals

♦ Always renew O-rings, seals and gaskets.
♦ Before installing seal, coat sealing lips and area between
these with grease for oil seals ⇒ Electronic Parts Catalogue
(ETKA) and outer circumference with dual clutch gearbox oil
⇒ Electronic Parts Catalogue (ETKA) .
♦ Always use dual clutch gearbox oil ⇒ Electronic Parts Cata‐
logue (ETKA) as other lubricants cause malfunctions.
♦ Open side of oil seal faces oil.
♦ After installation, change the oil and adjust the oil level at the
same time ⇒ page 117 .

3.5 Nuts and bolts

♦ Loosen and tighten securing bolts and securing nut for covers
and housings diagonally.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
♦ Always renew self-locking bolts and nuts.
3. Repair instructions 5
4 Technical data
⇒ “4.1 Allocation gearbox - engine”, page 6
⇒ “4.2 Capacities”, page 9
4.1 Allocation gearbox - engine

Dual clutch gearbox 0BT
Gearbox code LZZ MAA MXZ
Manufactured from 05:09 10:09 11.10
to 05.11
Gear ratios 1st gear 57 : 16 = 3.563 57 : 16 = 3.563 57 : 16 = 3.563
2nd gear 48 : 19 = 2.526 48 : 19 = 2.526 48 : 19 = 2.526
3rd gear 46 : 29 = 1.586 46 : 29 = 1.586 46 : 29 = 1.586
4th gear 45 : 48 = 0.938 45 : 48 = 0.938 45 : 48 = 0.938
5th gear 39 : 54 = 0.722 39 : 54 = 0.722 39 : 54 = 0.722
6th gear 33 : 48 = 0.688 33 : 48 = 0.688 33 : 48 = 0.688
7th gear 31 : 54 = 0.574 31 : 54 = 0.574 31 : 54 = 0.574
Reverse gear 48 : 19 = 2.526 48 : 19 = 2.526 48 : 19 = 2.526
Final drive ra‐ Final drive 1 1) 79 : 17 = 4.647 79 : 17 = 4.647 79 : 17 = 4.647
tios
Final drive 2 2) 79 : 20 = 3.950 79 : 20 = 3.950 79 : 20 = 3.950
Allocation Model California California California
Caravelle Caravelle Caravelle
Transporter Transporter Transporter
Multivan Multivan Multivan
Engine 2.0 l - 103 kW diesel 2.0 l - 103 kW diesel 2.0 l - 103 kW diesel en‐
engine (common rail) engine (common rail) gine (common rail)
2.0 l - 132 kW diesel 2.0 l - 132 kW diesel 2.0 l - 132 kW diesel en‐
2.0 l - 100 kW diesel 2.0 l - 100 kW diesel en‐
engine (common rail) gine (common rail)
1) Final drive 1 for 1st, 4th, 5th and reverse gear
2) Final drive 2 for 2nd, 3rd, 6th and 7th gear

Gearbox code MYA NEY NEX
Manufactured from 11.10 07:11 05:11
to 05.11
Gear ratios 1st gear 57 : 16 = 3.563 57 : 16 = 3.563 57 : 16 = 3.563
2nd gear 48 : 19 = 2.526 48 : 19 = 2.526 48 : 19 = 2.526
3rd gear 46 : 29 = 1.586 46 : 29 = 1.586 46 : 29 = 1.586
4th gear 45 : 48 = 0.938 45 : 48 = 0.938 45 : 48 = 0.938
5th gear 39 : 54 = 0.722 39 : 54 = 0.722 39 : 54 = 0.722
6th gear 33 : 48 = 0.688 33 : 48 = 0.688 33 : 48 = 0.688
7th gear 31 : 54 = 0.574 31 : 54 = 0.574 31 : 54 = 0.574
Reverse gear 48 : 19 = 2.526 48 : 19 = 2.526 48 : 19 = 2.526
Final drive ra‐ Final drive 1 3) 79 : 17 = 4.647 79 : 17 = 4.647 79 : 17 = 4.647
tios
Final drive 2 4) 79 : 20 = 3.950 79 : 20 = 3.950 79 : 20 = 3.950


Gearbox code MYA NEY NEX
Allocation Model California California California
Caravelle Caravelle Caravelle
Engine 2.0 l - 103 kW diesel 2.0 l - 103 kW diesel 2.0 l - 103 kW diesel en‐
2.0 l - 132 kW diesel 2.0 l - 132 kW diesel 2.0 l - 132 kW diesel en‐
2.0 l - 150 kW (FSI di‐ 2.0 l - 100 kW diesel en‐
rect injection) gine (common rail)
2.0 l - 150 kW (FSI direct
injection)

Gearbox code NHX NZR NZQ
Manu‐ from 05:11 11:12 11:12
factured to
Gear ra‐ 1st gear 57 : 16 = 57 : 16 = 57 : 16 =
tios 3.563 3.563 3.563
2nd gea 48 : 19 = 48 : 19 = 48 : 19 =
r 2.526 2.526 2.526
3rd gear 46 : 29 = 46 : 29 = 46 : 29 =
1.586 1.586 1.586
4th gear 45 : 48 = 45 : 48 = 45 : 48 =
0.938 0.938 0.938
5th gear 39 : 54 = 39 : 54 = 39 : 54 =
0.722 0.722 0.722
6th gear 33 : 48 = 33 : 48 = 33 : 48 =
0.688 0.688 0.688
7th gear 31 : 54 = 31 : 54 = 31 : 54 =
0.574 0.574 0.574
Reverse 48 : 19 = 48 : 19 = 48 : 19 =
gear 2.526 2.526 2.526
Final Final 79 : 17 = 79 : 17 = 79 : 17 =
drive ra‐ drive 1 5) 4.647 4.647 4.647
tios
Final 79 : 20 = 79 : 20 = 79 : 20 =
drive 2 6) 3.950 3.950 3.950
Alloca‐ Model California California California
tion Caravelle Caravelle Caravelle
Engine 2.0 l - 132 2.0 l - 132 2.0 l - 103 kW
kW diesel kW diesel diesel engine
engine (com‐ engine (com‐ (common rail)
mon rail) mon rail) 2.0 l - 132 kW
2.0 l - 150 2.0 l - 150 diesel engine
kW (FSI di‐ kW (FSI di‐ (common rail)
rect injec‐ rect injec‐
tion) tion)
4. Technical data 7

Gearbox code NHX NZR NZQ
2.0 l - 100 kW
diesel engine
(common rail)
2.0 l - 150 kW
(FSI direct in‐
jection)


Gearbox code NKD NYB NYC
Manu‐ from 05:12 05:12 05:12
factured to
Gear ra‐ 1st gear 57 : 16 = 57 : 16 = 57 : 16 =
tios 3.563 3.563 3.563
2nd gea 48 : 19 = 48 : 19 = 48 : 19 =
r 2.526 2.526 2.526
3rd gear 46 : 29 = 46 : 29 = 46 : 29 =
1.586 1.586 1.586
4th gear 45 : 48 = 45 : 48 = 45 : 48 =
0.938 0.938 0.938
5th gear 39 : 54 = 39 : 54 = 39 : 54 =
0.722 0.722 0.722
6th gear 33 : 48 = 33 : 48 = 33 : 48 =
0.688 0.688 0.688
7th gear 31 : 54 = 31 : 54 = 31 : 54 =
0.574 0.574 0.574
Reverse 48 : 19 = 48 : 19 = 48 : 19 =
gear 2.526 2.526 2.526
Final Final 79 : 17 = 79 : 17 = 79 : 17 =
drive ra‐ drive 1 5) 4.647 4.647 4.647
tios
Final 79 : 20 = 79 : 20 = 79 : 20 =
drive 2 6) 3.950 3.950 3.950
Alloca‐ Model California California California
tion Caravelle Caravelle Caravelle
Engine 2.0 l - 132 2.0 l - 2.0 l - 132 kW
kW diesel 103 kW die‐ diesel engine
engine (com‐ sel engine (common rail)
mon rail) (common 2.0 l - 150 kW
2.0 l - 150 rail) (FSI direct in‐
kW (FSI di‐ 2.0 l - jection)
rect injec‐ 132 kW die‐
tion) sel engine
(common
rail)
2.0 l -
100 kW die‐
sel engine
(common
rail)
2.0 l -
150 kW (FSI
direct injec‐
tion)
4.2 Capacities
Capacity Dual clutch gearbox (DSG) 0BT
Initial filling 7.2 l to 7.6 l
4. Technical data 9
Capacity Dual clutch gearbox (DSG) 0BT

Change quantity approx. 6.0 litres
♦ Without removal and installation of mecha‐
tronic unit
♦ Change interval: ⇒ Maintenance manual and/
or ⇒ service tables “ELSA”
Lubricant Dual clutch gearbox oil ⇒ Electronic Parts Catalogue (ET‐

KA)
Further information in the part number designates the container
size.

5 Electrical components
5.1 Overview of fitting locations - electrical components
1 - Mechatronic unit for dual

clutch gearbox - J743-
❑ Removing and installing
⇒ page 31
2 - Gearbox input speed send‐
er - G182- and oil temperature
sender in multi-plate clutch -
G509-
❑ Not for this model
3 - Selector lever - E313-
❑ With selector lever sen‐
sors control unit - J587- ,
selector lever lock sole‐
noid - N110- and selec‐
tor lever locked in posi‐
tion P switch - F319-
❑ The components are in‐
tegrated into the printed
circuit of the selector
mechanism and cannot
be renewed separately
❑ Checking ⇒ vehicle di‐
agnostic tester
selector mechanism
⇒ page 46
5. Electrical components 11
30 – Clutch
1 Dual clutch
⇒ “1.1 Assembly overview - dual clutch”, page 12
⇒ “1.2 Removing and installing clutch end cover”, page 13
⇒ “1.3 Removing dual clutch”, page 16
⇒ “1.4 Installing dual clutch”, page 19
1.1 Assembly overview - dual clutch

Replacement parts
1 - Retaining ring for dual

clutch end cover
2 - Retaining ring for dual
clutch
3 - Retaining ring for drive plate
4 - Dual clutch
Caution
The
♦ drive plate has to re‐
main engaged between
the teeth of the outer
plate carrier.
If♦the drive plate de‐
taches, the plates in the
dual clutch can shift. It
may then not be possible
to adjust the clutch cor‐
rectly when it is installed.
5 - Shims
❑ 10 spacer rings which
have different »thick‐
nesses«. Sized in
0.05 mm increments.
❑ Thickness of spacer ring
must be determined
when installing dual
clutch.
6 - Dual clutch end cover
12 Rep. gr.30 - Clutch

Caution
♦ This figure is intended only to provide an overview of the

components. The dual clutch must not be dismantled be‐
cause all the plates have been balanced relative to each
other.
♦ If the drive plate is detached, the plates in the dual clutch
can shift, and consequently it may not be possible to adjust
the clutch correctly when it is installed.
1.2 Removing and installing clutch end cov‐

er
Special tools and workshop equipment required
♦ Clean assembly sleeve - T10459- before using. Do not use a
scratched sleeve.
Brief description
The cover is held in its seat by a retaining ring. After the retaining
ring has been removed, the cover can be levered out of its seat.
Cover and retaining ring must always be renewed. Never install
a new cover with a hammer and never oil the centre seal or touch
it with a hand! However, if this should happen, the cover is certain
to leak!
Removing
– Remove gearbox ⇒ page 61 .
– Secure gearbox to assembly stand ⇒ page 87 .
– Remove drain plug -arrow- and drain oil.
1. Dual clutch 13
– Install drain plug -A- with new seal.

Tightening torque: 45 Nm
– Remove retaining ring from cover.
Cover can be levered out with a screwdriver.

Install new cover.
Installing
Cover seals off gearbox from atmosphere. Cover is held in its seat
by a retaining ring. After the retaining ring has been removed, the
cover can be levered out of its seat. Cover and retaining ring must
always be renewed. Never install a new cover with a hammer and
never oil the centre seal or touch it by hand! However, if this
should happen, the cover is certain to leak!
Caution
Do not grasp new cover in centre hole. The centre hole of the
cover must not be touched, oiled or brought into contact with
other materials. Leaks will result.
– Only handle cover as shown in this picture.

Cover must be free of oil and dry around centre seal.

– If necessary, clean sealing sleeve of dual clutch.
– There must be no stickers on the inside of the cover. If any
stickers are present, remove them carefully!
Moisten only the outer edge of the seal with DSG transmission
oil.
– Set assembly sleeve - T10459- on a flat surface.
The centre seal of the new cover must now be »preformed«:
– Guide cover horizontally and evenly over entire sleeve. This

will bring the sealing lip into installation position.
– Remove assembly sleeve - T10459- upwards from cover, and
fit it onto end of dual clutch shaft.
– Guide cover horizontally over sleeve and press evenly onto its
seat.
Caution
Work carefully. Any sort of blow to the cover is certain to cause

leaks.
It is possible to lever cover carefully into its seat with a

-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring -arrow-.
1. Dual clutch 15
1.3 Removing dual clutch

♦ 2 x hooks - 3438-
♦ Tapered roller bearing puller - T10055-
♦ 2 x retaining pins - T10524-
Brief description
To remove or install the clutch, the gearbox must be securely at‐
tached to an assembly stand in vertical position.

Removing
– Secure gearbox to assembly stand ⇒ page 87 .
– Remove dual clutch cover ⇒ page 13 .
– Insert both retaining pins - T10524- , each offset by 180 de‐
grees.
– Lever out retaining ring -2- of drive plate using screwdriver

-1- -arrow-.
Important! Installation location of drive plate

– Check that marking on drive plate -arrow- aligns with the mark‐
ing on the outer plate carrier.
If there is no marking:
– Mark installation position of drive plate relative to periphery of
outer plate carrier with permanent marker, as shown in illus‐
tration.
• During installation, drive plate must always be repositioned at
marked position.
1. Dual clutch 17
– Apply puller - T10525- together with puller - T10055- on

splines and carefully pull drive plate off its seat -arrows-.

grees.
Caution
Secure the retaining ring against falling. The retaining ring

might fall through an opening into the interior of the gearbox.
– Remove retaining ring -arrow- and save it for now.
Note
Do not dispose of the retaining ring yet because it will be needed

to measure axial clearance.
– Remove shim -arrow-.
Caution
Carefully remove the dual clutch. Take care that no parts fall
out. Therefore, do not turn the clutch over!

– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.
– Remove dual clutch using hooks - 3438- .
1.4 Installing dual clutch
Caution
♦ The drive plate has to remain engaged between the teeth

of the outer plate carrier.
♦ If the drive plate detaches, the plates in the dual clutch can
shift. It may then not be possible to adjust the clutch cor‐
rectly when it is installed.

♦ Universal dial gauge holder - VW 387-
1. Dual clutch 19
♦ Dial gauge - VAS 6079-
♦ 2 x retaining pins - T10524-
♦ Press tool - T10526-
Caution
Do not lift (not even slightly) or remove plate carrier! The plates
could turn.
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
Installing

– Take great care when removing the dual clutch from its pack‐
age.
– Turn piston rings by hand. They must move freely and must
not bind.
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
align.
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
Important! Position of drive plate

– Before installing, check if there is a marking -arrow- on dual
clutch.
– If there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the outer plate carrier.

grees.
When inserting dual clutch, have a second mechanic hold retain‐
ing pin - T10524- .
1. Dual clutch 21
– Carefully insert -dual clutch-, ensuring it does not fall.

– If necessary, insert clutch by turning slightly.
The dual clutch is properly fitted if there is almost no play in the

two retaining pins - T10524- .
The -retaining pins- remain inserted until the drive plate of the dual
clutch is installed.
– Lever out retaining ring of drive plate.
– Apply puller - T10525- together with puller - T10055- on

splines and carefully pull drive plate off its seat -arrows-.
Note
Both retaining pins - T10524- must be held in position by a second

mechanic.
– Carefully remove drive plate from dual clutch -arrows- and

place it on one side.
Caution
Do not lift (not even slightly) or remove plate carrier! The plates
could turn.
Determining shim for dual clutch
– Temporarily install “old” retaining ring -arrow-.

Before this ring is removed again, 2 measurements must be
made.
First measurement (axial play of shaft)
• Retaining pins - T10524- remain inserted.
– Screw universal dial gauge - VW 387- to gearbox flange.

– Set -tip of dial gauge- on input shaft.

– Set -dial gauge- to 0 with preload.
– Using hooks - 3438- , firmly raise dual clutch in

-direction of arrow- onto stop, and note result of measurement.
Measured value Designation: Result

Second measurement Measurement on hub … mm
First measurement Axial clearance of shaft … mm
/ Correction value axial clearance - 0.11 mm
Shim thickness … mm
Second measurement
• Retaining pins - T10524- remain inserted.
1. Dual clutch 23
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Tip must not sit on retaining ring.
– Set -dial gauge- to 0 with preload again.

– Firmly raise dual clutch onto stop, and note result of meas‐
urement.
Now calculate which shim must be fitted:
– Use this formula:
Second measurement minus first measurement minus
0.11 mm = thickness of shim to be installed
– Note result.
The shims are sized in 0.05 mm increments.
– Measure the shims and determine which one is closest to the
result.
Always use the next-largest shim, never the next-smallest.
Example:
Calculated dimension for shim New shim
1.28 mm 1.3 mm
1.26 mm 1.3 mm
– Remove old retaining ring -arrow-.
– Fit calculated shim.

Performing check measurement

– Install old retaining ring -arrow- once more.
– Perform second measurement again, and note result of meas‐

urement.
Note
Set the tip of the dial gauge on the shim -1-.
Measured value Designation: Result

Second measurement Measurement on shim … mm
First measurement Axial clearance of shaft (from first … mm
measurement)
Result … mm
Second measurement minus first measurement (axial clear‐

ance of shaft) = specified value 0.05 to 0.12 mm
If the specification is not attained, rectify this by installing a shim
of higher or lower thickness.
– Install new retaining ring -arrow-.
1. Dual clutch 25
– Fit drive plate into dual clutch.

• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier -arrows-. If the markings were
subsequently make, align these.
– Have a second mechanic press the retaining pin - T10524-
outwards.
– Using thrust piece - T10526- and a plastic hammer, carefully
drive the drive plate into its seat.
– Install »new« drive plate retaining ring.
– Starting at the opening, press retaining ring in clockwise di‐
rection into its fitting position.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Then remove retaining pin - T10524- from between dual clutch
and housing.
– Install clutch end cover ⇒ page 13 .

34 – Controls, housing
1 Assembly overview - dual clutch gearbox
1 - Retaining ring
❑ Renew after removal
2 - Dual clutch cover
3 - Retaining ring
4 - Shim
5 - Tapered ring
6 - Dual clutch
❑ Currently, no repairs
can be made to the
clutch.
7 - Seal, right
❑ For drive shaft.
8 - Breather pipe
9 - Breather cap
10 - Plug
11 - Sealing ring
12 - Gear oil cooler
13 - Bolt, 20 Nm + 45° (1/8 turn)
14 - Filter housing, 20 Nm
15 - Sealing ring
16 - Heat shield
17 - Oil filter
18 - Bolt, 5 Nm + 90° (1/4 turn)
19 - Cable support bracket
20 - Detent lever for parking lock
21 - Bolt, 10 Nm + 90° (1/4 turn)
22 - Gearbox
23 - Left seal
24 - Sealing ring
25 - Oil drain plug, 20 Nm
❑ For mechatronic unit
1. Assembly overview - dual clutch gearbox 27

26 - Oil level pipe, 3 Nm
Caution
Comply
♦ with the torque
setting precisely.
The
♦ oil level pipe can
break between the
thread and the collar.
Note
♦ The oil level pipe comes in dif‐

ferent lengths and colours.
♦ If the oil level pipe is renewed, it
is essential that the oil level pipe
appropriate for the gearbox is in‐
stalled ⇒ Electronic parts cata‐
logue (ETKA) .
♦ Do not install the oil level pipe
from another gearbox! The oil
level pipe determines the oil level
in the gearbox.
♦ Fitting a different oil level pipe
can result in the oil level in the
gearbox being too high or too
low.
❑ Note the screw-in depth and remove/install ⇒ page 124
❑ Drain and fill oil ⇒ page 120
27 - Sealing ring
28 - Oil drain plug, 45 Nm
❑ For gearbox
29 - Bolt
❑ Depending on equipment
❑ 10 Nm
30 - Gearbox input speed sender - G182- and oil temperature sender in multi-plate clutch - G509-
❑ Removing and installing ⇒ page 33
31 - Mechatronic unit for dual clutch gearbox - J743-
32 - Bolt, 10 Nm + 30° (1/12 turn)
33 - Cover
❑ With seal
34 - Bolt, 10 Nm + 45° (1/8 turn)
35 - Securing clip
28 Rep. gr.34 - Controls, housing

36 - Sealing ring
1. Assembly overview - dual clutch gearbox 29

2 Electrical and electronic components

of the dual clutch gearbox (DSG®)
and their locations
⇒ “2.1 Electrical and electronic components and their locations”,
page 30
⇒ “2.2 Removing and installing mechatronic unit for dual clutch
gearbox J743 ”, page 31
⇒ “2.3 Removing and installing gearbox input speed sender G182
and oil temperature sender in multi-plate clutch G509 ”,
page 33
2.1 Electrical and electronic components

and their locations
The electrical components are located in the gearbox.
Only the Tiptronic switch - F189- and the selector lever lock sol‐
enoid - N110- are located on the selector lever.
1 - Gearbox input speed send‐

er - G182- and oil temperature
sender in multi-plate clutch -
G509-
❑ Both senders are com‐
bined in one component
and can be renewed to‐
gether only.
❑ Before removal of the
sender, the mechatronic
unit for dual clutch gear‐
box - J743- must be re‐
moved ⇒ page 31 .
⇒ page 33
2 - Mechatronic unit for dual
clutch gearbox - J743-
⇒ page 31
3 - Tiptronic switch - F189-
❑ Assembly overview
⇒ page 40 .
⇒ page 45
4 - Cover
❑ The Tiptronic switch -
F189- is installed on the
underside of the cover.
5 - Selector lever position indi‐
cator - Y6-
❑ Installation position and
removing and installing
⇒ Electrical system;
Rep. gr. 90 ; Dash panel
insert

2.2 Removing and installing mechatronic

unit for dual clutch gearbox - J743-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Release tool - T10465-
♦ Torque wrench - V.A.G 1331-
Removing
Note
♦ Always take care that, when the gearbox is open, no dirt gets
into the gearbox or the mechatronic unit for dual clutch gear‐
box - J743- .
♦ In particular, dirt entering an exposed mechatronic unit for dual
clutch gearbox - J743- can lead to gearbox failure.
♦ Before the new mechatronic unit for dual clutch gearbox -
J743- is installed, clean the sealing surface on the gearbox
housing thoroughly, leaving no residue. Do not use cleaning
agents. Make sure that absolutely no dirt can find its way in‐
side.
2. Electrical and electronic components of the dual clutch gearbox (DSG®) and their locations 31
– If fitted, remove noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Drain oil ⇒ page 120 .
– Pull off locking clip -3-.
– Loosen bolts -1- in diagonal sequence.
– Unscrew bolts -1-
– Remove cover -2-.
– If necessary, detach cover -2- by tapping lighting with a rubber-
headed hammer.
Note
Touch an earthed object before coming into contact with the me‐
chatronic unit for dual clutch gearbox - J743- .
– If necessary, release electrical connector -1- using release

tool - T10465- .
– Separate connector -1- from mechatronic unit for dual clutch

gearbox - J743- -2-.

– Loosen bolts -arrows- diagonally.

– Remove bolts -arrows-
– Remove mechatronic unit for dual clutch gearbox - J743- -1-.
Note
Do not place mechatronic unit for dual clutch gearbox - J743- on

sensors -arrows-.
Installing
Install in reverse order of removal, observing the following:
– Lubricate oil seal -arrow- with DSG transmission oil .

– Fill with oil ⇒ page 120
– Perform basic adjustment of mechatronic unit for dual clutch
gearbox - J743- using ⇒ Vehicle diagnostic tester.
Torque settings
♦ ⇒ “1 Assembly overview - dual clutch gearbox”, page 27
2.3 Removing and installing gearbox input

speed sender - G182- and oil tempera‐
ture sender in multi-plate clutch - G509-
Both senders are combined in one component and can be re‐
newed together only. They are in the gearbox near the dual clutch.
Before removal, the mechatronic unit for dual clutch gearbox -
J743- must be removed.
Removing
– Remove mechatronic unit for dual clutch gearbox - J743-
⇒ page 31 .
2. Electrical and electronic components of the dual clutch gearbox (DSG®) and their locations 33
Do not pull on line!

– Unscrew and remove bolt -2- and pull out sender -1-.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Reinstall old sender only if:
• The sender has no defect
• The cable was not pulled on when it was removed
Otherwise, install a new sender.
– Insert sender moistened with DSG transmission oil .
– Tighten bolt -2- ⇒ page 27 .

– Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 31 .

3 Components of dual clutch gearbox

⇒ “3.1 Removing and installing gear oil cooler”, page 35
⇒ “3.2 Renewing bleeder”, page 37
3.1 Removing and installing gear oil cooler

♦ Hose clamps to 25 mm - 3094-
Removing
Following repairs, fill with oil without renewing filter ⇒ page 120 .
– Move selector lever to position “P”.
Caution
• Observe notes concerning hose connections using screw-

type clips ⇒ 4-cyl. diesel engine (2.0 l common rail en‐
gine); Rep. gr. 21 ; General notes on charge air system .
– Open -2- clip and pull hose off throttle valve control unit - J338-
together with throttle valve potentiometer - G69- and motor for
intake manifold flap - V157- -1-.
3. Components of dual clutch gearbox 35

– Open clip -2- and remove hose -1-.

– Lay lint-free cloths on gear oil cooler and gearbox to catch
escaping coolant.
– Clamp off coolant hoses -1- and -2- using hose clamps to 25
mm - 3094- and disconnect hoses from gear oil cooler.
– Route coolant hoses -1- upwards and tie-up.
– Remove bolts -A- and remove gear oil cooler -B-.
Caution
No coolant must be allowed to drip into gearbox!
Installing
the following:

– Renew O-rings -C- of gear oil cooler -B-.

– Set gear oil cooler -B- in place. When doing this, note O-rings
-C-.
– Screw in new bolts -A- and tighten.
– Connect coolant hoses -1- and -2- to gear oil cooler and re‐
move hose clamps to 25 mm - 3094- .
Specified torques ⇒ page 27 .
– Top up dual clutch gearbox oil ⇒ page 120 .
Caution
Do not start engine while checking coolant level, because no

DSG transmission oil is filled yet.
– Check coolant level and top up with coolant as needed ⇒ Rep.

gr. 19 ; Removing and installing parts of cooling system .
3.2 Renewing bleeder

♦ Front end hook - 3370-
3. Components of dual clutch gearbox 37

Removing
– Release connector -1- and pull off.
– Pull out wiring harness -3- from expansion tank -2-.
– Unscrew bolts -4- from coolant expansion tank -2- and push
coolant expansion tank aside.
– Pull off cap -arrow- using front-end hook - 3370- .
– Pull out breather pipe -2- using commercially available pliers

-1-.
Installing
the following:
– Push on breather pipe -2- powerfully by hand.
Breather pipe -2- must be heard and felt to engage.
Vehicles with petrol engine:
– Remove breather pipe -3-.

– Unclip pipe -3- together with retainer -2- and detach connec‐
tion from gearbox -4-.
Installing
– Press bleeder pipe -3- on by hand by pushing it firmly onto
gearbox and clip it on again by means of the retainer -2-.
– You should feel and hear the pipe engaging.

4 Selector mechanism
⇒ “4.1 Checking selector mechanism”, page 39
⇒ “4.2 Assembly overview - dismantling and assembling selector
mechanism”, page 40
⇒ “4.3 Checking and adjusting selector lever cable”, page 41
⇒ “4.4 Removing and installing selector lever handle”,
page 44
⇒ “4.5 Removing and installing Tiptronic switch F189 ”,
page 45
⇒ “4.6 Removing and installing selector mechanism”, page 46
⇒ “4.7 Removing and installing gear selector cable”, page 49
⇒ “4.8 Carrying out emergency release”, page 53
4.1 Checking selector mechanism

The starter must not operate in the selector lever positions “R”,
“D” or “S”.
On right-hand drive vehicles, the starter must operate in selector
lever positions “P” and “N” only when the button in the selector
lever knob is not pressed.
When selector lever is shifted to position “N” at speeds above
5 km/h, solenoid for selector lever lock must not engage and block
selector lever. Selector lever can be shifted into a driving range.
When travelling at speeds below 5 km/h (almost stationary) and
shifting into selector lever position “N”, solenoid for selector lever
lock should only engage after about 1 second. Selector lever can‐
not be shifted out of “N” position until brake pedal is depressed.
Selector lever in “P” position and ignition switched on
• Brake pedal not depressed.
Selector lever is locked and cannot be shifted out of “P” position
when the button is pressed. Solenoid for selector lever lock blocks
selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Move the selector lever from “P”
to “S” and shift through slowly. Check whether selector lever po‐
sition in dash panel insert corresponds to selector lever position.
Selector lever in “N” position and ignition switched on
• Brake pedal not depressed.
Selector lever is locked and cannot be shifted out of “N” position
when the button is pressed. Solenoid for selector lever lock blocks
selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
Selector lever in Tiptronic position
• Shift selector lever into Tiptronic gate.
The illuminated “D” symbol in the selector mechanism cover must
go out and the “+” and “-” symbols must light up.
4. Selector mechanism 39
When the selector lever is shifted into the Tiptronic gate, the se‐
lector lever position display in the dash panel insert must change
from “P R N D S” to “7 6 5 4 3 2 1”.
Ignition and light switched on
The respective symbol in the shift mechanism cover lights up.
Selector lever position indicator
Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
4.2 Assembly overview - dismantling and assembling selector mechanism
1 - Bolt, 5 Nm + 90° (1/4 turn)

❑ Renew
❑ For selector lever cable
to gearbox
3 - Selector lever cable
❑ Checking and adjusting
⇒ page 41
⇒ page 49
❑ For selector lever cable
to gearbox
5 - Spacer bracket
❑ Observe spacer dimen‐
sion ⇒ page 41
6 - Selector lever handle
❑ With symbol inlay
⇒ page 44
7 - Clip
❑ Always renew
8 - Tiptronic switch - F189-
⇒ page 45
9 - Lever for emergency re‐
lease
❑ Carrying out emergency
release ⇒ page 53 .
10 - Selector mechanism
11 - Bolt, 20 Nm + 90° (1/4 turn)
❑ Always renew
12 - Shim
13 - Grommet
14 - Spacer sleeve
15 - Bolt, 10 Nm
❑ To adjust selector lever cable

16 - 20 Nm
17 - Dual clutch gearbox
18 - Retaining plate
❑ With seal
❑ Attached to floor pan
Dimension for spacer

– Slide spacer -2- on to selector lever cable so that dimension
-a- to floor plate -1- is 20 mm.
4.3 Checking and adjusting selector lever

cable
4.3.1 Check
To ensure correct operation and smooth action, selector lever
cable must always be adjusted if:
♦ the selector lever cable or selector mechanism does not move
freely
♦ the gearbox has been removed and installed
♦ the selector lever cable has been removed from the gearbox
♦ the cable support bracket has been removed from the gearbox
♦ there is a message to this effect from vehicle diagnostic tester
Procedure
– Switch selector lever to “P” position.
Caution


– Push locking device -2- of selector lever -4- forwards

-arrow A- until it engages.
– Remove selector lever cable -4- from selector shaft lever
-arrow B-.
– Pull cable support bracket -3- to rear and upwards out of dual
clutch gearbox.
– Do not bend or kink selector lever cable -4-.
– Place selector lever cable down so its end can move freely.
– Move selector lever from “P” to “S”.
• Selector mechanism and selector lever cable must be free to
move. If necessary, renew selector lever cable or repair se‐
lector mechanism.
– Move selector shaft lever on gearbox to position “P”. Locking
lever must engage in parking lock wheel so that both front
wheels are blocked (cannot be turned together in same direc‐
tion).
• It must be possible to press the selector lever cable onto the
selector shaft lever. If this is not possible, adjust selector lever
cable ⇒ page 43 .
– Do not grease ball socket of selector lever cable.
– Press selector lever cable by hand onto selector shaft lever.
4.3.2 Adjusting
♦ Polycarbamide grease ⇒ Electronic Parts Catalogue (ETKA)

• Selector lever cable is disconnected from selector shaft lever.
Procedure
– Move selector shaft lever on gearbox to position “P”. Locking
lever must engage in parking lock wheel so that both front
wheels are blocked (cannot be turned together in same direc‐
tion).
– Remove middle footwell trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trim, insulation; Removing and installing dash
panel .
– Loosen bolt for selector lever cable.

– Press selector lever cable by hand onto selector shaft lever.
– Tighten bolt for selector lever cable to 10 Nm.
– Install middle footwell trim ⇒ General body repairs, interior;
panel .
– Check selector mechanism ⇒ page 39 .
4.4 Removing and installing selector lever

handle
♦ Hose clip pliers - V.A.G 1275-
Removing
Only pull button -1- out far enough until it can be secured using
the transport guard. If there is no transport guard, the button can
be secured with a thin cable tie or wire.
– Carefully pull button -1- out of handle until a slight resistance
can be felt and button engages in handle.
– Secure button with, e.g., a thin wire -2-.

– From the left, reach under right side of cover and pull cover
upwards slightly and out of dash panel.
– Pull cover out of dash panel all around.
– Pull up cover and gaiter, inside out, over handle.
– Mark connectors -1- and -2- as well as connections in Tiptronic

switch - F189- so they cannot be interchanged during instal‐
lation.
– Release connectors -1- and -2-, and pull them off.
– Remove clamp -3-.
– Pull the handle off the selector lever together with the boot and
the cover.
Installing
– If a new handle is fitted, transport guard must remain in place
during installation.
– Place handle on selector lever with cover and a new clamp.
– Push handle onto selector lever to stop.
– Push connectors -1- and -2- onto connections according to

markings made during removal.
– Use hose clip pliers - V.A.G 1275- to fasten clamp -3-.
– Insert cover with locking lugs in corresponding notches in dash
panel. Engage cover in dash panel.
– Remove guard from button. Press button into handle until it
engages in selector lever.
4.5 Removing and installing Tiptronic switch

- F189-
Caution
Touching the printed circuit of the Tiptronic switch - F189- can

damage it.
Grasp Tiptronic switch - F189- only at the appropriate point.
Removing
– Carefully push locking lugs -1- outwards and remove Tiptronic
switch - F189- -2- from cover.
– Renew cover if any locking lug -1- is damaged.
Installing
– Before installing Tiptronic switch - F189- , check that locking
lugs -1- are undamaged.
– Insert Tiptronic switch - F189- -2- into cover and lock.
4.6 Removing and installing selector mech‐

anism
Removing
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery: Disconnecting and connecting
battery .
– Remove grip for selector lever ⇒ page 44 .
panel .
– Release connector -arrow- and separate.

– Use a screwdriver to prise selector lever cable off selector

mechanism -in direction of arrow-.
– Using a -pair of long nose pliers-, carefully press locking de‐

vices together on support bracket for selector lever cable and
pull selector lever cable out of selector mechanism.
– Release connector -arrow- and pull off.
Note
In addition, two screws must be removed from dash panel so that

top left securing bolt -1- of selector mechanism can be removed.
– Unscrew bolt -1-.

– Unscrew bolts -2- and remove them from selector mechanism.
– Remove bolts -arrows A-.

– Pull back bottom right trim -arrow B- and hold.
– Remove top left securing bolt from selector mechanism.
– Remove selector mechanism from dash panel.
Installing
the following:
– Insert selector mechanism into dash panel and screw in new

bolts -2- finger-tight.

– Pull back bottom right trim -arrow B- and hold.

– Insert new securing bolt for selector mechanism at top left and
screw it in until finger-tight.
– Tighten bolts -1- and -2- to 20 Nm + 90°.

– Press cable support bracket into selector mechanism onto
stop.
Note
Make sure that both locks of selector lever cable audibly engage
in selector mechanism.
– Install grip for selector lever ⇒ page 44 .

– Install middle footwell trim ⇒ General body repairs, interior;
panel .
– With ignition switched off, connect battery earth strap ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
4.7 Removing and installing gear selector

cable
Removing
– Check whether a coded radio is fitted. If so, obtain anti-theft
code.
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery: Disconnecting and connecting
battery .

panel .
– Use a screwdriver to prise selector lever cable off selector
mechanism -in direction of arrow-.
– Using a -pair of long nose pliers-, carefully press locking de‐

vices together on support bracket for selector lever cable and
pull selector lever cable out of selector mechanism.
– Move driver seat to rear as far as it will go.
– Fold carpet in driver side footwell to one side.
– Unscrew and remove bolts and remove retaining plate from

floor pan.
Caution



-arrow B-.
clutch gearbox.
– Carefully pull selector lever cable -4- out into passenger com‐
partment.
Installing
the following:
Note
♦ The assistance of a second mechanic is required to install the

selector lever cable.
♦ The second mechanic is required to guide the selector lever
cable through the cable support bracket and past the coolant
pipes (models with auxiliary heater) and brake lines to the se‐
lector shaft lever when the selector lever cable is being pushed
from the passenger compartment and into the engine com‐
partment over the gearbox.
– Carefully push selector lever cable -4- from passenger com‐

partment into engine compartment, over gearbox and into
cable support bracket -1-.
– Push selector lever cable -4- onto selector shaft lever by hand.
Note
Ensure that the cable support bracket engages audibly into the
dual clutch gearbox.
– Lock cable support bracket -3- into dual clutch gearbox.
– Position retaining plate on floor panel. Tighten bolts -arrows-

for retaining plate to 20 Nm.
– Slide spacer -2- on to selector lever cable so that dimension

-a- to floor plate -1- is 20 mm.
Note
Make sure that both locks of cable support bracket audibly en‐
gage in selector mechanism.

– Adjust selector lever cable ⇒ page 41 .

4.8 Carrying out emergency release

Procedure
Only pull button -1- out far enough until it can be secured using
the transport guard. If there is no transport guard, the button can
be secured with a thin cable tie or wire.
– Carefully pull button -1- out of handle until a slight resistance
can be felt and button engages in handle.
– Secure button with, e.g., a thin wire -2-.
– From the left, reach under right side of cover and pull cover
upwards slightly and out of dash panel.
– Pull cover out of dash panel all around.
– Pull up cover and gaiter, inside out, over handle.
– Depress brake pedal or set handbrake.
– Press lever down in -direction of arrow- and hold down.

– Press lock button on selector lever button with solenoid re‐
leased and shift selector lever out of “P”.
5 Dismantling and assembling gearbox

⇒ “5.1 Assembly overview - gearbox”, page 54
⇒ “5.2 Renewing sealing cap”, page 56
⇒ “5.3 Renewing bleeder”, page 58
5.1 Assembly overview - gearbox
1 - Retaining ring
2 - Dual clutch cover
⇒ page 12
3 - Retaining ring
4 - Shim
❑ Determining shims
⇒ page 22 .
5 - Tapered ring
6 - Dual clutch
❑ Currently, no repairs
can be made to the
clutch.
7 - Seal, right
⇒ page 130
8 - Breather pipe
⇒ page 37
9 - Breather cap
10 - Plug
11 - Sealing ring
12 - Gear oil cooler
gear oil cooler
⇒ page 35
13 - Bolt
❑ 20 Nm +45°
14 - Filter housing
❑ 20 Nm
15 - Sealing ring
16 - Heat shield
17 - Oil filter
❑ Information about oil and filter change ⇒ page 3

18 - Bolt
❑ 5 Nm +90°
❑ For selector lever cable to gearbox
20 - Detent lever for parking lock
21 - Bolt
❑ 10 Nm +90°
22 - Gearbox
23 - Left seal
24 - Sealing cover
25 - Sealing ring
26 - Oil drain plug
❑ For mechatronic unit
❑ 20 Nm
27 - Oil level pipe
❑ Note the screw-in depth and remove/install
❑ Drain and fill oil ⇒ page 120
❑ 3 Nm
28 - Sealing ring
29 - Oil drain plug
❑ For gearbox
❑ 45 Nm
30 - Bolt
❑ 10 Nm
31 - Gearbox input speed sender - G182- and oil temperature sender in multi-plate clutch - G509-
32 - Mechatronic unit for dual clutch gearbox - J743-
33 - Bolt
❑ 10 Nm +30°
34 - Cover
❑ With seal
❑ Always renew
35 - Bolt
❑ 10 Nm +45°
5. Dismantling and assembling gearbox 55

36 - Securing clip
37 - Sealing ring
5.2 Renewing sealing cap

♦ Internal puller e.g. KUKKO 21-2 - VAS 251 605-
♦ Counter support e.g. KUKKO 22-1 - VAS 251 621-
♦ Special wrench - T40297-

♦ Knife
♦ Plastic hammer
Removing
– Switch selector lever to P position.
– Front suspension; Subframe; Removing and installing sub‐
frame without steering rack ⇒ Rep. gr. 40 ; Front suspension;
Subframe; Removing and installing subframe without steering
rack .
– Assembly mountings; Remove gearbox mountings ⇒ Rep. gr.
10 ; Assembly mountings; Removing and installing gearbox
mountings .
– Lower gearbox until cover is accessible.
– Place drip tray for workshop hoist - VAS 6208- under gearbox.
– Pierce centre of cover -2- with a knife -1- and remove rubber
coating around it. Diameter of opening approx. 15 mm.
– Pull cap -3- out of gearbox housing using internal puller, e.g.
KUKKO 21-2 - VAS 251 605- and counter support, e.g. KUK‐
KO 22-1 - VAS 251 621- .
– Thoroughly clean sealing surface on gearbox housing with a
lint-free cloth.
Note
Dispose of used oil in the correct manner.
Installing
Install in reverse order of removal, observing the following:
– Fit sealing cap -1- in direction of -arrow-.
5. Dismantling and assembling gearbox 57

– Using special wrench - T40297- -1-, drive new sealing cap into
gearbox housing -2- to stop. Take care not to cant sealing cap.
– Clean gearbox housing of any oil that has escaped.
– Assembly mountings; Install gearbox mountings ⇒ Rep. gr.
10 ; Assembly mountings; Removing and installing gearbox
mountings .
– Check gear oil level ⇒ page 117 .
– Check and adjust selector lever cable ⇒ page 41 .
Specified torque
♦ ⇒ “6.7 Torque settings”, page 93
♦ Subframe; Assembly overview - subframe ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Assembly overview -
subframe
5.3 Renewing bleeder

Removing
– Pull off cap -arrow- by hand.
– Insert screwdriver -1- between collar of gearbox and breather

pipe -2-.
– Pry off breather pipe -2- with screwdriver -1-.
Installing
– Push on breather pipe -2- powerfully by hand.
Breather pipe must be heard and felt to engage.
– Put on cap.

6 Removing and installing gearbox

⇒ “6.1 General notes on removing and installing gearbox”,
page 59
⇒ “6.2 Converting adapter 10 - 222 A /23 with adapter 10 - 222
A /23-1 ”, page 60
⇒ “6.3 Removing gearbox”, page 61
⇒ “6.4 Transporting gearbox”, page 83
⇒ “6.5 Securing gearbox to assembly stand”, page 87
⇒ “6.6 Installing gearbox”, page 89
⇒ “6.7 Torque settings”, page 93
6.1 General notes on removing and instal‐

ling gearbox
– Before removal, print out a diagnosis log for this vehicle. Be‐
fore returning the gearbox, secure the log to the gearbox so
that it cannot be lost during transport.
Brief description
The gearbox is removed downwards separately.
»From above«:
♦ coolant hoses clamped of,
♦ selector lever cable disconnected,
♦ intake pipe removed,
♦ coolant expansion tank removed.
»From below«
♦ starter removed,
♦ subframe removed.
For information on removing the -subframe-, please refer to ⇒
Rep. gr. 40 ; Assembly overview, subframe, anti-roll bar, sus‐
pension links . Valuable information can be found there. If the job
is done correctly, the subframe can be removed and reinstalled
without subsequently causing increased tyre wear, which may
lead to customer complaints. Therefore, it is wise to read this in‐
formation »before« removing gearbox. Then the position of the
-subframe- can be properly fixed and the subframe removed.
In any case, locating pins - T10227- are necessary.
6. Removing and installing gearbox 59

If the position of the subframe is not fixed, it will be necessary to

perform wheel alignment later.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
It requires only a small effort to install the locating pins - T10227- .
Their benefit is enormous.
After the subframe has been removed, the engine and gearbox
must be supported and the left assembly mounting must be sep‐
arated. Then the »last« connecting bolt between the engine and
gearbox must be removed and the gearbox lowered.
– Remove gearbox ⇒ page 61 .
6.2 Converting adapter - 10 - 222 A /23- with

adapter - 10 - 222 A /23-1-
♦ Torque wrench (5 ... 50 Nm) - V.A.G 1331-
♦ Adapter - 10 - 222 A /23- with adapter - 10 - 222 A /23-1-

Procedure
– Remove cap -1-.
– Remove cap -2- and unscrew underlying support bolt -3-.
– Insert adapter - 10 - 222 A /23-1- -4- into adapter - 10 - 222
A /23- -5-.
– Insert bolt -6- into adapter - 10 - 222 A /23- from below and
tighten to 40 Nm.
6.3 Removing gearbox

Removing gearbox, vehicles with diesel engine
⇒ “6.3.1 Removing gearbox, vehicles with diesel engine”,
page 61 .
Removing gearbox, vehicles with petrol engine
⇒ “6.3.2 Removing gearbox, vehicles with petrol engine”,
page 72 .
6.3.1 Removing gearbox, vehicles with diesel engine

Special tools and workshop

equipment required
♦ Support - 10-222A-
♦ Hooks - 10-222A/2-
♦ Adapter - 10-222A/3-
♦ Shackle - 10-222A/12-
♦ Adapter - 10-222A/16-
♦ Adapter - 10-222A/23-

♦ Gearbox support - 3282-

♦ Adjustment plate - 3282/61- for front-wheel drive vehicles
♦ Adjustment plate - 3282/67- for all-wheel drive vehicles
♦ Torque wrench (5 ... 50 Nm) - V.A.G 1331-
♦ Torque wrench (40 … 200 Nm) - V.A.G 1332-
♦ Engine and gearbox jack - V.A.G 1383 A- or engine and gear‐
box jack - VAS 6931-
♦ Ladder - VAS 5085- discontinued

♦ Steps - VAS 6292/4-
♦ Engine bung set - VAS 6122-

♦ Hose clamp pliers - VAS 6340-
♦ Locating pins - T10227-
♦ High-temperature grease ⇒ Electronic Parts Catalogue (ET‐
KA)
♦ Multi-purpose grease ⇒ Electronic Parts Catalogue (ETKA)
code.
– Remove outer lock carrier covers above headlights ⇒ General
body repairs, exterior; Rep. gr. 63 .
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .

– Then remove left and right plenum chamber bulkhead panels

-arrows- from plenum chamber ⇒ General body repairs, inte‐
rior; Rep. gr. 50 ; Assembly overview - plenum chamber
bulkhead .
Caution

– Open -2- clip and pull pressure hose off throttle valve control
unit - J338- together with throttle valve potentiometer - G69-
and motor for intake manifold flap - V157- -1-.
– Open clip -2- and remove pressure hose -1- leading to charge
air cooler.

– Pull wiring harness -3- out of coolant expansion tank -2-.
– Remove bolts -4- from coolant expansion tank -2-.
– Remove return hose from coolant expansion tank. Seal cool‐
ant expansion tank and return hose with bungs from engine
bung set - VAS 6122- .

– Unhook clip -2- from transportation eye -1-.

-arrow B-.
clutch gearbox.
– If fitted, unclip breather line -3- with retainer -2-.

– Remove engine/gearbox connecting bolt -1-.

– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Release quick-release cover by turning it -arrow- and then pull

it off.
– Raise vehicle.
– Remove front wheels.
terior; Rep. gr. 50 ; Noise insulation .
– Remove exhaust system from subframe.
– Remove subframe. First fix position of subframe ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Repairing front suspension;
Removing and installing subframe .
– Detach left and right drive shaft from gearbox flange, and tie
them up ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
pairing drive shafts; Removing and installing drive shafts .
– Release right track rod ball joint from wheel bearing housing
using ball joint puller - T40010- ⇒ Running gear, axles, steer‐
ing; Rep. gr. 44 ; Assembly overview - front wheel bearings .
Note
Lead sealing of tachograph sender - G75- may only to be carried

out by authorised specialist workshops ⇒ Electrical system; Rep.
gr. 90 .
– If present, disconnect connector -arrow- for tachograph send‐

er - G75- .
Vehicles with all-wheel drive

– Loosen bolts -1- of propshaft heat shield -2-. Remove heat

shield.
– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.
39 .
Vehicles with front-wheel drive

– Unscrew nut -3- and remove support -2-.
Continued for all vehicles
• If there are hose and cable connections in the area of the en‐
gine support eye, they must first be removed so that the
support bracket - 10-222A- can be mounted.
– Remove protective caps for suspension struts.
If required, convert adapter - 10-222A/23- with adapter - 10-222A/
23-1- ⇒ page 60 .
– Place adapter - 10-222A/23-1- behind suspension strut

-arrow A- and on lock carrier at front -arrow B-.

– Secure adapter - 10-222A/3- , adapter - 10-222A/16- and

adapter - 10-222A/23-1- to support bracket - 10-222A- .
– Attach spindle - 10-222A/10- in support eye on front of engine.
– Attach hook - 10-222A/2- -3- in rear lifting eye -4- on engine.

– Attach hook - 10-222A/2- -3- in shackle -2-.
– Hook shackle -2- in adapter - 10-222A/16- .
– Slightly preload engine/gearbox assembly using spindle -
10-222A/10- and adapter - 10-222A/16- .
– Position engine and gearbox jack - V.A.G 1383 A- or engine
and gearbox jack - VAS 6931- under dual clutch gearbox and
exert slight counter pressure.
– Unscrew bolts -arrows A- from left assembly mounting.

– Remove engine and gearbox jack - V.A.G 1383 A- or engine
and gearbox jack - VAS 6931- from under dual clutch gearbox.

– Remove engine/gearbox connecting bolts -3-, -5-, -6- and

-7-.
– Release wiring harness -1- from retainer -2-.
– Now step onto steps - VAS 6292/4- to lower engine/gearbox

assembly using adapter and spindle.
– Using adapter - 10-222A/16- and spindle of support bracket -
10-222A- , lower engine/gearbox by approx. 115 mm to di‐
mension -a-.
Note
Measure dimension -a- between lower side of longitudinal mem‐

ber -1- and bolting surface of engine/gearbox mounting -2-.
– Only when dual clutch gearbox is being replaced, unscrew

assembly mounting from gearbox -arrow B-. The third bolt is
not visible in the figure.
– Unhook selector lever cable from cable support bracket when
lowering dual clutch gearbox.
To remove dual clutch gearbox 0BT, set up gearbox support -
3282- with adjustment plate - 3282/61- .
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .
– Align arms of gearbox support according to holes in adjust‐
ment plate .
The symbols on the adjusting plate indicate the supports required.
Arrow points in direction of travel.
– Place engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- with gearbox support - 3282- under
vehicle.

– Secure mounting -2- using one M10 bolt -1-.

– Insert pin -3- into dual clutch gearbox support.
– Insert hook -1- into dual clutch gearbox support.

– Insert pin into dual clutch gearbox support.

– Unscrew front bolt of assembly mounting, fit support, and
tighten it.

– Unscrew bolt from bevel box, fit support, and tighten it.

– Remove engine/gearbox connecting bolts -4- and -8-.

– Pull dual clutch gearbox away from engine, off dowel sleeves.
– Lower dual clutch gearbox on engine and gearbox jack - V.A.G
1383 A- or engine and gearbox jack - VAS 6931- slightly. Tilt
dual clutch gearbox slightly using gearbox support - 3282- .
– Adjust gearbox support - 3282- sufficiently to allow the front of

the dual clutch gearbox -1- to pass by the indentation
-arrow- in the longitudinal member -2-.
1383 A- or engine and gearbox jack - VAS 6931- again slightly.
– Adjust gearbox support - 3282- to create a gap -arrow- to allow

the dual clutch gearbox -2- to pass by the longitudinal member
-1-
– Tilt dual clutch gearbox forwards.
– Pull engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- with dual clutch gearbox outwards
and lower slowly.
– For purposes of analysis, attach diagnosis log of this gearbox
securely to gearbox when it is ready for shipping.
– Note procedure when transporting gearbox ⇒ page 87 .
6.3.2 Removing gearbox, vehicles with petrol engine


equipment required
♦ Support - 10-222A-
♦ Hooks - 10-222A/2-
♦ Hook - 10 - 222 A /10-

♦ Adjustment plate - 3282/61- for front-wheel drive vehicles

♦ Adjustment plate - 3282/67- for all-wheel drive vehicles
♦ Ladder - VAS 5085- discontinued
♦ Engine and gearbox jack - V.A.G 1383 A- or engine and gear‐
box jack - VAS 6931-
♦ Locating pins - T10227-
♦ Steps - VAS 6292/4-

♦ Engine bung set - VAS 6122-
♦ Hose clamp pliers - VAS 6340-

KA)
code.
– Remove outer lock carrier covers above headlights ⇒ General
body repairs, exterior; Rep. gr. 63 .
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Then remove left and right plenum chamber bulkhead panels
-arrows- from plenum chamber ⇒ General body repairs, inte‐
rior; Rep. gr. 50 ; Assembly overview - plenum chamber
bulkhead .
Caution


air cooler.

– Pull wiring harness -3- out of coolant expansion tank -2-.
– Remove bolts -4- from coolant expansion tank -2-.
– Remove return hose from coolant expansion tank. Seal cool‐
ant expansion tank and return hose with bungs from engine
bung set - VAS 6122- .


-arrow B-.
– If fitted, unclip breather line -3- with retainer -2-.

– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .

– Release quick-release cover by turning it -arrow- and then pull

it off.
– Raise vehicle.
– Remove front wheels.
– Remove exhaust system from subframe.
– Remove subframe. First fix position of subframe ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Repairing front suspension;
Removing and installing subframe .
– Detach left and right drive shaft from gearbox flange, and tie
them up ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
pairing drive shafts; Removing and installing drive shafts .
– Release right track rod ball joint from wheel bearing housing
using ball joint puller - T40010- ⇒ Running gear, axles, steer‐
ing; Rep. gr. 44 ; Assembly overview - front wheel bearings .
Note
Lead sealing of tachograph sender - G75- may only to be carried

out by authorised specialist workshops ⇒ Electrical system; Rep.
gr. 90 .
– If present, disconnect connector -arrow- for tachograph send‐

er - G75- .
– Loosen bolts -1- of propshaft heat shield -2-. Remove heat

shield.
39 .
– Remove downstream catalytic converter ⇒ 4-cylinder injection
engine (2.0 l direct injection engine, turbocharger); Rep. gr.
26 ; Emission control; Removing and installing downstream
catalytic converter .
– Remove rear engine support ⇒ 4-cylinder injection engine (2.0
l direct injection engine, turbocharger); Rep. gr. 10 ; Assembly
mountings; Removing and installing assembly mountings .

– Unscrew bolts -1 and 2-.

– Remove retainer -3-.
– Unscrew bolts -1- from steering rack, and tie up oil line -2-.
– Bolt on retainer -2- with bolts -1-.
• If there are hose and cable connections in the area of the en‐
gine support eye, they must first be removed so that the
support bracket - 10-222A- can be mounted.
– Remove protective caps for suspension struts.
If required, convert adapter - 10-222A/23- with adapter - 10-222A/
23-1- ⇒ page 60 .
– Place adapter - 10-222A/23-1- behind suspension strut

-arrow A- and on lock carrier at front -arrow B-.

– Secure adapter - 10-222A/3- and adapter - 10-222A/23-1- to

support bracket - 10-222A- .
– Slightly take up weight of engine/gearbox assembly on spindle
- 10-222A/10- with hook - 10 - 222 A /2- .
– Unscrew bolts -arrows A- from left assembly mounting.

– Remove engine and gearbox jack - V.A.G 1383 A- or engine
and gearbox jack - VAS 6931- from under dual clutch gearbox.
– Remove engine/gearbox connecting bolts -3-, -5-, -6- and

-7-.
– Release wiring harness -1- from retainer -2-.

– Now step onto steps - VAS 6292/4- to lower engine/gearbox

– Using spindle and hook - 10 - 222 A /10- of support bracket -
10-222A- , lower engine/gearbox by approx. 115 mm to di‐
mension -a-.
– Pull cable support bracket towards rear and upwards out of
dual clutch gearbox.
Note
Measure dimension -a- between lower side of longitudinal mem‐

ber -1- and bolting surface of engine/gearbox mounting -2-.

– Unhook selector lever cable from cable support bracket when
lowering dual clutch gearbox.
Gearbox support - 3282- is aligned with adjustment plate -
3282/61- (front-wheel drive vehicles) or adjustment plate -
3282/67- (all-wheel drive vehicles) for removal of dual clutch
gearbox 0BT.
ment plate .
vehicle.




tighten it.

– Remove engine/gearbox connecting bolts -4- and -8-.

– Pull dual clutch gearbox away from engine, off dowel sleeves.
1383 A- or engine and gearbox jack - VAS 6931- slightly. Tilt
dual clutch gearbox slightly using gearbox support - 3282- .

– Adjust gearbox support - 3282- sufficiently to allow the front of

the dual clutch gearbox -1- to pass by the indentation
-arrow- in the longitudinal member -2-.
1383 A- or engine and gearbox jack - VAS 6931- again slightly.
– Adjust gearbox support - 3282- to create a gap -arrow- to allow

the dual clutch gearbox -2- to pass by the longitudinal member
-1-
– Tilt dual clutch gearbox forwards.
– Pull engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- with dual clutch gearbox outwards
and lower slowly.
– For purposes of analysis, attach diagnosis log of this gearbox
securely to gearbox when it is ready for shipping.
– Note procedure when transporting gearbox ⇒ page 87 .
6.4 Transporting gearbox

⇒ “6.4.1 Transporting gearbox, all-wheel drive”, page 83
⇒ “6.4.2 Transporting gearbox”, page 85
6.4.1 Transporting gearbox, all-wheel drive

♦ Workshop hoist - VAS 6100-

♦ Shackle - 10 - 222 A /12-
♦ Lifting tackle - 2024 A-

♦ Lifting tackle - 3033-
Procedure
Note
♦ During transport, always secure parts to be transported.

♦ There is still oil in gearbox even after oil has been drained.
When transporting gearbox, do not turn it so its vents or open‐
ings are pointing upwards or downwards, otherwise oil will
drain out.
Transporting gearbox
– Secure extension - 2024 A /1- onto gearbox housing with three
washers -arrow-.

Extensions - 3282- and shackle - 2024 A/1- may be used in con‐

junction with lifting tackle - 10 - 222 A /12- and workshop hoist -
3033- to transport gearbox and to set up gearbox support - VAS
6100- .
– Secure extension - 2024 A /1- to housing of bevel box.
– Support gearbox with workshop hoist - VAS 6100- and lifting
tackle - 3033- in conjunction with shackles - 10 - 222 A /12- .
6.4.2 Transporting gearbox

♦ Workshop hoist - VAS 6100-
♦ Shackle - 10 - 222 A /12-

♦ Lifting tackle - 2024 A-
♦ Lifting tackle - 3033-
Procedure
Note
♦ During transport, always secure parts to be transported.

♦ There is still oil in gearbox even after oil has been drained.
When transporting gearbox, do not turn it so its vents or open‐
ings are pointing upwards or downwards, otherwise oil will
drain out.
Transporting gearbox
– Secure extension - 2024 A /1- -3- to gearbox housing -1- using
bolt -2- and 3 washers -arrow-.

– Secure shackle - 10 - 222 A /12- -1- to extension - 2024 A /1-

-2-.
– Secure shackle - 10 - 222 A /12- -1- to gearbox -3-.
– Attach lifting tackle - 3033- -1- to shackle - 10 - 222 A /12-

-3-.
– Connect lifting tackle - 3033- -1- to workshop hoist - VAS
6100- .
6.5 Securing gearbox to assembly stand


equipment required
♦ Gearbox support - VW 353-

♦ Support plate - VW 309-
♦ Engine and gearbox support - VAS 6095-
Procedure
When working on engine, secure it in engine and gearbox support
- VW 309- with support plate - VW 353- and gearbox support -
VAS 6095- .

Secure gearbox on engine and gearbox support

– Screw gearbox support - VW 353- onto gearbox housing at top
-arrow A- and bottom -arrow B-.
– Suspend gearbox from workshop hoist - VW 309- with retain‐
ing plate - VW 353- and gearbox support - VAS 6100- .
– Secure gearbox to engine and gearbox support - VW 309- with

retaining plate - VW 353- and gearbox support - VAS 6095- .
6.6 Installing gearbox

KA)
Install in reverse order of removal. Observe the following when
doing this:
Note
♦ Before installation, check dowel sleeves are correctly installed

and seated properly.
♦ Missing dowel sleeves result in misalignment of the axes of
engine and gearbox, leading to destruction of the needle bear‐
ing.
– Renew retaining ring on left drive shaft.

– Lubricate left and right stub shaft splines -arrows- with multi-
purpose grease .
– Renew needle bearing ⇒ Rep. gr. 13 ; Crankshaft drive;
Crankshaft; Renewing needle bearing in crankshaft
– Lubricate needle bearing -arrow- lightly with high-temperature

grease .
– Lightly grease journal (not the splines) of gearbox input shaft.
– Clean splines and then lubricate with multi-purpose grease .

– Always renew self-locking nuts and bolts.
– Check whether dowel sleeves -arrows- for aligning engine and

gearbox are fitted in cylinder block and install if necessary.
Gearbox support - 3282- is aligned with adjustment plate -
3282/61- (front-wheel drive vehicles) or adjustment plate -
3282/67- (all-wheel drive vehicles) for installation of dual clutch
gearbox 0BT.
ment plate .
vehicle.




tighten it.

Continuation all vehicles
– Align dual clutch gearbox to engine and join.
– Screw in one engine/gearbox connecting bolt hand-tight on
each side.

– Tighten lower engine/gearbox connecting bolts -3- and -8-

⇒ page 93 .
– Tighten connection bolt -2- before installing starter.
– After gearbox has been bolted to engine, remove gearbox
support - 3282- .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter
– Insert selector lever cable into cable support bracket. When
raising engine/gearbox assembly, ensure selector lever cable
is not pinched.
– Now step onto steps - VAS 6292/4- to raise engine/gearbox
– Align engine and gearbox in installation position. To do this,
tighten threaded spindle of adapter - 10-222A/16- and spindle
of support bracket - 10-222A- until gearbox mounting contacts
left longitudinal member.
– Tighten bolts -arrows A- for assembly mounting to specified

torque ⇒ page 93 .
Caution
Do not remove support bracket 10-222/A until all bolts of left

engine/gearbox mounting have been tightened to specified
torque and turned an additional angle.
– Install left and right drive shafts ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Repairing drive shafts; Removing and
installing drive shafts .
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing front suspension; Removing and installing sub‐
frame .
– Install propshaft ⇒ Propshaft and rear final drive; Rep. gr. 39 .
– Attach exhaust system to subframe ⇒ Rep. gr. 26 ; Removing
and installing parts of exhaust system .

– Connect coolant lines -1- and -2- to gear oil cooler and remove
hose clamps to 25 mm - 3094- .
– Remove support bracket - 10-222A- with adapter - 10-222A/
3- , adapter - 10-222A/16- and adapter - 10-222A/23-1- .
– Fit protective caps for suspension struts.
– Install selector lever cable on dual clutch gearbox
⇒ page 49 .
– Adjust selector lever cable ⇒ page 41 .
– Install breather pipe if there is one.
– Install left and right bulkhead panels of plenum chamber ⇒
General body repairs, interior; Rep. gr. 50 ; Assembly over‐
view - plenum chamber bulkhead .
– Follow procedure after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
– Install outer lock carrier covers above headlights and engine
compartment cover ⇒ General body repairs, exterior; Rep. gr.
63 .
– Bolt right track rod ball joint to wheel bearing housing ⇒ Run‐
ning gear, axles, steering; Rep. gr. 44 ; Assembly overview -
front wheel bearings .
– Install wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Torque settings for wheel bolts .
Note
Carry out a road test after completing repairs.
6.7 Torque settings

Gearbox to engine:
Item number Specified torque
1 - Bolt M12 x 50 80 Nm
2 - Bolt M12 x 50 80 Nm
3 - Bolt M12 x 70 80 Nm
4 - Bolt M12 x 70 80 Nm
5 - Bolt M10 x 50 40 Nm
6 - Bolt M10 x 50 40 Nm
7 - Bolt M10 x 50 40 Nm
8 - Centre hex. stud M12 x 60 80 Nm
Arrows - dowel sleeves

Assembly mounting to dual clutch gearbox and longitudinal mem‐

ber:
– Renew bolts -arrows A- and tighten to 50 Nm + 90°.
– Renew bolts -arrows B- and tighten to 50 Nm + 90°.

7 Bevel box
⇒ “7.1 Assembly overview - bevel box”, page 95
⇒ “7.2 Removing and installing bevel box (4-cylinder diesel en‐
gines)”, page 97
⇒ “7.3 Removing and installing bevel box (4-cylinder petrol en‐
gines)”, page 103
⇒ “7.4 Checking gear oil in bevel box”, page 110
⇒ “7.5 Installing repair kit for stub shaft”, page 111
7.1 Assembly overview - bevel box
Note
Removing and installing bevel box ⇒ page 97 .
1 - Stub shaft
⇒ page 143
❑ Installing repair kit for
stub shaft ⇒ page 111
2 - Retaining ring
3 - Bearing mounting
❑ For deep groove ball
bearing
⇒ Item 4 (page 95) .
4 - Deep groove ball bearing
❑ Installing deep groove
ball bearing
⇒ page 111
5 - Retaining ring
❑ The second retaining
ring is not installed on all
stub shafts
6 - Retaining ring
7 - Retaining ring
❑ For bearing mounting in
bevel box
8 - Dust seal
9 - O-ring
10 - Retaining ring
11 - Bolt
❑ Not fitted in all bevel
boxes
❑ 35 Nm
7. Bevel box 95
12 - Securing bolt
❑ M 10 × 28
❑ Specified torque ⇒ page 97
13 - Securing bolt
❑ M 10 × 28
❑ Specified torque ⇒ page 97
14 - Bevel box carrier
❑ Assembly sequence ⇒ page 97
15 - Radial oil seal
❑ For right stub shaft.
❑ Renewing ⇒ page 143
16 - Combined plug screw
❑ 10 Nm
17 - Magnetic screw
❑ 45 Nm
18 - Sealing ring
19 - Bolt
❑ Qty. 4
❑ 40 Nm +45°
❑ For left stub shaft, interior
❑ For left stub shaft, exterior
❑ For drive flange
23 - Protective cap
24 - Deflector ring
25 - Output flange
26 - O-ring
27 - Shim
28 - Retaining ring

Observe assembly sequence when installing gearbox carrier

-3-:
Stage Bolts Specified torque
1 -2- Screw in by hand
2 -1- 45 Nm
3 -2- 45 Nm
7.2 Removing and installing bevel box (4-cylinder diesel engines)

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- with universal sup‐
port - V.A.G 1359/2-
♦ Or engine and gearbox jack - VAS 6931-
♦ Socket insert - T10107 A-
7. Bevel box 97
♦ Counter-hold tool - T10140-

♦ or counter-hold tool - T50053-
♦ Clutch plate spline grease ⇒ Electronic parts catalogue (ET‐
KA)
♦ Socket insert - T10061-
Removing
noise insulation .
39 .
– Remove catalytic converter ⇒ 4-cylinder diesel engine (2.0 l
engine, common rail); Rep. gr. 26 ; Emission control; Assem‐
bly overview - catalytic converter, four-wheel drive vehicles .
– Remove particulate filter ⇒ Rep. gr. 26 .
– Remove bolts -1- and remove catalytic converter bracket -2-.
– Pull right drive shaft from stub shaft of bevel box ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts and tie up.
– If fitted, unscrew nut from bottom of vehicle level sender

-arrow-.

– Unscrew bolts -1- and -2- and remote gearbox carrier -3- from
rear torque reaction support and from bevel box.
– Remove subframe with bracket for rear torque reaction sup‐
port ⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing
front suspension; Removing and installing subframe .
– Open O-type clip on protective sleeve -1-.

– Push protective sleeve -1- upwards and secure it against slip‐
ping with, e.g. a 6 mm hexagon socket wrench -A-.
– Unbolt universal joint from steering pinion.
Vehicles with countersunk bolt for right stub shaft

– Remove retaining ring -arrow A- and seal -arrow B- of stub
shaft.
– Remove countersunk bolt for right stub shaft with socket -

T10107 A- . Counterhold stub shaft with counterhold tool -
T10140- or counterhold tool - T50053- when doing this.
7. Bevel box 99

– Unscrew threaded connections of anti-roll bar/subframe
-arrows- using socket and multi-point bit - T10061- .
– Swing anti-roll bar onto subframe.
– Remove bolt -1- from support mounting -3- of engine mounting

-2-.
– Remove support -3-.
– Remove top bevel box/dual clutch gearbox connecting bolts

-arrows-.
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
WARNING
Risk of injury from hot gearbox oil.

• Wear protective goggles.
• Wear acid-resistant gloves

– Remove bottom bevel box/dual clutch gearbox connecting

bolts -arrows-.
Note
A second mechanic is required for further removal.
– Carefully push bevel box off dual clutch gearbox.

– Turn bevel box until propshaft flange is at top.
– Place bevel box on engine and gearbox jack - V.A.G 1383 A-
or engine and gearbox jack - VAS 6931- .
Installing
the following:
– Lubricate stub shaft splines of differential with multi-purpose
grease .
– Lubricate right stub shaft splines -arrow- with multi-purpose

grease .
Note
The aid of a second mechanic is required to position the bevel

box.

– Lift bevel box and guide it past steering rack.
– Turn bevel box into installation position and bolt fully onto
manual gearbox. In the process, guide splines of bevel box lay
shaft concentrically together with splines of differential.
– Align splines of right stub shaft and differential bevel gear; turn
stub shaft as necessary.
Note
♦ When installing, ensure that installation position of stub shaft

does not change (is not pushed out of bevel box).
♦ Do not use securing bolts to pull bevel box onto gearbox, or
bevel box will cant and bolt holes can break off.
– Screw in bottom bevel box/dual clutch gearbox connecting

bolts -arrows- and tighten to specified torque ⇒ page 27 .
7. Bevel box 101

– Screw in top bevel box/dual clutch gearbox connecting bolts

-arrows- and tighten to specified torque ⇒ page 95 .
– Fit nut -3- and eccentric bolt.
– To tighten universal joint on steering pinion, turn eccentric bolt

-2- left »to stop« -arrow- and hold.
– Tighten nut -3-.
– Pull protective sleeve -1- down to stop.

Ensure that mark -arrow A- on protective sleeve and mark
-arrow B- on steering rack align.


– Screw in countersunk bolt for right stub shaft with socket -
T10107 A- , and tighten it. Counterhold stub shaft using coun‐
terhold tool - T10140- or counterhold tool - T50053- while
doing so.
– Renew retaining ring -arrow A- and oil seal -arrow B- of stub

shaft.
– Lubricate right stub shaft splines with multi-purpose grease .
– Screw rear torque reaction support onto cylinder block ⇒ Rep.
gr. 10 .
– Bolt gearbox carrier -3- onto rear torque reaction support and
bevel box (bolts -1- and -2-), note tightening sequence when
doing so ⇒ page 97 .
– Press right drive shaft onto gearbox stub shaft ⇒ Running
moving and installing drive shaft .
– Install subframe with bracket for rear torque reaction support
⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing front
suspension; Removing and installing subframe .
– Install particulate filter ⇒ Rep. gr. 26 .
– Install front propshaft ⇒ Rep. gr. 39 .
– Check and adjust oil level ⇒ page 117 .
– If present, install noise insulation ⇒ General body repairs, ex‐
noise insulation .
Torque settings
♦ ⇒ “7.1 Assembly overview - bevel box”, page 95
7.3 Removing and installing bevel box (4-cylinder petrol engines)
7. Bevel box 103


equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- with universal sup‐
port - V.A.G 1359/2-
♦ Socket insert - T10107 A-
♦ Grease ⇒ Electronic parts catalogue (ETKA)
Removing

– Loosen bolts -1- of propshaft heat shield -2-, and remove

them.
39 .
– Remove downstream catalytic converter ⇒ Exhaust system;
Rep. gr. 26 ; Emission control .
Note
The bracket may vary depending on vehicle equipment.
– Remove bolts -1- and remove catalytic converter bracket -2-.
– Unscrew bolts -1- and -2- and remote gearbox carrier -3- from
rear torque reaction support and from bevel box.
– Remove bolt -1- from support mounting -3- of engine mounting

-2-.
– Remove support -3-.
7. Bevel box 105

– Unscrew bolts -2- and bolt -3-, and remove rear torque reac‐
tion support -1- from cylinder block -4-.
– Detach wheel.
– Unscrew right suspension link from swivel joint.
– If fitted, unscrew nut from bottom of vehicle level sender

-arrow-.
– Using ball joint puller - T40010- , pull suspension link from

swivel joint.
– Pull right drive shaft from stub shaft of bevel box ⇒ Running
moving and installing drive shafts and tie up.
– Pull connector off oil level and oil temperature sensor - G266- ,
and unclip wiring harness.
– Unscrew bolts -4-.

– Unscrew bolt -2-, and remove support.
Note
If bolt -2- has been loosened, tighten this bolt last as it also carries
out a vertical tolerance compensation.
– Using tensioning strap - T10038- , pull engine and gearbox

towards front, and secure them in this position.


– Remove circlip -arrow A- and oil seal -arrow B- from right stub
shaft.
– Remove countersunk bolt for right stub shaft with socket -

T10107 A- . Counterhold stub shaft with counterhold tool -
T10140- / counterhold tool - T50053- when doing this.
– Remove top bevel box/dual clutch gearbox connecting bolts

-arrows-.
7. Bevel box 107

– Remove bottom bevel box/dual clutch gearbox connecting

bolts -arrows-.
Note
A second mechanic is required for further removal.
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
WARNING

• Wear protective goggles.
• Wear acid-resistant gloves
– Carefully push bevel box off dual clutch gearbox.

– Remove bevel box out between sump and subframe.
– Place bevel box on engine and gearbox jack - V.A.G 1383 A-
or engine and gearbox jack - VAS 6931- .
Installing
the following:
♦ Lubricate right stub shaft splines -arrow- with multi-purpose

grease .
Note
The aid of a second mechanic is required to position the bevel

box.

– Guide bevel box in between sump and subframe.
– Turn bevel box into installation position and bolt fully onto
manual gearbox. In the process, guide splines of bevel box lay
shaft concentrically together with splines of differential.
– Align splines of right stub shaft and differential bevel gear; turn
stub shaft as necessary.
Note
♦ When installing, ensure that installation position of stub shaft

does not change (is not pushed out of bevel box).
♦ Do not use securing bolts to pull bevel box onto gearbox, or
bevel box will cant and bolt holes can break off.

– Screw in bottom bevel box/dual clutch gearbox connecting

bolts -arrows- and tighten bolts first hand-tight, then tighten to
specified torque ⇒ page 27 .
– Screw in top bevel box/dual clutch gearbox connecting bolts

-arrows- and tighten bolts first hand-tight, then tighten to speci‐
fied torque ⇒ Gearbox mechanical operating mechanism
assembly, differential lock; Rep. gr. 34 ; Assembly overview -
bevel box .

– Screw in countersunk bolt for right stub shaft with socket -
T10107 A- , and tighten it. Counterhold stub shaft using coun‐
terhold tool - T10140- / counterhold tool - T50053- while doing
so.
– Renew retaining ring -arrow A- and oil seal -arrow B- of stub

shaft.
– Lubricate right stub shaft splines with multi-purpose grease .
– Screw rear torque reaction support to cylinder block, tighten
bolts first hand-tight, then tighten to specified torque ⇒ Engine,
Assembly, Cylinder, Crankcase; Rep. gr. 10 ; Assembly
mountings .
– Install support.
– Bolt gearbox carrier -3- onto rear torque reaction support and
bevel box (bolts -1- and -2-), note tightening sequence and
specified torque when doing so ⇒ page 95 .
7. Bevel box 109

Tighten bolts first hand-tight, then tighten to specified torque.

– Press right drive shaft onto gearbox stub shaft ⇒ Running
moving and installing drive shaft .
– Install support at front. Tighten bolts first hand-tight, then tight‐
en them to specified torque.
– Connect connector to oil level and oil temperature sensor -
G266- , and route wiring harness.
– Bolt suspension link to swivel joint ⇒ Front suspension, drive
shaft; Rep. gr. 40 ; Assembly overview - subframe, anti-roll
bar, suspension links .
– If fitted, screw on nut at bottom of vehicle level sender.
– Fit wheel ⇒ Maintenance ; Booklet 19.1 .
– Fit catalytic converter bracket -2- using bolts -1-, then tighten
to specified torque.
– Install propshaft ⇒ Propshaft and rear final drive; Rep. gr. 39 .
– Insert heat shield -2-, screw in bolts -1-, and then tighten bolts
to specified torque.
– Install downstream catalytic converter ⇒ Exhaust system;
Rep. gr. 26 ; Exhaust gas cleaning .
– Top up dual clutch gearbox oil ⇒ page 120 .
– Secure opened/removed cable ties to original position.
– Install any noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
7.4 Checking gear oil in bevel box


♦ Filling device - VAS 6291-
Bevel box is bolted to side of gearbox and has its own oil supply.
Allocation of gear oil only via ⇒ Electronic Parts Catalogue (ET‐
KA) .
Test sequence
noise insulation .
– Unscrew oil filler plug -arrow-.
Oil level is correct when bevel box is filled to lower edge of filler
hole.
– Tighten oil filler plug -arrow- to 10 Nm.
When filling with oil, note the following:
– Unscrew oil filler plug -arrow-.
– Using filling device for Haldex coupling 2 - VAS 6291- , add
enough oil so that it runs out between the adapter of the filling
device and the final drive housing.
– Tighten oil filler plug -arrow- to 10 Nm.
– If present, install noise insulation ⇒ General body repairs, ex‐
noise insulation .
7.5 Installing repair kit for stub shaft
Note
Adhere to the general repair notes for bearings and shims

⇒ page 3 .
7. Bevel box 111

♦ Thrust plate - VW401-
♦ Thrust plate - VW402-
♦ Inductive heater - VAS 6414-
♦ Press tool - VW412-

♦ Tube - 3259-
Installing deep groove ball bearings to stub shaft

– Insert retaining ring -2- into lower groove -arrow- of stub shaft
-1-.
• It must not be possible to turn the retaining ring by hand in the
annular groove of the stub shaft.
Inserting deep groove ball bearing -1- in bearing mounting -2-

– Heat bearing mounting -2- to approx. 70°C.
– Insert deep groove ball bearing -1- in bearing mounting -2-
without canting it.
• Push deep groove ball bearing -1- to stop into bearing mount‐
ing -2-.
– Insert retaining ring -3- into annular groove -arrow- of bearing
mounting -2-.
annular groove of the bearing mounting.
7. Bevel box 113

Pressing stub shaft -3- into deep groove ball bearing -2-
– Use inductive heater - VAS 6414- to heat grooved ball bearing
with bearing mounting -2- to approx. 100°C.
• The shoulder of the bearing mounting -arrow- must face to‐
wards the retaining ring -1- when pressing in.
• Align thrust plates - VW401- , -VW402- and tube - 3259- in
such a way that the stub shaft -3- does not rest against the
thrust plates when pressing in.
– Press in stub shaft -3- until it rests against retaining ring -1-.
Stub shaft with two retaining rings
Note
The second retaining ring is not installed on all stub shafts.
– Insert second retaining ring -1- into annular groove of stub

shaft in front of deep groove ball bearing -2-.
annular groove of the stub shaft.
– Install stub shaft for bevel box ⇒ page 143 .

8 Oil and oil filter

⇒ “8.1 Oil filter: renewing”, page 115
⇒ “8.2 Checking and adjusting oil level”, page 117
⇒ “8.3 Draining and filling oil”, page 120
⇒ “8.4 Installing oil level pipe”, page 124
8.1 Oil filter: renewing
Note
♦ Normally, there is no need to remove oil filter.

♦ Oil filter change “Yes or no?”: ⇒ page 3 .
♦ Drain oil first before changing oil filter ⇒ page 120 .
Removing
Procedure:
Note
♦ A residual amount of oil remains in oil filter. It runs out when

oil filter is unscrewed.
♦ Before unscrewing oil filter, cover area around oil filter with a
sufficient number of cloths.
air cooler.
– Drain oil ⇒ page 120 .
Note
Only the control lines of vehicles with front-wheel drive have to be

removed.
Vehicles with front-wheel drive:
8. Oil and oil filter 115

– Open spring-type clips -2- and pull off hoses -1-.

– Unscrew bolt -4- and remove retainer -3-.
– Unscrew bolt -5- until retainer -6- can be rotated downwards.

– Unscrew union nut -3- and remove control line -2-.
– Unclip cable at control line -5- -arrows-.
– Unscrew union nut -6- and remove control line -5-.
Continued for all vehicles:
– Unscrew filter housing -1-.

– Renew missing or damaged heat shield -2-.
Installing
Procedure:
the following:
– Thoroughly clean oily areas on gearbox.

– Insert oil filter with collar -arrow- downwards.

– Tighten filter housing.
Specified torques ⇒ page 27 .
Vehicles with front-wheel drive:
– Install control lines by fitting union nuts -3 and 6- and tightening
them hand-tight.
– Fit bolts -1- and tighten hand-tight.

– Clip cable on control line -arrows-.
– Tighten securing bolt and control lines ⇒ Exhaust system;
Rep. gr. 26 ; Assembly overview - particulate filter, vehicles
with front-wheel drive .
Continued for all vehicles:
– Install pressure hose.
– Fill with oil ⇒ page 120 .
8.2 Checking and adjusting oil level


♦ Vehicle diagnostic tester
Conditions
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed
♦ Vehicle diagnostic tester is connected.
♦ At start of work, oil temperature must not be above 45°C.
♦ Test temperature: 35 to 45°C
Procedure
– Connect vehicle diagnostic tester and identify the vehicle in
Guided functions .
– Select Dual clutch gearbox .

– Select Check oil level .

Note
If oil temperature is above 45 °C, let the gearbox cool off.
Engine is running at idling speed with selector lever in “P”.
WARNING

♦ Wear protective goggles.
♦ Wear acid-resistant gloves
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
Note
♦ Renew oil filter if oil is contaminated ⇒ page 115 .

♦ Observe the information for the oil filter change ⇒ page 3 .
– Remove oil drain plug -arrow-.
• The accumulated gear oil flows out of the oil level pipe
-arrow 2-.
Note
♦ Even if oil level is too low, a small amount of oil will initially run
out of oil level pipe because pipe fills up during operation.
♦ A small surge will emerge from oil level pipe every 30 seconds.
This emerging oil must not be taken into account when check‐
ing oil level.
– Make sure that the oil level pipe is properly secured in the hole
for the inspection plug.
Note
If the oil level pipe is loose, the gear oil level cannot be checked
precisely.
– Let surplus oil flow out. This means oil level is OK.
– Replenish oil if no oil flows out ⇒ page 123 .

– Renew oil seal -arrow- of bolt.
– After oil level check, tighten oil drain plug -arrow-

⇒ Item 28 (page 28) .
– Switch off ignition and separate diagnosis connections.
Torque settings
8.3 Draining and filling oil


♦ Vehicle diagnostic tester
♦ Adapter for oil filling - VAS 6262 A-
♦ Used oil collector and extractor - VAS 6622A-
♦ Oil spill cloth - VAS 6204/1-

♦ Safety glasses
♦ Acid-resistant protective gloves

Conditions
♦ Engine switched off
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed
♦ Selector lever at “P”
♦ Vehicle diagnostic tester is connected.
♦ At start of work, oil temperature must not be above 45 °C.
Procedure
– Comply with rules for cleanliness when working on gearbox
⇒ page 3 .
– Comply with notes on dual clutch gearbox “Disposal regula‐
tions for oils” ⇒ page 3 .
– Only gear oil available as spare part is allowed to be used for
dual clutch gearbox. Other oils will lead to malfunctions or fail‐
ure of gearbox ⇒ page 3 .
WARNING

♦ Wear protective goggles.
♦ Wear acid-resistant gloves
– Connect vehicle diagnostic tester and identify the vehicle in

Guided functions .
– Select Dual clutch gearbox .

– Select Check oil level .
Note
If the oil temperature is higher than 45°C, allow gearbox to cool

down.
WARNING
Risk of gearbox damage.

It is not permissible to start the engine if there is no oil in the
gearbox.
– Engine is off. Do not start engine!

Place used oil collection and extraction unit - VAS 6622A- below
gearbox.

– Unscrew oil drain plug -3-.

– Remove oil level pipe -1- and allow oil to run out.
– Renew seal -2-.
– Screw in oil level pipe -1- hand-tight. When doing so, observe
screw-in depth ⇒ “8.4 Installing oil level pipe”, page 124 .
– Remove oil drain plug -arrow- from mechatronic unit.
Note
A further approx. 1.2 litres of oil will run out.
– Fit new oil seal -arrow- onto oil drain plug of mechatronic unit,
screw in oil drain plug, and tighten it to specified torque
⇒ Item 25 (page 27) .
Fill with gear oil
WARNING
• Shake bottles thoroughly before opening to ensure that

sediment at the bottom of the bottle mixes well with the oil.
– Shake bottles before opening.

– Then, screw gear oil bottle onto adapter for oil filling - VAS
6262 A- .
Note
If the thread of the bottle does not fit onto the oil filling adapter -
VAS 6262 A- , use adapter - VAS 6262/6- .

– Screw adapter -A- from adapter for oil filling - VAS 6262 A-
hand-tight into inspection hole.
– Replenish gear oil and observe correct fill volume ⇒ page 9 .
Hold the bottle upside down higher than the gearbox, with hose
connected and tap open, to allow the oil to run out of the bottle
and into the gearbox.
– To change bottle, shut off tap or hold adapter for filling oil -
VAS 6262 A- higher than gearbox
– Start engine.
– Depress brake pedal and select each selector lever position
for about 3 seconds, then move lever back to »P«
– Do NOT switch off engine.
– Start engine and keep it running until gear oil temperature
reaches 40 °C.
– With engine running, disconnect quick-release coupling of
adapter for oil filling - VAS 6262 A- .
– Allow surplus oil to drain out.
– As soon as oil no longer runs out but starts to drip, unscrew
adapter for oil filling - VAS 6262 A- .
– Check oil level ⇒ page 117 .
Torque settings
8.4 Installing oil level pipe

♦ Caliper gauge, digital, 150 mm - VAS 6335-

Or
♦ Depth gauge, digital - VAS 6320-
– If installing latest oil level pipe, proceed as follows:

Note
♦ The oil level pipe comes in different lengths and colours.

♦ If the oil level pipe is renewed, it is essential that the oil level
pipe appropriate for the gearbox is installed.
♦ Do not install the oil level pipe from another gearbox! The oil
level pipe determines the oil level in the gearbox.
♦ Fitting a different oil level pipe can result in the oil level in the
gearbox being too high or too low.
♦ The oil level pipe can break between the thread and the collar.
♦ Check whether oil level pipe is seated deeply enough in its
thread. Check dimension -A-: 12.4 0.2 mm between end of oil
level pipe and support of sealing plug.
♦ Carefully turn oil level pipe further if necessary until dimension
-A- is reached.
♦ Specified torques ⇒ page 27 .

35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts.
126 Rep. gr.35 - Gears, shafts

39 – Final drive - front differential

1 Oil seals
⇒ “1.1 Assembly overview – seals”, page 127
⇒ “1.2 Renewing seal on left of gearbox”, page 128
⇒ “1.3 Renewing seal on right of gearbox, front-wheel drive vehi‐
cles”, page 130
⇒ “1.4 Renewing seal on right of gearbox, vehicles with all wheel
drive”, page 132
⇒ “1.5 Renewing small stub shaft on bevel box between manual
gearbox and bevel box”, page 135
⇒ “1.6 Renewing large stub shaft on bevel box between manual
gearbox and bevel box”, page 138
⇒ “1.7 Renewing bevel box output flange oil seal”, page 140
⇒ “1.8 Renewing seal on right of bevel box”, page 143
1.1 Assembly overview – seals
1 - Sealing ring
❑ All-wheel drive only
❑ For right stub shaft in
bevel box
2 - Sealing ring
❑ Between output flange
and propshaft
3 - Sealing ring
❑ Low
❑ For left stub shaft in bev‐
el box
4 - Sealing ring
❑ High
❑ For left stub shaft in bev‐
el box
5 - Sealing ring
❑ right
❑ On manual gearbox
❑ Renewing for front-
wheel drive
⇒ page 130
❑ Renewing for all-wheel
drive ⇒ page 132
1. Oil seals 127

6 - Sealing ring
❑ left
❑ On manual gearbox
1.2 Renewing seal on left of gearbox

Removing
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Front suspension, drive shaft; Drive shafts .
– Determine installation depth of seal, and take a note of it.
128 Rep. gr.39 - Final drive - front differential

– Grease drill bit -3- so that metal chips adhere to it.

– Drill only through sheet metal ring -1- (about 3 mm) because
gearbox may otherwise be damaged.
– Seal drive shaft aperture on transmission with a clean cloth
-2-.
– Carefully drill a hole with a drill bit -3- (diameter 2 to 4 mm) into
outer sheet metal ring -1- of oil seal.
– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled in oil seal. Do not screw in sheet metal screw too
far to avoid damaging bearing behind it.
– Pull out oil seal using puller - T10055- and adapter -
T10055/2- .
Make sure no metal chips get into gearbox and into opening for
drive shaft. Vacuum out metal chips first if necessary.
– Carefully remove cloths. When doing this, make sure that no
metal chips get into gearbox.
– Carefully clean gearbox and opening for drive shaft.
If only the sheet metal ring could be pulled out, carefully lever out
rest of seal with a screwdriver.
Installing
the following:
– Apply ATF to circumference and sealing lips of oil seal.
Installation position:
Open side of oil seal faces gearbox.
– Press oil seal in straight as far as possible by hand.
Note
Observe the installation depth of the seal.
– Drive in seal with thrust piece - T10457- . Do not cant oil seal
in the process.
– Then check oil level and top up ⇒ page 117 .
1. Oil seals 129

– Lubricate left stub shaft splines -arrow- with multi-purpose

grease .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
1.3 Renewing seal on right of gearbox, front-wheel drive vehicles

Electric drill, commercially available

Removing
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Front suspension, drive shaft; Drive shafts .
-2-.

T10055/2- .
Installing
the following:
Note
1. Oil seals 131

in the process.

grease .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
1.4 Renewing seal on right of gearbox, vehicles with all wheel drive


Electric drill, commercially available
Removing
– Remove bevel box ⇒ page 97 .
1. Oil seals 133


-2-.

T10055/2- .
Installing
the following:
Note
in the process.


grease .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
1.5 Renewing small stub shaft on bevel box between manual gearbox and bevel
box

♦ Drift sleeve - 40-20-
♦ Multi-purpose tool - VW 771-
1. Oil seals 135

♦ Plastic hammer
Removing:
Note
The oil seal between input shaft and output shaft can be renewed
only with the bevel box removed.

– Secure bevel box with M10 x 60 bolts and nuts to gearbox
support - 2004 - -arrows-.
– Drain gear oil from bevel box.
– Pull dust seal off input shaft by levering off retaining tabs
-arrow-.
Note
Always renew dust disc -A-.
– Lever off retaining ring -B- from bearing mounting -C- using 2
screwdrivers.
Note
If retaining ring -B- is not loose, slightly press on bearing mounting

-C- until retaining ring moves and can be removed. If fitted, do not
remove the snap ring -A- for the bearing -D-.
– Place component and tools in position as shown in illustration.
Note
Secure bevel box with the help of a second mechanic.

– Press output shaft -A- with bearing bracket.

– Press down seal -A- with 3 mm screwdriver.
Note
To do this, position screwdriver at different points to prevent seal

from canting.
Note
Do not damage -B- bearing.
– Turn bevel box in assembly bracket with bolting surface for

gearbox upwards.
– Pull out seal using multi-purpose tool - VW 771/1- and multi-

purpose tool - VW 771/37- .
Installing:
– Lightly oil new oil seal on outer diameter. Fill space between
sealing lips -arrow- half full with sealing grease ⇒ Electronic
parts catalogue (ETKA) .
Note
1. Oil seals 137

– Drive in seal without canting using thrust piece - T 10142- .

– Place component and tools in position as shown in illustration.
Note
– Press in output shaft and bearing mounting -A- with drift sleeve
- 40-20- until circlip can be inserted.
– Install dust seal.

– Install bevel box ⇒ page 97 .
– Check / top up gear oil in bevel box ⇒ page 110 .
1.6 Renewing large stub shaft on bevel box between manual gearbox and bevel
box


♦ Thrust piece - T10143- or thrust piece - T50049-
♦ Extractor hook - T20143-
♦ Plastic hammer
♦ Depth gauge
♦ Sealing grease ⇒ Electronic parts catalogue (ETKA)
Removing:
Note
Seal for output shaft/bevel box to manual gearbox can be re‐

newed only with bevel box removed.
1. Oil seals 139


– Turn bevel box in assembly bracket with bolting surface for
gearbox upwards.
– Lever out seal using puller hooks - T20143/2- .

Installing:
sealing lips -arrow- half full with sealing grease .
Note
– Drive in seal without canting using thrust piece - T10143- or

thrust piece - T50049- .
– Check gear oil in bevel box ⇒ page 110 .
1.7 Renewing bevel box output flange oil seal


equipment required
♦ Extractor tool - T20143- or thrust piece - T50062-

♦ KUKKO 1
♦ Circlip pliers - 0-
♦ Plastic hammer
♦ Depth gauge
♦ Sealing grease ⇒ Electronic parts catalogue (ETKA)
Removing:
Note
Always insure proper seating of tools and components throughout

the entire procedure. If necessary, ask a second mechanic for
help.
– Remove front propshaft. ⇒ Propshaft and rear final drive; Rep.

gr. 39 ; Final drive, rear differential
1. Oil seals 141

– Remove circlip ring with appropriate circlip pliers.
– Pull off output flange of bevel box using puller, e.g. KUKKO
18-1 - VAS 251 417- .
Note
When pulling off the output flange of the bevel box using the puller
- VAS 251 417- (e.g. KUKKO 18-1), make sure that the flange is
kept straight at all times to prevent damage to the dust cover
-arrow-.
– Lever out seal using puller hooks - T20143/2 - .

Installing:

Note
– Drive in seal without canting using thrust piece - T10143- or

thrust piece - T50062- .
– Install output flange / bevel box together with dust seal.
– Fit circlip.
– Install front propshaft tube ⇒ Propshaft and rear final drive;
Rep. gr. 39 ; Final drive, rear differential .
1.8 Renewing seal on right of bevel box
Note
The bevel box oil seal for the drive shaft / bevel box can only be
renewed with the bevel box removed.
1. Oil seals 143


♦ Thrust piece - T10143- or thrust piece - T50062-
♦ Assembly tool - T10214-
♦ Thrust plate - VW 402-
♦ Plastic hammer
♦ Allocate sealing grease using ⇒ Electronic parts catalogue
(ETKA) .
♦ Depth gauge
Note
Always insure proper seating of tools and components throughout

the entire procedure. If necessary, ask a second mechanic for
help.
Removing:

– Drain gear oil from bevel box.
– Pull dust seal -A- off drive shaft by levering off securing tabs
-arrow-.
Note
Always renew dust seal -A-.
– Lever off retaining ring -B- from bearing mounting -C- using 2
screwdrivers.
Note
If retaining ring -B- is not loose, slightly press on bearing mounting

-C- until retaining ring moves and can be removed. If fitted, do not
remove the snap ring -A- for the bearing -D-.
Note
– Press out stub shaft/bevel box -A- together with bearing

mounting and bearing.
1. Oil seals 145

– Lever out seal by pushing it on one side -arrow-.

– Remove seal.
Installing:
Note
– Drive in seal using thrust piece - T10143 - or thrust piece -

T50062- .
Note
– Press in stub shaft/bevel box and bearing mounting -A- with

drift sleeve - 40-20- until retaining ring can be inserted.
– Install dust seal.


7 Speed Dual Clutch Gearbox 0bt Repair Manual Eng PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

7 Speed Dual Clutch Gearbox 0bt Repair Manual Eng PDF

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

6.3 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Volkswagen Technical Site: https://vwts.ru

1.1 Safety measures when working on vehicles with a start/stop system

2.1 Gearbox identification

LZZ - Gearbox code

2 Rep. gr.00 - Technical data

3.1 General information

3.2 Rules for cleanliness

3.3 General repair instructions

A number of general notes on the individual repair procedures,

3.4 Gaskets and seals

4 Rep. gr.00 - Technical data

3.5 Nuts and bolts

4.1 Allocation gearbox - engine

Dual clutch gearbox 0BT

6 Rep. gr.00 - Technical data

Dual clutch gearbox 0BT

Dual clutch gearbox 0BT

Dual clutch gearbox 0BT

8 Rep. gr.00 - Technical data

Dual clutch gearbox 0BT

Capacity Dual clutch gearbox (DSG) 0BT

Lubricant Dual clutch gearbox oil ⇒ Electronic Parts Catalogue (ET‐

10 Rep. gr.00 - Technical data

5.1 Overview of fitting locations - electrical components

1 - Mechatronic unit for dual

1.1 Assembly overview - dual clutch

1 - Retaining ring for dual

12 Rep. gr.30 - Clutch

♦ This figure is intended only to provide an overview of the

1.2 Removing and installing clutch end cov‐

– Remove drain plug -arrow- and drain oil.

– Install drain plug -A- with new seal.

Cover can be levered out with a screwdriver.

– Only handle cover as shown in this picture.

14 Rep. gr.30 - Clutch

Cover must be free of oil and dry around centre seal.

– Guide cover horizontally and evenly over entire sleeve. This

Work carefully. Any sort of blow to the cover is certain to cause

It is possible to lever cover carefully into its seat with a

1.3 Removing dual clutch

♦ Tapered roller bearing puller - T10055-

♦ Tapered roller bearing puller - T10525-

♦ 2 x retaining pins - T10524-

16 Rep. gr.30 - Clutch

– Lever out retaining ring -2- of drive plate using screwdriver

Important! Installation location of drive plate

– Apply puller - T10525- together with puller - T10055- on

– Insert both retaining pins - T10524- , each offset by 180 de‐

Secure the retaining ring against falling. The retaining ring

– Remove retaining ring -arrow- and save it for now.

Do not dispose of the retaining ring yet because it will be needed

– Remove shim -arrow-.

18 Rep. gr.30 - Clutch

– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.

– Remove dual clutch using hooks - 3438- .

1.4 Installing dual clutch

♦ The drive plate has to remain engaged between the teeth

Special tools and workshop equipment required