8 Speed Automatic Gearbox 0d5 Eng

Service
Workshop Manual
Touareg 2018 ➤
8-speed automatic gearbox 0D5
Edition 12.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, housing
38 - Gears, control
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.
Touareg 2018 ➤
8-speed automatic gearbox 0D5 - Edition 12.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 3
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2.4 Safety precautions when working on subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Safety precautions when tow-starting or towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Assembly overview - torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Checking torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2 Assembly overview - manual release mechanism for parking lock . . . . . . . . . . . . . . . . . . 19
1.3 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.7 Removing and installing emergency release cable for parking lock . . . . . . . . . . . . . . . . . . 27
1.8 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Removing and installing tunnel cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6 ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1 Assembly overview - ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2 Removing and installing ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.3 Removing and installing ATF pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Contents i
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7 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.2 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1 ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1 Assembly overview - ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Removing and installing hydraulic impulse accumulator with accumulator solenoid N485
........................................................................ 90
1.3 Removing and installing gearbox oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.1 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1 Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2 Removing and installing O-ring on cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . 101
2 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.1 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.2 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.1 Removing and installing left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.2 Removing and installing right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5 Self-locking centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.1 Assembly overview - self-locking centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.2 Removing and installing self-locking centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.3 Renewing seal for rear splined shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.4 Renewing ball bearing for rear splined shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.5 Renewing ball bearing for centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
ii Contents
Touareg 2018 ➤
00 – Technical data
1 Identification
(VRL012566; Edition 12.2018)
⇒ “1.1 Gearbox identification”, page 1
1.1 Gearbox identification

Location of code letters on gearbox
♦ The gearbox code letters appear on the type plate at the bot‐
tom of the gearbox. Fitting location of type plate -arrow-.
Gearbox code and gearbox serial number

Example:
1- Gearbox serial number
2- BOM number
3- Gearbox designation by manufacturer: 8HP-55
4- Gearbox code, in this example: MNX
Note
♦ The gearbox code also appears on the vehicle data stickers.

♦ Fitting location of vehicle data sticker ⇒ Maintenance ; Booklet
413 .
1. Identification 1
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2 Safety information
⇒ “2.1 Safety precautions when working on the vehicle”,
page 2
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 3
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “2.4 Safety precautions when working on subframe”,
page 3
⇒ “2.5 Safety precautions when tow-starting or towing”,
page 4
2.1 Safety precautions when working on the

vehicle
To prevent personal injury and material damage to the vehicle,
observe the following:
WARNING
Risk of injury and accident by accidental engagement of gear

while engine is running.
♦ Before work is done with the engine running, shift the
gearbox to “P” position, and pull the parking brake button
to activate the electromechanical parking brake.
Risk of poisoning from exhaust gases while engine is running.
♦ While the engine is running, an exhaust gas extraction
system must be attached to the exhaust system.
Danger of injury; the radiator fans can run at any time.
♦ Disconnect electrical connectors before starting work in
the area of the radiator cowl.
To prevent personal injury and damage to or destruction of elec‐

trical and electronic components, observe the following:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
To prevent damage to the electronic components when dis‐

connecting the battery:
♦ Take the necessary measures when disconnecting the
battery.
♦ Always switch off the ignition before disconnecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
2 Rep. gr.00 - Technical data

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2.2 Safety precautions when working on ve‐

hicles with start/stop system
Observe the following when working on a vehicle with a start/stop
system:
WARNING
Injury hazard as a result of automatic engine start in vehicles

with start/stop system.
♦ In vehicles with an activated start/stop system (indicated
by a message in the dash panel insert), the engine may
start automatically if the required conditions are met.
♦ Always ensure that the start/stop system is deactivated
when working on vehicle (switch ignition off, switch ignition
on again as required).
2.3 Safety precautions when using testers

and measuring instruments during a
road test
Please note the following if test and measuring equipment is re‐
quired during a road test:
WARNING
Risk of accident due to distraction and inadequate securing of

test and measuring equipment.
Danger as a result of activation of front passenger airbag in
event of an accident.
• Operation of test and measuring equipment while driving
results in distraction.
• Greater injury hazard as a result of unsecured test and
measuring equipment.
♦ Always secure test equipment to the rear seat with a strap
and have it operated from there by a second person.
2.4 Safety precautions when working on

subframe
When working on the subframe, note the following:
Caution
Risk of damage to running gear components.

♦ The vehicle must NOT be lowered onto its wheels if the
engine/gearbox mountings, steering rack or subframe
cross brace are not properly installed.
♦ Do NOT support the vehicle at the subframe or the sub‐
frame cross brace (e.g. with a trolley jack).
2. Safety information 3
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2.5 Safety precautions when tow-starting or

towing
Caution
Danger of irreparable damage to gearbox.

♦ When towing the vehicle, the gearbox must be set to in “N”
position, or the parking lock must be released via the man‐
ual release mechanism ( ⇒ page 24 ).
♦ Do not tow for more than 50 km or faster than 50 km/h.
Note
It is not possible to tow-start the engine, e.g. if the battery is too

flat or the starter is not functioning.

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3 Repair notes
⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 General information”, page 5
⇒ “3.3 General repair instructions”, page 6
⇒ “3.4 Routing and attachment of lines”, page 8
3.1 Rules for cleanliness

♦ Before disconnecting, thoroughly clean connections and the
surrounding areas.
♦ Clean the gearbox and gearbox components using cleaning
solution - D 009 401 04- .
♦ Use commercially available, lint-free cloths for cleaning.
♦ 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 over.
Use plastic foils or lint-free cloths.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only: do not remove replacement
parts from packing until immediately before installing.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
3.2 General information

Gearbox
♦ The 8-speed automatic gearbox 0D5 is equipped with 8 hy‐
draulically actuated forward gears. These forward gears are
mechanically driven when the torque converter lock-up clutch
is closed, bridging the torque converter.
♦ A special feature of the 0D5 gearbox is that the front final drive
(front differential lock with flange shafts) is located before the
torque converter. In this way, the weight is distributed more
evenly between the front and the rear axle of the vehicle.
Torque converter
The torque converter is equipped with a slip-controlled lock-up
clutch. Thanks to the new design of this gearbox, the torque con‐
verter is located behind the front final drive.
Mechatronic unit
The mechatronic unit incorporates the following components as
a complete synchronised unit:
♦ Hydraulic control system, automatic gearbox control unit -
J217-
♦ Sensors and actuators.
The mechatronic unit is installed in the gearbox, in the area of the
ATF pan.
Automatic gearbox control unit - J217-
The control unit is part of the mechatronic unit in the gearbox.
The gear change point, which is dependent on the driving situa‐
tion and driving resistance, is determined automatically.
3. Repair notes 5
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Advantages:
♦ Gear change points controlled for enhanced fuel economy
♦ Maximum engine output is always available
♦ Individual adaptation of gear change points in all driving sit‐
uations
♦ Gear change points are infinitely variable
Gear change point variations for gradients
An additional gear change map automatically selects gear
changes for gradients. The gear changes are selected according
to accelerator pedal position and driving speed.
♦ Gear change map for extreme uphill stretches is matched to
engine output.
♦ Gear change map for extreme downhill gradients is matched
to the braking efficiency of the engine.
♦ By directly selecting a specific gear via the Tiptronic function,
the driver can also use the engine braking effect, e.g. when
towing a trailer on downhill gradients.
Selector mechanism
♦ With the “shift by wire” concept, there is no longer any me‐
chanical connection between the selector lever and the gear‐
box. Basically, “shift by wire” means that shifting is performed
completely electronically.
♦ The driver input is registered and transmitted electronically to
the gearbox without any mechanical fallback level.
♦ The selector lever does not follow the selected gear in a se‐
lector mechanism anymore but always returns to the original
(basic) position, similar to a joystick. This means that the se‐
lector lever position does not any longer correspond to the
selected gear or the operating mode.
♦ The parking lock is operated electro-hydraulically. In the event
of a fault, the parking lock can be released by operating the
emergency release mechanism so that the vehicle can be
moved ⇒ page 24 .
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.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply for this particular workshop manual.
Guided Fault Finding, vehicle self-diagnosis and test instruments
♦ Before performing repair work on the gearbox, determine the
cause of damage as precisely as possible using the operating
modes Guided Fault Finding , Vehicle Self-Diagno-
sis and Test Instruments ⇒ Vehicle diagnostic tester.
Regulations concerning oil handling, environment and disposal

♦ Be careful when handling ATF, gear oil and other oil.
♦ Dispose of drained oil according to regulations.
♦ Observe the legal environmental and disposal regulations.
♦ Always follow the instructions on the oil packaging.

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Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ Workshop equipment and special tools
Gearbox
♦ Comply with rules for cleanliness when working on gearbox
⇒ page 5 .
♦ Never run engine or tow vehicle if housing for self-locking cen‐
tre differential has been removed or if there is no ATF in
gearbox.
♦ Check fluid level after installation, and replenish fluid as re‐
quired: ATF in gearbox ⇒ page 80 and gear oil in gearbox
⇒ page 103 . Capacities ⇒ page 9 ; Specifications ⇒ Elec‐
tronic parts catalogue (ETKA) .
♦ After work on the parking lock manual release mechanism or
following removal or installation of the gearbox, the manual
release mechanism of the parking lock must be checked
⇒ page 24 .
O-rings, seals, gaskets
♦ Always renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Lightly lubricate outer circumference and sealing lip of oil seals
with ATF before installing.
♦ Coat O-rings with ATF to prevent pinching of rings during as‐
sembly.
♦ Only use ATF for automatic transmission components. Other
types of lubrication cause faults to occur in the gearbox hy‐
draulics.
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Press in new oil seals so that sealing lip does not contact the
shaft in the same place as the old seal (make use of insertion
depth tolerances).
♦ Check fluid level after installation, and replenish fluid as re‐
quired: ATF in gearbox ⇒ page 80 and gear oil in gearbox
⇒ page 103 . Capacities ⇒ page 9 ; Specifications ⇒ Elec‐
tronic parts catalogue (ETKA) .
Nuts and bolts
♦ Loosen bolts in sequence opposite to the tightening sequence.
♦ Tighten securing bolts and nuts for covers and housings in
stages, according to specified tightening sequence and pro‐
cedure.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened diagonally in stages if no tightening
sequence is specified.
♦ Renew self-locking nuts and bolts.
♦ 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- .
♦ Threaded holes into which self-locking bolts or bolts coated
with locking fluid are screwed, must be cleaned (e.g. tap).
3. Repair notes 7
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Otherwise, there is a danger that the bolts will shear off when
refitted.
♦ Specified torques given are for unoiled nuts, bolts and screws.
Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
Bearings
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Depending on fitting location, apply gear oil or ATF to bearings
before installing.
♦ Do not interchange the inner and outer races of same size
bearings.
♦ Always replace tapered roller bearings which are mounted on
a shaft together and use bearings from a single manufacturer.
Shims
♦ Use a micrometer to measure the shims at several points.
Various shim thicknesses make it possible to obtain exactly
the shim thickness required, if necessary by using 2 shims.
♦ Check for burrs and damage. Install only flawless shims.
3.4 Routing and attachment of lines

♦ To prevent interchanging and to maintain the original installa‐
tion position, mark fuel lines, vacuum lines, pipes/hoses for
activated charcoal filter system and electrical wiring etc. be‐
fore removal. Make sketches or take photographs if necessa‐
ry.
♦ To avoid damaging lines and wires, ensure adequate clear‐
ance from all moving or hot components in the engine com‐
partment on account of the confined space.

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4 Technical data
⇒ “4.1 Capacities”, page 9
⇒ “4.2 Oil distribution”, page 10
⇒ “4.3 Allocation gearbox - engine”, page 10
4.1 Capacities
⇒ “4.1.1 Capacities, ATF section in gearbox”, page 9
⇒ “4.1.2 Capacities, front final drive”, page 9
⇒ “4.1.3 Capacities, transfer box”, page 10
4.1.1 Capacities, ATF section in gearbox

Capacities Automatic gearbox 0D5
First fill by manufacturer approx. 8.6 l
Change quantity 3.6 l to 4.0 l
change quantity may vary depending on engine
Lubricant ATF for automatic gearbox 0D5
⇒ Electronic parts catalogue
Caution
Risk of malfunctions or failure of gearbox.

♦ Only the ATF ordered through the replacement part sys‐
tem can be used for the automatic gearbox 0D5 ⇒ Elec‐
tronic parts catalogue .
♦ ⇒ “7.1 Checking ATF level”, page 80

♦ ⇒ “7.2 Draining and filling ATF”, page 84
4.1.2 Capacities, front final drive

Allocation ⇒ page 10 .
Initial filling 1.0 l
Filling volume after draining in dealer approx. 0.9 l
workshop
Changing ♦ No change
♦ Filled for life; change only after repairs, e.g. when cover for front
final drive has been detached
Lubricant Gear oil for automatic gearbox 0D5

♦ ⇒ “2.1 Checking gear oil level”, page 103

♦ ⇒ “2.2 Draining and filling gear oil”, page 107
Volkswagen Technical Site: http://vwts.ru http://vwts.info
4. Technical data 9
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4.1.3 Capacities, transfer box

Allocation ⇒ page 10 .
Initial filling 1.0 l
Filling volume after draining in dealer approx. 0.8 l
workshop
Changing ♦ No change
♦ Filled for life; change only after repairs, e.g. when cover for self-
locking centre differential has been detached
Lubricant Gear oil for automatic gearbox 0D5

♦ ⇒ “2.1.2 Checking gear oil level, transfer box”, page 105

♦ ⇒ “2.2.2 Draining and filling gear oil, transfer box”, page 109
4.2 Oil distribution

Gearboxes with separate oil systems
♦ The protective tube -2- is free of oil; the transfer box -1- and
the front final drive -3- are each sealed against the side shaft.
♦ Allocation ⇒ page 10 .
4.3 Allocation gearbox - engine
4.3.1 Allocation for vehicles with a petrol engine

Engine Code on gearbox
2.0 l - 185 kW R4 SBQ
3.0 l - 250 kW V6 SBU
4.3.2 Allocation for vehicles with a diesel engine

Engine Code on gearbox
3.0 l - 170 kW V6 SBR
3.0 l - 183 - 190 kW V6 SBS, TLW
3.0 l - 210 kW V6 SBT

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5 Overview - power transmission
1 - Rear final drive

❑ Removing and installing
⇒ Rear final drive; Rep.
gr. 39 ; Final drive; Re‐
moving and installing fi‐
nal drive
2 - Propshaft
⇒ Rear final drive; Rep.
gr. 39 ; Propshaft; Re‐
moving and installing
propshaft
3 - Automatic gearbox 0D5
5. Overview - power transmission 11

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32 – Torque converter
1 Torque converter
⇒ “1.1 Assembly overview - torque converter”, page 12
⇒ “1.2 Removing and installing torque converter”, page 12
⇒ “1.3 Draining torque converter”, page 15
⇒ “1.4 Checking torque converter”, page 16
⇒ “1.5 Removing and installing torque converter oil seal”,
page 16
1.1 Assembly overview - torque converter
❑ Allocation to gearbox ⇒
Electronic parts cata‐
logue
⇒ page 12
2 - Gearbox housing
3 - Seal
❑ For torque converter
❑ Renewing ⇒ page 16
4 - O-ring
❑ Renew
5 - Bolt
❑ Qty. 6
❑ Renew
❑ Tightening procedure
⇒ page 58
❑ 60 Nm
1.2 Removing and installing torque convert‐

er
Special tools and workshop equipment required
12 Rep. gr.32 - Torque converter

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♦ Extractor - T40176-
♦ Depth gauge - VAS 6082-
♦ Grease for splines - G 000 100-

♦ Sealing grease - G 052 128 A1-
Removing
• Gearbox is removed ⇒ page 35 .
– Remove left flange shaft.
– Secure extractor - T40176- to torque converter -A- with nut
-B-.
– Turn extractor - T40176- upwards.
Note
♦ To prevent the torque converter from tilting, counterhold at the

bottom of the torque converter as shown in illustration.
♦ Disregard -arrow-.
– Pull torque converter off input shaft -arrow- without canting.

While doing so, observe vent line.
– Carefully place torque converter on a workbench or similar.
1. Torque converter 13
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Installing
Install in reverse order of removal, observing the following:
– Thoroughly clean torque converter housing (in access area to
differential -arrow A-) and seal -arrow B-.
Note
Always renew seal between differential and gearbox housing

-arrow B- if it is damaged.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
– Renew O-ring -arrow- on input shaft.

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– Check torque converter ⇒ page 16 .

– Check seal for torque converter for damage, and renew it if
necessary ⇒ page 16 .
– Secure extractor - T40176- to torque converter with nut.
– Carefully and without canting it, push torque converter with
extractor - T40176- to first stop onto input shaft -2-.
– Turn torque converter inwards using light pressure until
splines of torque converter engage in drive hub for ATF pump
and torque converter can be felt to slip in place.
Caution
Risk of damage to the drive hub for the ATF pump if the torque
converter is inserted incorrectly.
♦ Check torque converter installation dimension.
The torque converter is inserted correctly if the distance -a- be‐

tween the surface of the fastening eyelets and the surface of the
torque converter housing is as follows:
• Dimension -a- = at least 16 mm.
– Unscrew extractor - T40176- from torque converter -A-.

– Remove nut -B-.
– Install left flange shaft.
1.3 Draining torque converter

♦ Used oil collection and extraction unit - VAS 6622A-
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Procedure
If the ATF has become fouled by abrasion or when a major gear‐
box overhaul is being performed, drain the torque converter as
follows:
– Extract ATF from torque converter using used oil collection
and extraction unit - VAS 6622A- or -V.A.G 1782- .
1.4 Checking torque converter

– Check torque converter hub -arrow- for scoring.
Note
The torque converter must be renewed completely if damaged or

faulty.
1.5 Removing and installing torque convert‐

er oil seal
♦ Extractor hooks -T20143/2-
♦ Press tool - T40240-

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Procedure
– Remove torque converter ⇒ page 12 .
– Lever out torque converter seal using extractor hook -
T20143/2- .
– Apply ATF to circumference and sealing lips of oil seal.
• Installation position: open side of seal faces towards gearbox
– Using thrust piece - T40240- , drive in torque converter oil seal

to stop of thrust piece -1-.
– Install torque converter ⇒ page 12 .
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37 – Controls, housing
1 Selector mechanism
⇒ “1.1 Assembly overview - selector mechanism”, page 18
⇒ “1.2 Assembly overview - manual release mechanism for park‐
ing lock”, page 19
⇒ “1.3 Checking selector mechanism”, page 20
⇒ “1.4 Emergency release from position P”, page 24
⇒ “1.5 Removing and installing selector lever handle”,
page 25
⇒ “1.6 Removing and installing selector mechanism”, page 26
⇒ “1.7 Removing and installing emergency release cable for park‐
ing lock”, page 27
⇒ “1.8 Renewing selector shaft seal”, page 32
1.1 Assembly overview - selector mechanism
1 - Selector lever handle, up‐

per section
⇒ page 25
2 - Bolt
❑ Cannot be supplied sep‐
arately
❑ 3.2 Nm
3 - Lower section of selector
lever handle with gaiter
❑ With the following inte‐
grated components:
♦ Button for selector lever re‐
lease - E681-
♦ Parking lock button - E816-
♦ Selector lever position dis‐
play - Y5-
❑ Components cannot be
renewed individually
when defective
⇒ page 25
4 - Insert for centre console
⇒ General body repairs,
interior; Rep. gr. 68 ;
Centre console; Re‐
moving and installing
centre console
5 - Bolt
❑ 8 Nm
6 - Selector mechanism
❑ With the following integrated components:
18 Rep. gr.37 - Controls, housing

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♦ Selector lever - E313-

♦ Selector lever position sender - G727-
♦ Transverse selector lever lock sensor - G868-
♦ Selector lever sensors control unit - J587-
♦ Selector lever lock solenoid - N110-
♦ Transverse selector lever lock motor - V577-
❑ Components cannot be renewed individually when defective
❑ Removing and installing ⇒ page 26
1.2 Assembly overview - manual release mechanism for parking lock
1 - Rear emergency release

cable
❑ For parking lock
❑ Do not bend or kink
⇒ page 30
2 - Nut
❑ Qty. 2
❑ 4 Nm
3 - Cover
4 - Bolt
❑ 9 Nm
5 - Bolt
❑ Qty. 2
❑ 9 Nm
6 - Front emergency release
cable
❑ For parking lock
❑ Do not bend or kink
⇒ page 27
7 - Gearbox selector lever
❑ For manual release of
parking lock
8 - Securing clip
❑ For selector lever cable
❑ Renew
1. Selector mechanism 19
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1.3 Checking selector mechanism
WARNING
Risk of injury and accident by accidental engagement of gear

while engine is running.
♦ Before work is done with the engine running, shift the
gearbox to the “P” position, and pull the parking brake
button to activate the electromechanical parking brake.
♦ Observe safety precautions for the driving mode
⇒ page 2 .
♦ All items from the checklist must be checked.
♦ If specifications are not met, check if the selector lever
handle is installed correctly ⇒ page 25 , and perform
“Guided Fault Finding” ⇒ Vehicle diagnostic tester.
Overview:
♦ 1) Check gear locks/button function ⇒ page 21
♦ 2) Functional check of selector mechanism ⇒ page 22
♦ 3) Check selector lever position display ⇒ page 23
♦ 4) Check display in dash panel insert ⇒ page 24
♦ 5) Check parking lock ⇒ page 24

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1) Check gear locks/button function

Test step 1.1
• Engine is running, “P” position is selected, foot brake is not
operated.
– Press release button -2-, and pull selector lever towards rear:
“P” position must remain engaged.
Test step 1.2
• Engine is running, “P” position is selected, release button -2-
is not pressed.
– Operate foot brake, and pull selector lever towards rear:
“P” position must remain engaged.
Test step 1.3
• Engine is running, “P” position is selected, foot brake de‐
pressed, release button -2- pressed.
– Select “D” position:
“D” position must be indicated on selected range display - Y5-
-item 1- and in dash panel insert.
Test step 1.4
• Engine is running, “D” position is selected, release button -2-
is not pressed.
– Push selector lever forward towards “N”:
It must not be possible to move the selector gear, and the “D”
position must remain engaged.
Test step 1.5
• Engine is running, “D” position is selected, release button -2-
is pressed.
– Select “N” position:
“N” position must be indicated on selected range display - Y5-
-item 1- and in dash panel insert.
Test step 1.6
• Engine is running, “D” position is selected.
– Move selector lever towards rear:
It must be possible to select “S” position, and display in dash
panel insert must change from “D” to “S”. When selector lever
is gently pushed towards rear again, position must switch back
to “D” and displayed accordingly.
Test step 1.7
• Engine is running.
– Select “P”, “R” or “N” position.
– Move selector lever to Tiptronic gate:
It must only be possible to switch to Tiptronic gate from posi‐
tions “D” or “S”.
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2) Functional test of selector mechanism (shift lock)

Test step 2.1
• Engine is running, “D” position is selected, vehicle speed is
above 3 km/h.
– Select “N” position. Then, without pressing release button -2-
or applying the brake, select “D” position.
This must be possible.
Test step 2.2
• Engine is running, “D” position is selected, vehicle speed is
below 3 km/h.
– Select “N” position for at least 1 second, (do NOT apply brake),
and press release button -2-:
It must not be possible to switch to “R” or “D” positions.
Test step 2.3
• Engine is running, “N” position is selected, vehicle speed is
below 3 km/h.
– Depress foot brake, do NOT press release button -2-:
It must not be possible to select “R” position.
“D” gear must be selectable.
Test step 2.4
• Engine is running, “M” position is selected.
– Select “P” position by pressing P button in selector lever han‐
dle:
The “P” position must be selected and indicated on the P but‐
ton of selector lever handle as well as in the dash panel insert.
In addition, the P symbol must light up between positions “N”
and “D/S” on the selected range display - Y5- -item 1-.
The selector lever must automatically move back into the au‐
tomatic gate.
Test step 2.5
– Move selector lever towards “+” and “-”:
In driving mode, the selector lever position display in the dash
panel insert must change to the next highest or the next lowest
position, if the engine speed permits it.

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3) Check selector lever position display

Test step 3.1
– One after other, select positions “P”, “R”, “N”, “D/S” and “+/-”:
The selected position must light up significantly brighter com‐
pared to the other position symbols.
Test step 3.2
– Select “P” position by pressing button -3-:
The P symbol on the selector lever handle button must be il‐
luminated as a white function light.
The P symbol on the selected range display - Y5- -item 1- must
be illuminated as a red function light.
If any other position is selected, the P symbol must not light
up.
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4) Check display in dash panel insert

Test step 4.1
• Engine is running, “P” position is selected, foot brake is NOT
operated
– Press release button -2-, and move selector lever in direction
“D” or “R”:
In the dash panel insert, the following message must appear:
“Please operate foot brake and lock button on selector lever
to select a position”.
Test step 4.2
• Engine is running, “P” position is selected, foot brake is de‐
pressed
– Without pressing release button -2-, move selector lever in di‐
rection “D” or “R”:
“Please operate foot brake and lock button on selector lever
to select a position”.
Test step 4.3
– Press lock button while at the same time blocking the selector
lever in “M” position for over 20 seconds (not with Tip Plus or
Tip Minus):
“Move selector lever to automatic position”. In addition, an
acoustic signal must be heard.
5) Check parking lock
Test step 5.1
• Engine is running, “D”, “S”, “R” or “M” positions are selected,
vehicle is stationary.
– Switch off engine:
The “P” position must be selected automatically.
Test step 5.2
• Engine is running, “N” position is selected, vehicle is station‐
ary.
– Switch off engine, and open driver door:
Following message must appear in dash panel insert: “Select
“P” before leaving the vehicle to prevent vehicle from rolling
away”. In addition, an acoustic signal must be heard.
1.4 Emergency release from position P
Note
After work on the manual release mechanism or following removal

or installation of the gearbox, the manual release mechanism of
the parking lock must be checked.
Release
– Remove floor mat on driver side.

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– Pull off cover -1- for manual release mechanism -arrows-.
WARNING
Risk of accident due to rolling away of the vehicle.

♦ Pull parking brake button to activate the electromechani‐
cal parking brake.
– Take release tool -1- from vehicle tool kit.

– Insert release tool into mounting -2- for manual release mech‐
anism as shown in illustration.
• The release tool is positioned transverse to direction of travel.
– Turn release tool by 90° -arrow A- while simultaneously press‐
ing it down -arrow B- until it engages.
• The parking lock is released.
Note
♦ If the parking lock is released via the manual release mecha‐

nism, the “N” mode is displayed in the dash panel insert.
♦ In addition, the following message is displayed in the dash
panel insert: “Risk of vehicle rolling away! P not possible.
Please operate the parking brake”.
Reactivate parking lock

– In order to engage the parking lock, pull the release tool up‐
wards out of mounting for the manual release mechanism.
Note
When the parking lock is engaged, “P” must appear in the dash
panel insert and on the selected range display - Y5- .
1.5 Removing and installing selector lever

handle
Note
The selector lever handle is removed together with the selector

lever boot.
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♦ Torque wrench - V.A.G 1410-
Removing
• Ignition is switched off.
– Grasp upper section of selector lever handle -1- at front, and
pull if off upwards.
– Unscrew bolt -2-.
– Pull off lower section of selector lever handle upwards.
Installing
– Make sure that retaining clips -arrows- at bottom of selector
lever handle upper section -1- are seated correctly, and press
them on again if necessary.
– Push upper section of selector lever handle onto lower section
of selector lever handle.
– Clip selector lever boot to selected range display - Y5- .
– Check selector mechanism ⇒ page 20 .
Specified torques
♦ ⇒ “1.1 Assembly overview - selector mechanism”, page 18
1.6 Removing and installing selector mech‐

anism

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♦ Torque wrench - V.A.G 1410-
Removing
– Remove selector lever handle ⇒ page 25 .
– Remove insert for centre console ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Removing and installing
centre console .
– Disconnect electrical connector -1-.
– Unscrew bolts -arrows-, and detach selector mechanism -2-.
Installing
– Install insert for centre console ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Centre console; Removing and installing
centre console .
– Install selector lever handle ⇒ page 25 .
– Check selector mechanism ⇒ page 20 .
Specified torques
♦ ⇒ “1.1 Assembly overview - selector mechanism”, page 18
1.7 Removing and installing emergency re‐

lease cable for parking lock
⇒ “1.7.1 Removing and installing front emergency release cable
for parking lock”, page 27
⇒ “1.7.2 Removing and installing rear emergency release cable
for parking lock”, page 30
1.7.1 Removing and installing front emergen‐

cy release cable for parking lock
Removing
WARNING

cal parking brake.
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– Detach noise insulation (centre part and left side).

– Release fasteners -arrows A-, and shift sleeve -1- on emer‐
gency release cable in direction of -arrow B-.
– Detach rear emergency release cable from front emergency
release cable -arrow C-.
– Unscrew bolt -1-, and move aside rear emergency release ca‐
ble -2-.
Disregard nuts -arrows-.
Vehicles with 3.0l TDI engine:
– Detach screw-type clip -2- from exhaust gas recirculation pipe

-1- ⇒ 6-cyl. common rail (3.0 l, 4 V, EA 897 Gen II, turbo‐
charger); Rep. gr. 26 ; Exhaust gas recirculation; Removing
and installing exhaust gas recirculation cooler .
In order to get access to the bolts for the emergency release ca‐
ble, the exhaust gas recirculation cooler bracket must be detach‐
ed from the gearbox and pushed aside slightly.
– Unscrew bolts -arrows- from exhaust gas recirculation cooler

-3- ⇒ 6-cyl. common rail (3.0 l, 4 V, EA 897 Gen II, turbo‐
charger); Rep. gr. 26 ; Exhaust gas recirculation; Removing
and installing exhaust gas recirculation cooler .
1) Disregard items -1, 2 and 4-.

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– Move aside wiring harness -2-.

– Push exhaust gas recirculation cooler slightly to one side, and
unscrew bolts -arrows-. Detach front emergency release cable
-1- for parking lock.
Vehicles with 3.0l TFSI engine:

– Move aside wiring harness -2-. Unscrew bolts -arrows-, and
detach front emergency release cable -1- for parking lock.
– Unscrew bolts -arrows-, and detach front emergency release

cable -1- for parking lock.
Installing
– Make sure that the distance between the emergency release
cable -2- and the lever -1- is maintained.
• Dimension -a- = at least 1 mm.
• Dimension -b- = at least 1 mm.
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– Install bolt -1-, and move aside rear emergency release cable
-2-.
– Attach rear emergency release cable -2- from above to front

emergency release cable -1- -arrow A-.
– Push on sleeve -3- until it is engaged -arrow B-.
Caution
Make sure that the sleeve is securely seated.
– Check manual release mechanism of parking lock

⇒ page 24 .
Specified torques
♦ ⇒ “1.2 Assembly overview - manual release mechanism for
parking lock”, page 19
1.7.2 Removing and installing rear emergen‐

cy release cable for parking lock
Removing
WARNING

cal parking brake.

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– Move aside rear emergency release cable at bracket -1-, and

press grommet -2- inwards.
– Move driver seat to rearmost and highest position.
– Remove lower A-pillar trim and foot rest cover ⇒ General body
repairs, interior; Rep. gr. 70 ; Interior trims; Removing and
installing A-pillar trim .
– Push floor covering in driver footwell slightly upwards.
– Unscrew nuts -arrows-.

– Guide rear emergency release cable -1- inwards through hole
in centre tunnel, and detach it.
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Installing
– Carefully guide rear emergency release cable -1- through hole
in centre tunnel, and tighten nuts -arrows-.
Note
Observe torque specifications since the studs will break off oth‐
erwise.
– Attach grommet -2- in hole in centre tunnel.

• The sealing lip of the grommet must seal the hole in centre
tunnel all around.
– Attach emergency release cable to bracket -1-.
– Attach rear emergency release cable -2- from above to front

emergency release cable -1- -arrow A-.
– Push on sleeve -3- until it engages -arrow B-, and check it for
proper seating.
⇒ page 24 .
Specified torques
♦ ⇒ “1.2 Assembly overview - manual release mechanism for
parking lock”, page 19 .
♦ ⇒ General body repairs, interior; Rep. gr. 70 ; Interior trims;
Assembly overview - A-pillar trim .
1.8 Renewing selector shaft seal

Procedure
– Remove mechatronic unit ⇒ page 94 .

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– Remove cable tie -arrow- on gearbox selector lever -3-.
Caution
Please note that an engaged parking lock will make the instal‐
lation more difficult.
♦ The parking lock must therefore NOT be engaged if the
following work is to be performed. Check if the parking lock
is engaged by turning the propshaft.
♦ Position the rear splined shaft (if required after operation
of manual release mechanism) so that the parking lock is
not engaged. From here on, do not turn the propshaft any‐
more.
– Drive out hold-down pin -2- on shaft of gearbox selector lever

using pin drift -1-.
Note
When pulling off the gearbox selector lever for manual release of
the parking lock, tension is released from the return spring.
– Pull off gearbox selector lever -1- with shaft -arrow-.

– Lever out seal using a small screwdriver.
– Apply ATF to outer circumference and space between sealing
lips of new seal.
• Installation position: open side of seal faces towards gearbox
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– Position seal on gearbox housing, and press it in as far as stop

using suitable socket -arrow-.
– Insert gearbox selector lever with shaft, and at the same time
attach return spring to stop lever and to gearbox housing
-arrows-.
Note
If the operating rod for the locking pawl has slipped too far towards
the rear, it can only be pulled back forwards -arrow 1- with the
locking pawl pressed -arrow 2-.
– Drive in hold-down pin -2- on shaft of gearbox selector lever

using pin drift -1-. Observe installation position while doing so
⇒ page 101 .
– Installing mechatronic unit ⇒ page 94 .
– Fill ATF ⇒ page 80 .
⇒ page 24 .

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2 Removing and installing gearbox

⇒ “2.1 Removing gearbox”, page 35
⇒ “2.2 Installing gearbox”, page 55
⇒ “2.3 Specified torques for gearbox”, page 61
2.1 Removing gearbox

⇒ “2.1.1 Removing gearbox, vehicles with 3.0l TSI engine”, page
35
⇒ “2.1.2 Removing gearbox, vehicles with 3.0l TDI engine”, page
41
⇒ “2.1.3 Removing gearbox, vehicles with 2.0l TSI engine”, page
49
2.1.1 Removing gearbox, vehicles with 3.0l

TSI engine
♦ Engine and gearbox jack - VAS 6931-
♦ Adapter - T40058-
♦ Gearbox support - T40173-
2. Removing and installing gearbox 35

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♦ Stepladder, commercially available

Removing
– Move front wheels to straight-ahead position.
Caution

battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Remove air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Remove propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing and
installing propshaft .
– Remove subframe cross brace ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Subframe; Removing and installing subframe
cross brace .
– Remove front silencer ⇒ Rep. gr. 26 ; Exhaust pipes/silenc‐
ers; Removing and installing front silencer .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
Note
For removal of the gearbox, the engine support with engine

mounting must be reinserted in order to hold the engine in instal‐
lation position. However, the engine support and the engine
mounting are just fixed in position. For this, the old (removed)
bolts can be used.
– Reinstall engine support -1- after removal of starter. Tighten

bolts -arrows- hand-tight ⇒ Rep. gr. 10 ; Assembly mountings;
Assembly overview - assembly mountings .

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– Insert right engine mounting -1-. Tighten bolts -arrows- hand-

tight.
– Tighten bolt -arrow- for engine support on engine mounting

hand-tight.
– Remove tunnel cross member ⇒ page 65 .
– Unscrew bolts -arrows-, and detach gearbox support with

gearbox mounting -1- from gearbox ⇒ Rep. gr. 10 ; Assembly
mountings; Removing and installing gearbox mounting .
In order to be able to use the engine and gearbox jack - VAS 6931-
for the removal of the gearbox later, support the gearbox using
the support bridge - T10323- . Proceed as follows:
Required material:
♦ Support bridge - T10323-
♦ Threaded rods of puller - T10472/1- , qty. 2
♦ Nut M12, qty. 2

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– Fit M12 nuts -arrows- onto threaded rods of puller - T10472/1- .

– Screw in threaded rods into rear threaded holes for cross
member on right and left in body.
– Bolt support bridge - T10323- with 2 nuts and suitable washers
-B- to threaded rods of puller - T10472/1- . Support gearbox
-1- in installation position by turning the spindle.
– The engine and gearbox jack - VAS 6931- can now be de‐
tached using a wooden block.
– Remove left subframe shield ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Subframe; Removing and installing subframe
shield .
– Detach intermediate steering shaft from steering rack, and
push together splines ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Steering rack; Removing and installing intermediate
steering shaft .

– Unbolt gearbox oil cooling valve - N509- from gearbox
-arrows-. Do not disconnect coolant lines -1-.
Caution
Risk of damaging gearbox control unit (mechatronic unit)

through electrostatic discharge.
♦ Do not touch contacts in the gearbox connector with
hands.
– Touch gearbox housing with your hand (without gloves) to dis‐

charge any static electricity.
– Turn rotary fastener anti-clockwise -arrow- to disconnect elec‐

trical connector -1- on gearbox.
– Disconnect electrical connector -arrow-.

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– Move aside wiring harness on gearbox -arrows A-.
– Unscrew bolts -arrows-, and remove heat shield for right drive
shaft.
– If fitted, unscrew bolts -arrows-, and remove heat shield for left
drive shaft.
– Unbolt left and right drive shafts from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Remove ATF cooler ⇒ page 75 .

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– Pull off cover -1- of gearbox at bottom -arrow-.
– Counterhold crankshaft with adapter - T40058- and cranked

ring spanner to loosen torque converter bolts.
Note
Only turn crankshaft in direction of engine rotation -arrow- for

subsequent turns.
– Unscrew 6 bolts -arrow- for torque converter on drive plate

-1-. To do this, turn crankshaft further by 60° in direction of
engine rotation.
– Support engine in installation position ⇒ Rep. gr. 10 ; As‐
sembly mountings; Supporting engine in installation position .
– Remove engine/gearbox securing bolts -4 … 11-. Do not re‐

move bolt -3- yet.
Note
♦ The bolts -2 and 3- have already been removed beforehand

with the starter.
♦ -Item A- = Dowel sleeves
Caution
Risk of the ATF pan leaking.

♦ Do not apply the gearbox support - T40173- at the ATF
pan.

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– Position gearbox support - T40173- -A- at engine and gearbox

jack - VAS 6931- -B- with mounting blocks -arrows- at bottom
of gearbox, as shown in illustration.
• On left side of gearbox, position front mounting block against
gearbox housing behind aperture for torque converter.
• On right side of gearbox, position front mounting block at front
final drive.
– Secure gearbox with tensioning strap of engine and gearbox
jack.
– Detach support bridge - T10323- -A- from threaded rods of

puller - T10472/1- -B-.
– Unscrew last bolt from gearbox, and carefully press gearbox
off engine.
– Carefully lower gearbox with engine and gearbox jack - VAS
6931- .
Transporting gearbox ⇒ page 71
Secure gearbox to engine and gearbox support ⇒ page 72 .
Installing gearbox ⇒ page 55

TDI engine
♦ Coolant collecting system - VAS 5014- or drip tray for work‐
shop hoist - VAS 6208-

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♦ Tensioning strap - T10038-

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♦ Puller - T10472-
Removing
Caution

battery.

insulation .
cross brace .
– Remove front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers; Removing and installing front exhaust pipe .
Note

bolts can be used.

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tight.

hand-tight.


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– Put square wooden block -arrow- (edge length 4-5 cm) on top
of the gearbox support - T10337- . Lower gearbox by approx.
10 cm using engine and gearbox jack - VAS 6931- . This
makes it easier to remove upper coolant lines from gearbox.
Then, bring gearbox back to installation position.
– Unscrew bolts -arrows- from exhaust gas recirculation cooler

-3- ⇒ Rep. gr. 26 ; exhaust gas recirculation; Removing and
installing cooler for exhaust gas recirculation .
2) Disregard items -1, 2 and 4-.
– Unscrew upper gearbox bolt -left arrow-. It is not necessary to

detach pipe -2- for exhaust gas recirculation any further.
– Detach coolant lines from gearbox (-lower arrows-). Turbo‐

charger bolt -upper arrow- does not need to be loosened.
– Bring gearbox back to installation position again using engine
and gearbox jack - VAS 6931- .
Required material:
♦ Nut M12, qty. 2

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steering shaft .
shield .
– Pull off electrical connector -2- for gearbox oil cooling valve -
N509- -3-. Do not disconnect coolant lines -1-.
Disregard bolts -arrows-.
– Unbolt valve with bracket -3- and heat shield -1- from gearbox
-2-. To loosen bolts, exhaust gas recirculation cooler can be
pushed aside slightly.
Caution

hands.
– Touch an earthed object by hand (without gloves) to discharge

any static electricity.


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– Disconnect electrical connector -arrow-.
shaft.

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– When loosening torque converter bolts, counterhold crank‐

shaft using wrench 21 mm - T40263- and adapter -T40314- .
Caution
Risk of irreparable damage due to jumping of camshaft timing

chain.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.

engine rotation.

move bolt -3- yet.
Note

with the starter.
Caution

pan.

final drive.
jack.

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puller - T10472/1- -B-.
off engine.
6931- .

TSI engine
♦ Wrench 21 mm - T40263-
♦ Adapter - T40314-

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Removing
Caution

battery.

insulation .
cross brace .
– Remove catalytic converter ⇒ Rep. gr. 26 ; Emission control;
Removing and installing catalytic converter .
Note

bolts can be used.

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tight.

hand-tight.

Required material:
♦ Nut M12, qty. 2

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shield .
steering shaft .

– Unbolt continued coolant circulation pump - V51- from gear‐
box -arrows-. Do not disconnect coolant lines -1-.
Caution

hands.
– Touch gearbox housing with your hand (without gloves) to dis‐

charge any static electricity.

– Move aside wiring harness on gearbox.

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shaft.
– Unscrew bolts -arrows-, and remove heat shield for left drive
shaft.
– Unbolt bracket for Climatronic coolant shut-off valve - N422-

and coolant line at top of gearbox -arrows-. Disregard bolts
-magnified view-.
Coolant lines remain connected.

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Caution

chain.
-arrow-.
– When loosening torque converter bolts, counterhold crank‐


engine rotation.

move bolt -3- yet.
Note

with the starter.
Caution

pan.

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final drive.
jack.

puller - T10472/1- -B-.
off engine.
6931- .
2.2 Installing gearbox

♦ Ring spanner insert AF 16 - V.A.G 1332/14-
♦ Transportation lock - T40170-

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Procedure
Note
♦ Renew bolts that are tightened with turning further angle.

♦ Renew self-locking nuts and bolts as well as gaskets, seals
and O-rings after each removal.
♦ Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
♦ Reattach all cable ties at the same locations when reinstalling.
Specified torques for installation of gearbox ⇒ page 61 .

– Always blow out ATF cooler and ATF lines with compressed
air (10 bar max.) prior to installing exchange gearbox
⇒ page 79 .
– It is essential to clean threaded holes in cylinder block of rem‐
nants with a thread tap prior to installing.
The next illustration shows the gearbox in its installed position.
– Fit gearbox to gearbox support - T40173- as shown in illus‐
tration, and secure it with tensioning strap of engine and
gearbox jack.
Caution
Risk of irreparable damage to the ATF pump follower due to

incorrectly inserted torque converter.
♦ Check torque converter installation dimension
⇒ page 12 .
– Insert transportation lock - T40170- into gearbox housing from

below, and secure it to flange shaft -1-.

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– Check that there are dowel sleeves -A- for centring engine and
gearbox fitted in the cylinder block. Insert any missing dowel
sleeves.
– Check whether bolts for engine/gearbox connection can be
reused, and mark them if necessary ⇒ page 63 .
Note
When joining engine and gearbox, make sure that the sealing part
is seated correctly.
Note
Renew seals for catalytic converters.
– Fit gear to engine, and tighten bolts -4 and 5- to final specified

torque.
– Remove engine support - T10533/1- .
– Raise gearbox with engine and gearbox jack - VAS 6931- ,
and tighten bolts for tunnel cross member ⇒ page 64 .
– Place aside engine and gearbox jack - VAS 6931- , and secure
remaining bolts.
Vehicles with 3.0l TDI engine:

– Fit gearbox to engine while at the same time screwing in bolt
-1- for starter.
– Screw in bolts -2 … 11- by hand as far as stop.
– Tighten bolts -1 … 11-.
– Detach tensioning strap - T10038- and hook - 10-222A/20- .
– Remove engine and gearbox jack - VAS 6931- with gearbox
support - T40173- from under gearbox.

– Fit gearbox to engine while at the same time screwing in bolt
-1- for starter.
– Screw in bolts -2 … 10- by hand as far as stop.
– Tighten bolts -1 … 10-.
– Detach tensioning strap - T10038- and hook - 10-222A/20- .
– Remove engine and gearbox jack - VAS 6931- with gearbox
support - T40173- from under gearbox.

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Continued for all vehicles:
– Remove transportation lock - T40170- .
Note
The following step is necessary to ensure that the torque con‐

verter is kept straight and makes uniform contact with the drive
plate.
– Use assembly lever -1- to press torque converter -2- slightly

against drive plate -3- -arrow-.
– Bolt torque converter to drive plate as follows:

– Turn torque converter so that hole next to notch -arrow- is
visible in cut-out at bottom of gearbox housing, as shown in
illustration.
Note
There is only one notch along the circumference. Turn the torque
converter accordingly.

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– Tighten bolt -arrow- for torque converter -1- which is accessi‐

ble in this position ⇒ Item 5 (page 12) .
Note
Use the ring spanner insert AF 16 - V.A.G 1332/14- to tighten

bolts.

– Counterhold crankshaft with adapter - T40058- and cranked
ring spanner when tightening torque converter bolts.
Note
Only turn crankshaft in direction of engine rotation -arrow- for

subsequent turns.
Vehicles with 2.0l TFSI and 3.0l TDI engine:
Caution

chain.
-arrow-.
– When tightening torque converter bolts, counterhold crank‐

Continued for all vehicles:

– Turn crankshaft by 60° each time to tighten remaining 5 bolts
-arrow- for torque converter.
– Tighten remaining bolts for engine/gearbox connection.
Continue installation in reverse order of removal, observing the
following:
– If applicable, install body brace ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Suspension strut, upper suspension link;
Assembly overview - suspension strut, upper suspension link .

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– Secure support bridge - T10323- with 2 nuts to threaded rods

of puller - T10472/1- , and support gearbox by turning the
spindle -arrow-.
– Install gearbox support with gearbox mounting ⇒ Rep. gr. 10 ;
Assembly mountings; Removing and installing gearbox
mounting .
– Install tunnel cross member ⇒ page 65 .
– Install emergency release cable for parking lock ⇒ page 27 .
– Install ATF cooler ⇒ page 73 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Assembly overview - drive shaft .
– Install heat shields for drive shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft heat shield .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Tighten intermediate steering shaft to steering rack ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering rack; Removing
and installing intermediate steering shaft .
Note
The engine support and engine mounting were removed in order

to remove the starter. They were reinserted afterwards and fixed
in position in order to hold the engine in installation position during
the removal of the gearbox. To install the starter, the engine sup‐
port must be removed again. After the starter has been installed,
reinstall the gearbox support and the engine mounting.

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– Remove engine support -1- ⇒ Rep. gr. 10 ; Assembly mount‐

ings; Assembly overview - assembly mountings .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter
– Install front exhaust pipe, and align exhaust system free of
stress ⇒ Rep. gr. 26 ; Emission control; Assembly overview
- emission control .
– Install gearbox oil cooling valve - N509- ⇒ Rep. gr. 19 ; Cool‐
ant pump/thermostat assembly; Assembly overview - electric
coolant pump .
– Install coolant circulation pump - V50- ⇒ Rep. gr. 19 ; Coolant
pump/thermostat assembly; Assembly overview - electric
coolant pump .
– Install coolant pipe on right of gearbox ⇒ Rep. gr. 19 ; Coolant
pipes; Removing and installing coolant pipes .
– Install subframe shield and subframe cross brace ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe .
– Install propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing and
– Fill coolant ⇒ Rep. gr. 19 ; Cooling system/coolant; Draining
and filling coolant .
– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing or ⇒ Rep. gr. 24 ; Air filter;
Removing and installing air filter housing .
– Observe measures required after connecting battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
Caution
Danger of destroying control units through excessive voltage.

♦ Never use battery chargers for jump starting.

⇒ page 24 .
– Check ATF level and adjust as necessary ⇒ page 80 .
2.3 Specified torques for gearbox
Note
♦ The specified torques are only valid for nuts and bolts which
have been slightly greased, oiled, phosphatised or black-oxi‐
ded.
♦ Additional lubricant such as engine oil or gear oil may be used,
but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for specified torques ± 15%.
Other specified torques:

Component Nm
Bolts and nuts M6 9

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Component Nm
M7 15
M8 20
M10 40
M12 65
Torque converter ⇒ Item 5 (page 12)
Gearbox to 4-cylinder FSI engine:
Item Bolt Nm
11) M10x50 2) 65
21) M12x100 4) 30 +90°
3, 6 M12x75 4) 30 +90°
4, 5 M12x120 4) 30 +90°
7 M12x100 4) 30 +90°
8, 9 M10x40 4) 15 +90°
10 M12x50 4) 30 +90°
A Dowel sleeves for centring
• 1) Also secures starter
• 2) Property class 10.9. The steel bolt may be reused indefi‐
nitely.
• 4)Bolts must not be used more often than twice
⇒ page 63 .
Securing gearbox to 6-cylinder engine:

Item Bolt Nm
1 M10x50 1) 65
2 to 6 M12x100 2) 30 +90°
7 M12x125 30 +90°
8, 11 M10x60 2) 15 +90°
9 M10x75 2) 15 +90°
10 M10x95 2) 15 +90°
A Dowel sleeves for centring
• 1) Secures starter to gearbox. Property class 10.9. The steel
bolt may be reused indefinitely.
• 2)Aluminium bolts must not be used more often than twice
⇒ page 63 .

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♦ The aluminium bolts must not be used more often than twice.
Thus, the bolts must be marked with an “X” (2 chipping marks)
-arrow- after the first use.
♦ To avoid damaging the bolts for marking, they must not be
clamped in a vice. Insert bolt into a 14 mm socket with 1/2"-
drive which is already clamped in a vice (see illustration).
♦ Bolts marked with an “X” must bot be used again.

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3 Assembly mountings
⇒ “3.1 Assembly overview - assembly mountings”, page 64
⇒ “3.2 Removing and installing tunnel cross member”,
page 65
3.1 Assembly overview - assembly mountings
1 - Bolt
❑ 55 Nm
2 - Tunnel cross member
⇒ page 65
3 - Stop
❑ For gearbox mounting
4 - Gearbox mounting
⇒ Rep. gr. 10 ; Assem‐
bly mountings; Remov‐
ing and installing gear‐
box mounting
5 - Nut
❑ Unscrew only if gearbox
mounting needs to be
detached from gearbox
support
❑ 20 Nm
6 - Bolt
❑ 20 Nm
7 - Gearbox support
⇒ Rep. gr. 10 ; Assem‐
bly mountings; Remov‐
ing and installing gear‐
box mounting
8 - Bolt
❑ 40 Nm
9 - Bolt
❑ Unscrew only if gearbox
mounting needs to be
detached from gearbox support
❑ Renew
❑ 20 Nm +90°
10 - Nut
❑ 20 Nm

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3.2 Removing and installing tunnel cross

member
⇒ “3.2.1 Removing and installing tunnel cross member, vehicles
with 2.0l TFSI and 3.0l TFSI engine”, page 65
⇒ “3.2.2 Removing and installing tunnel cross member, vehicles
with 3.0l TDI engine”, page 67
3.2.1 Removing and installing tunnel cross

member, vehicles with 2.0l TFSI and
3.0l TFSI engine
♦ Tensioning strap - T10038-
Removing
– Remove noise insulation at rear ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
3. Assembly mountings 65
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– Unscrew bolts -arrows- for front silencer.

of the gearbox support - T10337- . Support gearbox with en‐
gine and gearbox jack - VAS 6931- .
Note
In order not to damage the propshaft heat shield, place a suitable

piece of wood -arrow- underneath as shown in illustration.
– Raise gearbox slightly.
WARNING
Risk of accident.
♦ Do not lower the engine and gearbox jack - VAS 6931-
during installation work or leave it unattended under the
vehicle.

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– Unscrew bolts -arrows- for tunnel cross member.
– Unscrew nuts -arrows-, and lower the tunnel cross member

-3- a little.
ble -2-.
– Detach tunnel cross member.
Installing
Specified torques
♦ ⇒ “3.1 Assembly overview - assembly mountings”, page 64
♦ ⇒ Rep. gr. 26 ; Emission control; Assembly overview - emis‐
sion control
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation
3.2.2 Removing and installing tunnel cross

member, vehicles with 3.0l TDI engine
♦ Engine and gearbox jack - 6931-
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Removing
– Remove noise insulation at front centre ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and
installing noise insulation .
– Unscrew bolts -arrows- for front exhaust pipe.
– Unscrew nuts -arrows-.
– Loosen screw-type clip -2-.

– Unscrew bolts -arrows-, and detach exhaust pipe -1-.

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of the gearbox support - T10337- . Support gearbox with en‐
gine and gearbox jack - VAS 6931- .
Note
In order not to damage the propshaft heat shield, place a suitable

piece of wood -arrow- underneath as shown in illustration.
WARNING
Risk of accident.
♦ Do not lower the engine and gearbox jack - VAS 6931-
during installation work or leave it unattended under the
vehicle.
– Disconnect electrical connectors -1 and 2-.

– Unscrew bolts -arrows-, and move aside electrical wiring.
– Tie up bracket with control unit for NOx sender 2 - J881- and
particulate sensor - G784- towards exhaust pipe.
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– Unscrew bolts -arrows- for tunnel cross member.
– Unscrew nuts -arrows-, and lower the tunnel cross member

-3- a little.
ble -2-.
– Detach tunnel cross member.
Installing
– Install bracket for control unit for NOx sender 2 - J881- and
particulate sensor - G784- ⇒ Rep. gr. 23 ; Lambda probe;
Assembly overview - lambda probe .
Specified torques
♦ ⇒ “3.1 Assembly overview - assembly mountings”, page 64
♦ ⇒ Rep. gr. 26 ; Exhaust gas recirculation; Assembly overview
- exhaust gas recirculation

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4 Transporting gearbox
♦ Hook and support tool - 3311- with bolt -3311/1-
♦ Workshop hoist - VAS 6100-
Procedure
• Gearbox is removed ⇒ page 35 .
Caution
Risk of irreparable damage to gearbox components due to in‐

correct setting down of the gearbox.
♦ The gearbox must not be set down on the ATF cooler or
the ATF pan.
WARNING
Risk of accident due to inadequate securing of the gearbox.

♦ Renew the bolt of the hook and support tool - 3311- with
a new and longer bolt -3311/1- .
♦ This is the only way to make sure that the gearbox is prop‐
erly secured.
– Secure gearbox to hook and support tool - 3311- (use new,

longer bolt -3311/1- ).
– Use workshop hoist - VAS 6100- to raise and transport the
gearbox.
4. Transporting gearbox 71
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5 Securing to engine and gearbox sup‐

port
♦ Support plate - VW 309-
♦ Engine and gearbox support - VAS 6095-
Procedure
• Gearbox is on workshop hoist - VAS 6100- ⇒ page 71 .
– Bolt support plate - VW 309- to hook and support tool - 3311- .
– Using workshop hoist - VAS 6100- , insert gearbox into engine
and gearbox support - VAS 6095- .
Note
If the filled gearbox is to be turned on the engine and gearbox

support with the ATF pan facing upwards, the breathers for the
gearbox housing and final drive must be sealed.

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6 ATF circuit
⇒ “6.1 Assembly overview - ATF circuit”, page 73
⇒ “6.2 Removing and installing ATF cooler”, page 75
⇒ “6.3 Removing and installing ATF pipes”, page 77
6.1 Assembly overview - ATF circuit
Caution
Risk of damage to gearbox.

♦ Remove all plugs from ATF lines and from gearbox that
have been fitted during removal.
♦ If any of these plugs remain inserted, ATF cooling will fail
resulting in damage to the gearbox.
ATF cooler, ATF lines
1 - ATF line
❑ With or without retainer
❑ Cleaning ⇒ page 79
❑ Insert to stop by hand
with new O-ring
2 - O-ring
❑ If leaking, renew ATF
line
❑ Apply ATF before insert‐
ing
3 - ATF cooler
⇒ page 75
4 - Bolt
❑ Qty. 3
❑ 8 Nm
5 - O-ring
line
ing
6 - O-ring
line
ing
7 - ATF line
❑ Cleaning ⇒ page 79
❑ Insert to stop by hand
with new O-ring
8 - Retainer
9 - Bolt
❑ 20 Nm
6. ATF circuit 73
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10 - O-ring
❑ If leaking, renew ATF line
❑ Apply ATF before inserting
11 - Bolt
❑ Only for ATF line with retainer
❑ 20 Nm
Disconnecting ATF line

– Release retaining clip -1- at plug-in connector -2- -arrows B-,
and raise -arrow A-.
– Pull off plug-in connector.
Drain and sealing plugs
1 - ATF drain plug

❑ Tighten as far as stop
2 - O-ring
❑ Renew after removal
3 - Drain plug
❑ For gear oil in transfer
box
❑ Renew
❑ 12 Nm
4 - Plug
❑ For inspection and filler
hole
box
❑ Renew
❑ 27 Nm
5 - Plug
❑ For ATF inspection and
filler hole
❑ Renew
❑ 30 Nm
6 - Plug
hole
❑ For gear oil in front final
drive
❑ 27 Nm
7 - Drain plug
❑ For gear oil in front final
drive

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❑ 10 Nm
Measure length of breather pipe attached to adapter for filling oil

- VAS 6262 A- and shorten as necessary.
In order to ensure that the breather pipe of the -VAS 6262 A-
adapter for oil filling does not touch the bottom of some oil bottles,
the pipe must be shortened to the length -a-.
• Dimension -a- = 210 mm.
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling -VAS 6262 A- .
– Mark dimension on the breather pipe and shorten pipe with

pipe cutter -6056/2- .
– Clean adapter for filling oil - VAS 6262 A- .
6.2 Removing and installing ATF cooler

♦ Hose clamps, up to Ø 25 mm - 3094-
♦ Hose clip pliers - VAS 6362-
6. ATF circuit 75
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Removing
cross brace .
Caution

– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.

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– Disconnect ATF lines -1- and -4- ⇒ page 74 .
Note
♦ On a warm engine, the cooling system is under high pressure.

♦ Before pulling off the coolant hoses, cover the cap on the
coolant expansion tank with a cloth and open carefully.
♦ Lay a cloth under the coupling point to catch escaping coolant.
– Clamp off coolant hoses using hose clamps, up to Ø 25 mm -

3094- . Loosen hose clips -2 and 3-, and pull coolant hoses off
ATF cooler.
– Unscrew bolts -arrows-, and detach ATF cooler.
Installing
Note
Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
• Leaking ATF lines must be renewed.

• Renew securing clips that are bent or stretched excessively.
• Securing clips must be seated securely.
– Check ATF level ⇒ page 80 .
Specified torques
♦ ⇒ “6.1 Assembly overview - ATF circuit”, page 73 .
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview - subframe
6.3 Removing and installing ATF pipes

♦ Hose, approx. ∅ 18 mm
♦ Compressed air gun, commercially available
♦ Safety goggles
6. ATF circuit 77
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Removing and installing
Note
♦ General repair instructions ⇒ page 6 .

♦ Comply with rules for cleanliness ⇒ page 5 .
♦ Seal open lines and connections with clean plugs from engine
bung set - VAS 6122- .
♦ Renew O-rings after removal.
♦ Check ATF level after removal and installation of ATF lines
⇒ page 80 .
– Remove noise insulation at centre or at rear ⇒ General body

repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and
– Disconnect ATF lines -arrows- ⇒ page 74 .

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– Unscrew bolts -arrows-. (Note various versions).
Caution

♦ Remove all plugs from ATF lines and from gearbox that
have been fitted during removal.
♦ If any of these plugs remain inserted, ATF cooling will fail
resulting in damage to the gearbox.
Cleaning
Note
⇒ “3.1 Rules for cleanliness”, page 5 .
– Always blow out ATF cooler and ATF lines with compressed
air (10 bar max.) prior to installing exchange gearbox.
low gearbox.
Note
If excessively soiled ATF is coming out when blowing out, also

flush ATF cooler and ATF lines with clean ATF.
Specified torques
♦ ⇒ Rep. gr. 19 ; Coolant pump/thermostat assembly; Assem‐
bly overview - electric coolant pump
6. ATF circuit 79
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7 ATF
⇒ “7.1 Checking ATF level”, page 80
⇒ “7.2 Draining and filling ATF”, page 84
7.1 Checking ATF level

♦ Vehicle diagnostic tester
♦ Adapter for oil filling - VAS 6262 A-
♦ Adapter swivel hose - VAS 6262/5-

♦ Adapter - VAS 6262/6- , if necessary
♦ Original 1 l oil container for ATF

♦ Safety goggles
♦ Acid-resistant protective gloves
Test prerequisites
• Gearbox must not be in emergency running mode.

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• Vehicle must be placed on a 4-pillar lifting platform or above

an inspection pit to make sure it is absolutely horizontal.
• Parking brake button must be pulled to apply electromechan‐
ical parking brake.
• Extraction hose/extraction hoses of a switched-on exhaust
gas extraction system must be connected.
• Air conditioning system and heater switched off.
• Vehicle diagnostic tester connected.
• At start of test, ATF temperature must not be above 30℃. If
this temperature is exceeded, the gearbox must cool off first.
Note
♦ The ATF temperature is read on vehicle diagnosis tester .

♦ The ATF level is affected by the ATF temperature.
♦ Checking the ATF level when the ATF temperature is too low
leads to overfilling.
♦ Checking the ATF level when the ATF temperature is too high
leads to underfilling.
♦ Both an excessive and an insufficient ATF level affects the
function of the gearbox.
Determining the ATF temperature

– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select Guided Functions .
– Press Select own test , and select the following menu items
one after the other:
♦ Transmission
♦ 0D5 gearbox
♦ 01 - Systems capable of self-diagnosis
♦ 02 - Gearbox electronics
♦ 02 - Gearbox electronics, functions
♦ 02 - Measured values
– Select measured value “gear oil temperature” from list.
– Read the ATF temperature.
• Specification: max. 30°C.
Checking and correcting ATF level
Note
♦ The ATF level can be checked at the ATF inspection and filler
hole.
♦ The ATF level is correct if small amount of fluid comes out at
the ATF inspection and filler hole at an ATF temperature of 40°
C (due to the increased ATF level at higher temperatures).
♦ Renew plug for ATF inspection and filler hole.
7. ATF 81
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Caution

tem can be used for the automatic gearbox 0D5.
♦ Other oils will lead to malfunctions or failure of the gear‐
box.
♦ Note allocation ⇒ Electronic parts catalogue .
♦ The adapter for ATF filling unit must be clean, and the ATF
must not be mixed with other sorts of ATF!
– Secure oil container with adapter for oil filling - VAS 6262 A-
as high as possible on vehicle; ATF specifications ⇒ Elec‐
Caution

♦ The engine must not be started if there is no or very little
ATF in the gearbox following a repair or after heavy loss
of ATF.
♦ In this case, prefill with ATF ⇒ page 84 .

– Start engine with “P” position selected.
– Switch off ESP.
– To fill torque converter, run engine at 2000 rpm for 30 seconds
with “P” position selected.
– With brake pressed, shift to “P” and then to “D/S” position for
10 seconds each.
– Shift selector lever to “P” position.
– Continue running the engine at idling speed.
low gearbox.
WARNING
Risk of eye injury.

♦ Wear safety goggles.

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– Unscrew plug for ATF inspection and filler hole -arrow B-, and
drain any excessive ATF.
• ATF level is OK if ATF is emerging from inspection and filler
hole -arrow B- before ATF temperature of 40°C has been
reached.
• If no ATF comes out of ATF inspection and filler hole before
ATF temperature of 40°C has been reached, add ATF
⇒ page 83 .
Note
At 40°C at the latest, the ATF inspection and filler hole must be
closed again.
– Tighten new plug for ATF inspection and filler hole. This con‐
cludes the ATF check.
Topping up ATF
• If no ATF comes out at ATF inspection and filler hole
-arrow B- at 40°C:
Note
The ATF inspection and filler hole must be closed at 45°C. If re‐
quired, repeat the check after switching off engine and allowing
the gearbox to cool down.
– Insert adapter for ATF oil filling - VAS 6262/5- into ATF in‐
spection and filler hole -arrow-.
– Pour in ATF through adapter until ATF runs out of inspection
and filler hole.
Note
An insufficient ATF filling as well as excessive filling affects the

function of the gearbox.
7. ATF 83
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– Tighten new plug for ATF inspection and filler hole -arrow B-.
This concludes the ATF check.
Specified torques
♦ ⇒ page 74
7.2 Draining and filling ATF

♦ Adapter for oil filling - VAS 6262 A-
♦ Adapter swivel hose - VAS 6262/5-

♦ Adapter - VAS 6262/6- , if necessary
♦ Original 1 l oil container

♦ Safety goggles

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♦ Acid-resistant protective gloves

Draining
Note
♦ To drain ATF, the gearbox must be warm. However, the en‐

gine must not be started if there is too little or no ATF in the
gearbox.
♦ Observe disposal regulations.
• Engine not running.

• Gearbox is in “P” position.
ical parking brake.
7. ATF 85
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low gearbox.
WARNING
Risk of eye injury.

– Open ATF drain plug -arrow A-, and drain ATF.
Caution

♦ The engine must not be started when there is no ATF left
in the gearbox.
– Tighten drain plug -arrow A- to stop.

Adding ATF
Caution

tem can be used for the automatic gearbox 0D5.
♦ Other oils will lead to malfunctions or failure of the gear‐
box.
♦ Allocation ⇒ Electronic parts catalogue .
♦ The adapter for ATF filling unit must be clean, and the ATF
must not be mixed with other sorts of ATF!
– Secure oil container with adapter for oil filling - VAS 6262 A-
as high as possible on vehicle; ATF specifications ⇒ Elec‐
– Tighten plug for ATF inspection and filler hole arrow -B-.

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– Insert adapter for ATF oil filling - VAS 6262/5- into ATF in‐
spection and filler hole -arrow-.
– Pour in ATF through adapter until ATF runs out of inspection
and filler hole.
– Start engine with “P” position selected.
– Continue filling ATF through adapter until ATF starts running
out of inspection and filler hole.
– Tighten old plug for ATF inspection and filler hole hand-tight.
– Check and adjust ATF level ⇒ page 80 .
Note
Make sure to follow the instructions and observe the test require‐
ments specified for “Checking and adjusting ATF level” without
fail.
Specified torques
♦ ⇒ page 74
7. ATF 87
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38 – Gears, control
1 ATF system
⇒ “1.1 Assembly overview - ATF system”, page 88
⇒ “1.2 Removing and installing hydraulic impulse accumulator
with accumulator solenoid N485 ”, page 90
⇒ “1.3 Removing and installing gearbox oil pan”, page 92
1.1 Assembly overview - ATF system
Note
Apply ATF to O-rings and seals. Other lubricants lead to malfunctioning of the gearbox hydraulics.
1 - ATF pan
❑ With integrated ATF fil‐
ter
⇒ page 92
2 - Seal
3 - O-ring
4 - Bolt
❑ Specified torque and
tightening sequence
⇒ page 89
5 - Mechatronic unit
⇒ page 94
6 - O-ring
7 - ATF pipe
8 - Connector housing
9 - Bolt
❑ 5.5 Nm
10 - Seals
❑ Renew together with
connector housing
⇒ Item 8 (page 88)
11 - O-rings
❑ Renew together with ATF pipe ⇒ Item 7 (page 88)
12 - Hydraulic impulse accumulator with accumulator solenoid - N485-
88 Rep. gr.38 - Gears, control

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13 - O-ring
❑ Renew
❑ For hydraulic impulse accumulator connection
14 - Bolt
❑ Specified torque and tightening sequence ⇒ page 90
15 - Bolt
❑ Specified torque and tightening sequence ⇒ page 89
16 - ATF drain plug
❑ Tighten as far as stop
17 - O-ring
ATF pan - specified torque and tightening sequence
Note
♦ Renew bolts that are tightened with turning further angle.

♦ Observe assembly instructions
⇒ “1.3 Removing and installing gearbox oil pan”, page 92
– Tighten bolts in 3 stages in the sequence shown:

Stage Bolts Specified torque/turning further angle
1 -1 … 12- Screw in new bolts by hand until bolt
heads make contact
2 -1 … 12- 4 Nm
3 -1 … 12- Turn 45° further
Specified torque and tightening sequence for mechatronic unit

– Tighten bolts for mechatronic unit in the sequence -1 … 18- to
10 Nm.
– Install hydraulic impulse accumulator -A- ⇒ page 90 .
1. ATF system 89
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Hydraulic impulse accumulator - specified torque and tightening

sequence
Note
Renew bolts after removing.
– Tighten bolts in the sequence -1 … 3- to 10 Nm.
1.2 Removing and installing hydraulic im‐

pulse accumulator with accumulator sol‐
enoid - N485-
Note

Removing
• Gearbox is installed.
Caution

♦ The engine must not be started when there is no ATF in
the gearbox and the mechanic unit is removed.
– Shift selector lever to position “P”.

– Switch off ignition.
– Remove ATF sump ⇒ page 92 .

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Caution

♦ Before handling electrical connector, the person handling
it must “electrostatically discharge” himself/herself. To do
so, briefly touch e.g. an earth connection, a radiator in the
workshop or a lifting platform with the hand.
hands.
– Carefully pull off electrical connector -B- to hydraulic impulse

accumulator -A-.
– Unscrew bolts in sequence -3 to 1-.
– Pull off hydraulic impulse accumulator.
Installing
Note
♦ Renew O-ring and bolts for hydraulic impulse accumulator.

♦ New impulse accumulators are supplied with an additional
bracket. The bracket is located at position -3- and is not re‐
quired.
– Before installing new impulse accumulator, remove and dis‐

pose of bracket.
– Insert hydraulic impulse accumulator -A- with new O-ring -D-.
– Tighten bolts in the sequence -1 … 3-.
– Carefully pull off electrical connector -B- to hydraulic impulse
accumulator.
Note
Ensure that connector is properly engaged and secured.
– Route and fix position of electrical wire -C- as shown in illus‐

tration -arrows-.
– Install ATF sump ⇒ page 92 .
Specified torques
♦ ⇒ “1.1 Assembly overview - ATF system”, page 88
1. ATF system 91
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1.3 Removing and installing gearbox oil pan

Removing
Note


cross brace .
Caution

– Remove gearbox support with gearbox mounting ⇒ Rep. gr.

10 ; Assembly mountings; Removing and installing gearbox
mounting .
– Drain ATF ⇒ page 84 .
– Move aside electrical wiring -arrows-.

– Unscrew bolts for ATF pan in the sequence -12 … 1-.
– Remove ATF pan.

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Installing
Note
Use the entire repair kit when installing.
– Clean solenoids -arrows-.

– Thoroughly clean sealing surface.
– Screw in bolts -1 and 2- by hand until bolt heads make contact.

– Tighten bolts in the specified tightening sequence.
Specified torques
♦ ⇒ Fig. ““ATF pan - specified torque and tightening sequence”“ ,
page 89
♦ ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview -
assembly mountings
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview - subframe
1. ATF system 93
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2 Mechatronic unit
⇒ “2.1 Removing and installing mechatronic unit”, page 94
2.1 Removing and installing mechatronic

unit
♦ Guide pin - T40199-
Removing
Note

♦ Always renew a mechatronic unit which is fouled or defective.
Caution

♦ The engine must not be started when there is no ATF in
the gearbox and the mechanic unit is removed.
– Shift selector lever to position “P”.

– Switch off ignition.
Caution

hands.

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– Disconnect electrical connector on gearbox -1-. To do so, pull

off connector -2- at rear, and turn rotary fastener -3- at front of
gearbox anti-clockwise.
– Remove ATF sump ⇒ page 92 .

– Turn connector housing -2- anti-clockwise -arrow-, and pull it
off.
Note
♦ For better accessibility, position gearbox selector lever -3- for

manual release of parking lock vertically, and fix it in that po‐
sition with a cable tie -arrow-. This makes it easier to attach
the selector slide -1- to the claw -2- of the manual release
mechanism during installation.
♦ The illustration shows installation position on a vehicle with
3.0l TFSI engine.
2. Mechatronic unit 95
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Caution
Risk of damaging mechatronic unit.

♦ Only the bolts with Torx T40 heads may be loosened.
♦ Loosening other bolts may affect the operation of the me‐
chatronic unit, or the mechatronic unit could split.
– Remove hydraulic impulse accumulator ⇒ page 90 .

– Unscrew bolts in sequence -18 to 2-.
Note
Do not yet remove bolt -1-.
– Screw in the 4 guide pins - T40199- hand-tight into holes

-5, 7, 12, 14-.
– Pull off mechatronic unit.
Caution
Risk of damaging senders on backside of mechatronic unit.

♦ Only lay down mechatronic unit with bolt head side facing
downwards.
Installing
Note
Use the entire repair kit when installing.
– Insert new O-rings -1- and -3- in grooves of oil pipes.

– Insert ATF pipe -2- into mechatronic unit.
– Check oil pipes for damage, and make sure they are seated
securely in mechatronic unit.
– If not yet fitted, screw in 4 guide pins - T40199- hand-tight as

shown in illustration.

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Note
♦ The guide pins - T40199- keep the mechatronic unit straight

during installation. This ensures that the ATF lines on the
backside of the mechatronic unit are not being damaged.
♦ Due to the spring clip on its rear side, the mechatronic unit
cannot be fitted flush against the gearbox housing all around.
♦ Thus, the aid of a 2nd mechanic is recommended when in‐
stalling the mechatronic unit with gearbox installed.
• Gearbox selector lever -3- is fixed in vertical position with a

cable tie -arrow-.
– Position mechatronic unit on gearbox housing.

• Claw -2- of manual release mechanism must engage behind
pin in selector slide -1- -arrow-.
2. Mechatronic unit 97
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– Screw in bolts -1 to 4- by hand until bolt heads make contact.

– Unscrew the 4 guide pins - T40199- .
– Tighten bolts for mechatronic unit in prescribed tightening se‐
quence ⇒ page 89 .
– Install hydraulic impulse accumulator ⇒ page 90 .
Continue assembly in reverse order of removal, observing the

following:
Caution

hands.
– Insert new connector housing -2- with lug facing downwards,

and turn it clockwise against direction of arrow to engage.
– Ensure that connector is properly engaged and secured.
– Tighten bolt -1-.
– Remove cable ties -arrow-.

– Install ATF sump ⇒ page 92 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Specified torques
♦ ⇒ “1.1 Assembly overview - ATF system”, page 88

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39 – Final drive - front differential

1 Final drive
⇒ “1.1 Assembly overview - final drive”, page 99
⇒ “1.2 Removing and installing O-ring on cover for front final
drive”, page 101
1.1 Assembly overview - final drive
❑ Assembly overview
⇒ page 12
2 - Seal
❑ For torque converter
⇒ page 16
3 - Seal
❑ For left flange shaft
❑ Between final drive and
gearbox housing
4 - Shim
❑ Behind tapered roller
bearing outer race
5 - Retainer
❑ For solenoid
6 - Bolt
❑ 6 Nm
7 - Solenoid
❑ Clean if necessary
8 - Tapered roller bearing outer
race
9 - Bolt
❑ Different versions; for
allocation refer to ⇒
Electronic parts cata‐
logue
tightening sequence
⇒ page 100
10 - Seal
❑ For right flange shaft
11 - Right flange shaft
12 - Retaining ring
❑ Renew
13 - Plug
❑ For inspection and filler hole
1. Final drive 99
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❑ For gear oil in front final drive
❑ Specified torque ⇒ page 74
14 - Cover
❑ For front final drive
❑ Bear in mind dowel sleeves
15 - Shim
❑ Behind tapered roller bearing outer race
16 - Tapered roller bearing outer race
17 - O-ring
❑ On cover for front final drive
18 - Differential
19 - Gearbox
20 - Hold-down pin
❑ Installation position ⇒ page 101
21 - Parking lock lever
22 - Seal
❑ For parking lock shaft
23 - Bearing plate
❑ Secured to left flange shaft together with bearing ⇒ Item 26 (page 100) and retaining ring
⇒ Item 27 (page 100)
❑ The entire assembly is referred to as mounting bracket for left flange shaft
24 - Left flange shaft
25 - Bolt
❑ Renew
❑ 9 Nm +60°
26 - Bearings
❑ For left flange shaft
27 - Locking element
❑ For left flange shaft bearing
Front final drive cover - specified torque and tightening sequence

– Tighten bolts in stages in the specified sequence:
Stage Bolts Specified torque
1 -1, 2- 5 Nm
2 -3, 4, 6- 35 Nm
3 -1, 7, 2, 8- 35 Nm
4 -9, 10, 11- 47 Nm
100 Rep. gr.39 - Final drive - front differential

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Installation position of hold-down pin

– Drive in new hold-down pin -1- with narrow end leading
-arrow- until it is flush.
1.2 Removing and installing O-ring on cover

for front final drive
Procedure
Note

– Drain gear oil from front final drive ⇒ page 107 .

– Remove right flange shaft ⇒ page 119 .
– Unscrew bolts for front final drive cover in the sequence
-11 … 1-.
– Detach cover for front final drive together with tapered roller
bearing outer race and shim.
Note
Thickness of shim is calibrated; the shim must not be replaced

with another shim of different thickness.
– Renew O-ring -arrow-.

– Insert differential in gearbox housing.
If tapered roller bearing outer race and shim fell out of cover for
front final drive:
– Moisten shim and outer race for tapered roller bearing with
gear oil, and insert in cover for front final drive as far as stop.
1. Final drive 101

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– Tighten bolts for front final drive cover.

– Install right flange shaft ⇒ page 119 .
– After having finished repair work, fill gear oil in front final drive
⇒ page 107 .
Specified torques
♦ ⇒ Fig. ““Front final drive cover - specified torque and tightening
sequence”“ , page 100

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2 Gear oil
⇒ “2.1 Checking gear oil level”, page 103
⇒ “2.2 Draining and filling gear oil”, page 107
2.1 Checking gear oil level

⇒ “2.1.1 Checking gear oil level, front final drive”, page 103
⇒ “2.1.2 Checking gear oil level, transfer box”, page 105
2.1.1 Checking gear oil level, front final drive

♦ Hand pump for gear oil - VAS 6617-
♦ Safety goggles
Procedure
• Gear oil temperature approx. 20 °C (room temperature).
ical parking brake.
2. Gear oil 103

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Note

♦ Adhere exactly to the prescribed oil level; the gearbox reacts
very sensitively to over filling.
♦ Renew plug for inspection and filler hole.

insulation .
♦ A4/A5 noise insulation at rear
♦ Q5 noise insulation in centre
low gearbox.
Note
Place several cloths onto the subframe cross brace to collect es‐
caping gear oil.
WARNING
Risk of eye injury.

– Unscrew plug for inspection and filler hole -arrow A- on front

final drive.
• Specification: the oil level is correct when the front final drive
is filled to the lower edge of the inspection and filler hole.
– Allow excessive gear oil to run out.
If the oil level in the front final drive is not as high as the lower
edge of oil inspection and filler hole:
– Screw in adapter -VAS 6617/6- with adapter -VAS 6617/2-
hand-tight into inspection and filler hole for front final drive.
– Connect hand pump for gear oil - VAS 6617- , and fill front final
drive with gear oil.
• Gear oil specifications ⇒ Electronic parts catalogue (ETKA) .
– Then, detach -VAS 6617/6- from gearbox, and let excessive
gear oil drain off.

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– Tighten new plug -arrow A- on front final drive.

– Remove cloths from subframe cross brace.
Specified torques
♦ Drain and sealing plugs ⇒ page 74
2.1.2 Checking gear oil level, transfer box

♦ Safety goggles
Procedure
ical parking brake.
• The gearbox must be stationary for at least 15 minutes to allow
the oil level to stabilise.
2. Gear oil 105

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Note

low gearbox.
Note
Place several cloths onto the tunnel cross member in order to

collect escaping gear oil.
WARNING
Risk of eye injury.

– Unscrew plug for inspection and filler hole -arrow A- on hous‐

ing for self-locking centre differential.
• Specification: the oil level is correct when the transfer box is
filled to the lower edge of the inspection and filler hole.
– Allow excessive gear oil to run out.
If the oil level in the transfer box is not as high as the lower edge
of oil inspection and filler hole:
hand-tight into inspection and filler hole for transfer box.
– Connect hand pump for gear oil - VAS 6617- , and fill transfer
box with gear oil.
– Wait 5 minutes.
Note
♦ The transfer box incorporates a number of internal oil cham‐

bers. These must be filled evenly.
♦ The waiting time of at least 5 minutes is necessary so that the
internal oil level can be balanced out between the self-locking
centre differential and the baffle chamber.

gear oil drain off.

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– Tighten new plug -arrow A- on housing for self-locking centre

differential.
– Remove cloths from tunnel cross member.
Specified torques
2.2 Draining and filling gear oil

⇒ “2.2.1 Draining and filling gear oil, front final drive”, page 107
⇒ “2.2.2 Draining and filling gear oil, transfer box”, page 109
2.2.1 Draining and filling gear oil, front final

drive
♦ Safety goggles
Draining
ical parking brake.
2. Gear oil 107

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Note

♦ Renew drain plug with seal.

insulation .
♦ A4/A5 noise insulation at rear
♦ Q5 noise insulation in centre
low gearbox.
WARNING
Risk of eye injury.

– Unscrew drain plug -arrow B- on front final drive, and drain off
gear oil.
Caution

♦ The engine must not be started when there is no gear oil
left in the front final drive.
– Tighten new plug -arrow B- on front final drive.

Filling and adjusting
low gearbox.
WARNING
Risk of eye injury.

– Unscrew plug for inspection and filler hole -arrow A- on front

final drive.

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hand-tight into inspection and filler hole for front final drive.
– Connect hand pump for gear oil - VAS 6617- , and fill front final
drive with approx. 1 l of gear oil.
– Wait 5 minutes.
Note
The waiting time of at least 5 minutes is necessary so that the

internal oil level can be balanced out between the differential and
the baffle chamber.

gear oil drain off.
– Tighten new plug -arrow A- on front final drive.
Note
The level does not need to be re-checked after this step.
– Thoroughly clean subframe cross brace.

Specified torques
2.2.2 Draining and filling gear oil, transfer box

2. Gear oil 109

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♦ Safety goggles
Draining
ical parking brake.
Note

♦ Renew drain plug with seal.

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low gearbox.
WARNING
Risk of eye injury.

– Unscrew drain plug -arrow B-, and drain off gear oil.
Caution

♦ The engine must not be started when there is no gear oil
left in the transfer box.
– Tighten new drain plug -arrow B-.

– Install tunnel cross member ⇒ page 65 .
Filling and adjusting
low gearbox.
WARNING
Risk of eye injury.

– Unscrew plug for inspection and filler hole -arrow A- on hous‐

ing for self-locking centre differential.

hand-tight into inspection and filler hole for transfer box.
– Connect hand pump for gear oil - VAS 6617- , and fill transfer
box with approx. 1 l of gear oil.
– Wait 5 minutes.
Note
♦ The transfer box incorporates a number of internal oil cham‐

bers. These must be filled evenly.
♦ The waiting time of at least 5 minutes is necessary so that the
internal oil level can be balanced out between the self-locking
centre differential and the baffle chamber.

gear oil drain off.
• Specification: oil level is correct when transfer box is filled to
lower edge of oil filler hole. Fill more gear oil if necessary.
2. Gear oil 111

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– Tighten new plug -arrow A- on housing for self-locking centre

differential.
Note
The level does not need to be re-checked after this step.
Specified torques

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3 Seals
⇒ “3.1 Renewing left seal”, page 113
⇒ “3.2 Renewing right oil seal”, page 115
3.1 Renewing left seal
Note
A defective seal allows gear oil to enter the gearbox housing.

♦ Oil seal extractor - 3240-
Procedure
Note

– Drain gear oil

⇒ “2.2.1 Draining and filling gear oil, front final drive”,
page 107 .
3. Seals 113
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– Unscrew bolts for front final drive cover in the sequence

-11 … 1-.
– Detach cover for front final drive together with tapered roller
bearing outer race and shim.
Note

– Detach differential -arrow-.
– Remove outer race -1- for tapered roller bearing of differential,

and shim -2- located behind, from gearbox housing by hand.
Note

– Pull left flange shaft slightly off gearbox, but do not remove it
⇒ page 117 .
– Align inner part of oil seal extractor -3240- flush with outer part,
and lock inner part in position with knurled screw -arrow-.
– Lubricate threaded head of oil seal extractor, place oil seal
extractor in position, and, exerting firm pressure, screw it into
seal as far as possible until seal begins to turn with it.
– Continue turning and pulling oil seal extractor until seal is
pulled out.
– Clamp oil seal extractor on flats in a vice, and remove seal
using pliers.
– Examine seal seat in gearbox housing for damage; rework if
necessary.
– Clean contact surface and sealing surface.

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– Apply gear oil to outer circumference and sealing lip of seal.
Note
Push seal onto thrust piece so that protruding sealing lip of seal
faces towards tool.
– Drive new seal in onto limit stop.
– Insert shim -2- and tapered roller bearing outer race -1- for
differential to stop in gearbox housing.
– Renew O-ring -arrow-.

– Insert differential in gearbox housing.
If tapered roller bearing outer race and shim fell out of cover for
front final drive:
– Moisten shim and outer race for tapered roller bearing with
gear oil, and insert in cover for front final drive as far as stop.
– Install left flange shaft ⇒ page 117 .
– Tighten bolts for front final drive cover ⇒ page 100 .
– Fill gear oil, and check oil level ⇒ page 107 .
3.2 Renewing right oil seal

3. Seals 115
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Removing
– Lever out flange shaft seal.
Installing
– Lightly oil outer circumference of new oil seal.
– Drive in seal to stop using thrust piece - T40163- . Make sure
that seal always remains straight when driving in.
– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .

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4 Differential
⇒ “4.1 Removing and installing left flange shaft”, page 117
⇒ “4.2 Removing and installing right flange shaft”, page 119
4.1 Removing and installing left flange shaft

♦ Sealing grease ⇒ Electronic parts catalogue
Removing
– Drain gear oil
page 107 .
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Vehicle with rigid ATF lines: remove ATF cooler ⇒ page 75 .
– Vehicle with flexible ATF hose lines: unbolt ATF cooler, and
push it aside slightly ⇒ page 75 .
– Remove left shock absorber fork ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Suspension strut, upper suspension
link; Removing and installing shock absorber fork .
– Unscrew bolts -arrows- on mounting bracket for flange shaft.
– Pull lower cover -arrow- out of gearbox.
4. Differential 117
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WARNING
Risk of damage to the seal between the final drive and the
gearbox housing when pulling off the flange shaft.
♦ If you do not keep the flange shaft -arrow- centred, the
splines on the flange shaft will damage the seal.
♦ If the seal is damaged, it must be renewed.
– To avoid damaging the seal, support and guide the flange

shaft through the opening in gearbox when pulling out.
– Pull left flange shaft -2- out of gearbox -arrow A-.
Note
-Items 1, 3 and B- can be disregarded.
Installing
Note
Renew bolts that are tightened with turning further angle after
each removal.
WARNING
Risk of damage to the seal between the final drive and the
gearbox housing when pushing in the flange shaft.
♦ If you do not keep the flange shaft -arrow- centred, the
splines on the flange shaft will damage the seal.
♦ If the seal is damaged, it must be renewed.
– To avoid damaging the seal, support and guide the flange

shaft through the opening in gearbox when pushing in.

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– Push left flange shaft -2- into gearbox -arrow B-. While doing
so, keep end of flange shaft centred while guiding it into seal
on front differential -arrow 3-.
– Install shock absorber fork ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Suspension strut, upper suspension link; Re‐
moving and installing shock absorber fork .
– Install ATF cooler ⇒ page 75 .
Specified torque
♦ ⇒ “1.1 Assembly overview - final drive”, page 99
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Assembly overview - drive shaft
Removing and installing drive shaft heat shield
4.2 Removing and installing right flange

shaft
♦ Retaining ring pliers - VAS 5503A-
4. Differential 119
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♦ Multi-purpose tool - VW 771- with -VW 771/43- and -VW

771/45- for M14 threads

Removing
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .
low gearbox.
– Version with M12 thread: fit multi-purpose tool - VW 771- with
-VW 771/43- to flange shaft as shown in illustration.
– Version with M14 thread: fit multi-purpose tool - VW 771- with

-VW 771/43- and -VW 771/45- to flange shaft as shown in il‐
lustration.
– Pull off flange shaft.

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Installing
Note
Renew circlip after each removal.
– Insert circlip -1- using circlip pliers - VAS 5503A- .

– Check seal for right flange shaft for damage, and renew it if
necessary ⇒ page 115 .
grease - G 052 128 A1- .
– Insert right flange shaft.
– Fill gear oil, and check oil level
page 107 .
Specified torques
♦ ⇒ “1.1 Assembly overview - final drive”, page 99
Assembly overview - drive shaft
Removing and installing drive shaft heat shield
4. Differential 121
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5 Self-locking centre differential

⇒ “5.1 Assembly overview - self-locking centre differential”, page
122
⇒ “5.2 Removing and installing self-locking centre differential”,
page 123
⇒ “5.3 Renewing seal for rear splined shaft”, page 124
⇒ “5.4 Renewing ball bearing for rear splined shaft”, page 126
⇒ “5.5 Renewing ball bearing for centre differential”, page 130
5.1 Assembly overview - self-locking centre differential
1 - O-ring
❑ Renew
❑ Moisten with gear oil
2 - Plug
hole
box
❑ Specified torque
⇒ page 74
3 - Housing for self-locking
centre differential
⇒ page 123
4 - Rear splined shaft
⇒ “5.3 Renewing seal
for rear splined shaft”,
page 124
❑ When renewing rear
splined shaft, renew
seal as well
5 - Seal
❑ For rear splined shaft
6 - Dust ring
❑ Cannot be removed
without being damaged
7 - Bolt
❑ Renew
tightening sequence
⇒ page 123
8 - Ball bearing
9 - Retaining ring

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10 - Retaining ring
❑ For ball bearing of rear splined shaft
11 - Ball bearing
❑ For self-locking centre differential
12 - Self-locking centre differential
Housing for self-locking centre differential - specified torque and

tightening sequence
Note
Renew bolts that are tightened with turning further angle.
– Tighten bolts in 3 stages in the sequence shown:

Stage Bolts Specified torque/turning further angle
1 -1- and -6- 3 Nm
2 -1 … 6- 10 Nm
3 -1 … 6- Turn 90° further
5.2 Removing and installing self-locking

centre differential
Removing
• Gearbox installed
Caution

♦ Do not run engine or tow vehicle with self-locking centre
differential removed or without gear oil.
Note

– Remove propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;

Removing and installing propshaft .
– Drain gear oil from transfer box ⇒ page 107 .
5. Self-locking centre differential 123

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– Loosen bolts for self-locking centre differential housing in the

sequence -6 ... 1-, and unscrew bolts.
Caution
Gearbox components must be handled with care, otherwise

they will be damaged.
♦ Carefully pull centre differential housing off gearbox to‐
wards the rear. Make sure that the centre differential does
not drop out of housing.
– Secure centre differential -1- against falling out, or pull it off

output shaft towards the rear.
Installing
Note
Renew O-ring for centre differential housing.
If centre differential has been removed -1-:

– Fit centre differential onto splines of output shaft. Turn centre
differential slightly while doing so.
– Check whether centre differential can be turned by hand after
being fitted.
– Fit housing with rear splined shaft installed and with new O-
ring onto centre differential. Turn housing slightly if necessary.
– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
– Replenish gear oil in transfer box ⇒ page 107 .
Specified torques
♦ ⇒ Fig. ““Housing for self-locking centre differential - specified
torque and tightening sequence”“ , page 123
5.3 Renewing seal for rear splined shaft


Touareg 2018 ➤
♦ Extractor hook - T20143/1-
♦ Assembly tool - T40239-

Procedure
Note

– Remove propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;

– Lever off dust ring -1-.
Note
The dust ring cannot be removed without being damaged.

Touareg 2018 ➤
– Pull out seal for rear splined shaft.

– Clean contact surface and sealing surface.
– Moisten outer circumference of seal with gear oil.
– Fit guide sleeve - T40239/1- -item 1- onto rear splined shaft.

grease - G 052 128 A1- .
– Fit seal -2- over guide sleeve -item 1- and onto rear splined
shaft.
• Installation position: open side of seal faces gearbox housing.
– Drive in seal to stop using thrust piece - T40239- -item 1-. Do

not cant oil seal in the process.
Note
Carefully pull guide sleeve - T40239/1- out of seal so that sealing

lip is not rolled back.
– Clip on new dust ring -1-.

– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
5.4 Renewing ball bearing for rear splined

shaft

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♦ Thrust plate - VW 401-
♦ Press tool - VW 409-

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♦ Tube - VW 415A-
♦ Tube - 2040-
Procedure
– Remove centre differential housing ⇒ page 123 .
– Remove retaining ring -A- for rear splined shaft and retaining
ring -B- for ball bearing.
– Press rear splined shaft out of centre differential housing using

press tool - VW 409- .

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– Lever out seal.
Note
Place e.g. an assembly lever -A- underneath to protect the hous‐

ing.
– Press out ball bearing for rear splined shaft.
– Press in ball bearing for rear splined shaft.

• Collar on tube - VW 415 A- -arrow- faces press tool - VW 412- .
– Renew retaining ring -B- for ball bearing.
Note
Disregard -item A-.

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– Press rear splined shaft into centre differential housing using

press tool - VW 412- .
– Install retaining ring -arrow- into groove of rear splined shaft.

– Install centre differential housing ⇒ page 123 .
– Install seal for rear splined shaft ⇒ page 124 .
– Replenish gear oil in transfer box ⇒ page 109 .
5.5 Renewing ball bearing for centre differ‐

ential

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♦ Assembly tool - 3350-
♦ Splitter - VAS 251 411-

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Procedure
– Remove centre differential housing ⇒ page 123 .
– Pull centre differential -1- off output shaft towards the rear.
– Press ball bearing off centre differential.

A - Splitter - VAS 251 411-
• The collar of press tool - VW 432- points towards ball bearing.
– Press ball bearing onto centre differential.

8 Speed Automatic Gearbox 0d5 Eng

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Service

Service Department. Technical Information

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1.1 Gearbox identification

Gearbox code and gearbox serial number

♦ The gearbox code also appears on the vehicle data stickers.

2.1 Safety precautions when working on the

Risk of injury and accident by accidental engagement of gear

To prevent personal injury and damage to or destruction of elec‐

To prevent damage to the electronic components when dis‐

2 Rep. gr.00 - Technical data

2.2 Safety precautions when working on ve‐

Injury hazard as a result of automatic engine start in vehicles

2.3 Safety precautions when using testers

Risk of accident due to distraction and inadequate securing of

2.4 Safety precautions when working on

Risk of damage to running gear components.

2.5 Safety precautions when tow-starting or

Danger of irreparable damage to gearbox.

It is not possible to tow-start the engine, e.g. if the battery is too

4 Rep. gr.00 - Technical data

3.1 Rules for cleanliness

3.2 General information

3.3 General repair instructions

Regulations concerning oil handling, environment and disposal

6 Rep. gr.00 - Technical data

3.4 Routing and attachment of lines

8 Rep. gr.00 - Technical data

4.1.1 Capacities, ATF section in gearbox

Risk of malfunctions or failure of gearbox.

♦ ⇒ “7.1 Checking ATF level”, page 80

4.1.2 Capacities, front final drive

Lubricant Gear oil for automatic gearbox 0D5

♦ ⇒ “2.1 Checking gear oil level”, page 103

Volkswagen Technical Site: http://vwts.ru http://vwts.info

4.1.3 Capacities, transfer box

Lubricant Gear oil for automatic gearbox 0D5

♦ ⇒ “2.1.2 Checking gear oil level, transfer box”, page 105

4.2 Oil distribution

4.3 Allocation gearbox - engine

4.3.1 Allocation for vehicles with a petrol engine

4.3.2 Allocation for vehicles with a diesel engine

10 Rep. gr.00 - Technical data

5 Overview - power transmission

1 - Rear final drive

5. Overview - power transmission 11

1.1 Assembly overview - torque converter

1.2 Removing and installing torque convert‐

12 Rep. gr.32 - Torque converter

♦ Depth gauge - VAS 6082-

♦ Grease for splines - G 000 100-

– Turn extractor - T40176- upwards.

♦ To prevent the torque converter from tilting, counterhold at the

– Pull torque converter off input shaft -arrow- without canting.

Always renew seal between differential and gearbox housing

– Renew O-ring -arrow- on input shaft.

14 Rep. gr.32 - Torque converter

– Check torque converter ⇒ page 16 .

The torque converter is inserted correctly if the distance -a- be‐

– Unscrew extractor - T40176- from torque converter -A-.

1.3 Draining torque converter

1.4 Checking torque converter

The torque converter must be renewed completely if damaged or