7 Speed Dual Clutch Gearbox 0dl

Service
Workshop Manual
Arteon 2018 ➤ , Passat 2015 ➤ ,
Passat Variant 2015 ➤ , Tiguan 2016 ➤ ,
Tiguan RUS 2017 ➤
7-speed dual clutch gearbox 0DL
Edition 04.2017
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D4B804A300A

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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
spec
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
es, in part or in w
t to the co
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
rrectness of i
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 up to gearbox date 05/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1 Distinguishing between different types of bevel boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Detaching bevel box from gearbox - gearbox removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4 Moving push button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.6 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.9 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Contents i
Arteon 2018 ➤ , Passat 2015 ➤ , Passat oVariant 2015 ➤ , Tiguan 2016 ➤ , ...
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5.1 Assembly overview ris
ho - assembly mountings . . . . . . . . . . . . . .te.e o. . . . . . . . . . . . . . . . . . . . . . . 148
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6 Transporting gearbox
ss ................ . . . . . . . . . . . . . . . . . c. . . . . . .
.............. 151
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7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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8 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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9 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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9.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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9.2 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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10 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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10.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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2.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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2.2 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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2.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
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3 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.3 Renewing needle bearing (polygon bearing) for stub shaft . . . . . . . . . . . . . . . . . . . . . . . . 207
ii Contents
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1 Safety information
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(VRL010260; Edition 04.2017)
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⇒ “1.1 General safety provisions”, page 1
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⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Notes on tow-starting/towing”, page 2
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⇒ “1.4 Safety precautions when using testers and measuring in‐
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struments during a road test”, page 2
1.1 General safety provisions
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To prevent personal injury and material damage to the vehicle,
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Risk of injury and accident by accidental engagement of gear
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♦ Before working on vehicle with engine running, move se‐
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lector lever into position “P” and apply handbrake.
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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:
♦ Observe the necessary measures when disconnecting the
battery.
♦ Disconnect battery only after the ignition has been switch‐
ed off.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
1. Safety information 1
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
1.2 Safety measures when working on ve‐

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

with start/stop system.
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert) the engine
can start automatically if required.
♦ When working on the vehicle, always make sure that the
start-stop system is deactivated (switch off the ignition;
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Danger of irreparable damage to gearbox.
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♦ If the vehicle must be towed, the selector lever must be in
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the “N” position, and the vehicle must be towed at a speed
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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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1.4 Safety precautions when using testers

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and measuring instruments during a

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Observe the following if test and measuring equipment is required

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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 strap in place test and measuring equipment on
rear seat and have a 2nd person sitting on the rear seat
to operate them.
2 Rep. gr.00 - Technical data

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Please note the following to avoid personal ho injury and damage to,
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To prevent damage to the electronic components when dis‐
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connecting the battery: es, in part or in w
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♦ Observe the necessary measures when disconnecting the
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♦ Disconnect battery only after the ignition has been switch‐
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
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1. Safety information 3
2 Identification
2.1 Gearbox identification

The gearbox code can be found on top of the gearbox, near the
starter.
1 - Gearbox code
2 - Day of production
3 - Month of production
4 - Year of production
5 - Serial number
6 - Minute of production agen
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Note
The gearbox code is also indicated on the vehicle data stickers.

3 Repair notes
⇒ “3.1 General information”,
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⇒ “3.5 Nuts and bolts”, page 7
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3.1 General information
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Gearbox
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♦ The torque of the engine is transmitted via the flywheel to the
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dual clutch gearbox. The flywheel and the dual clutch are
joined together by a toothed connection. Together they take
on the function of the dual-mass flywheel.
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♦ The gearbox is structured like a manual gearbox. Through op‐
posed hydraulic actuation of the dual clutch, it is operated like
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an automatic gearbox. In other words, the gears are engaged

automatically or manually via the Tiptronic system. There is no
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cum
or
as is the case for the automatic gearbox. The information con‐

f
en
ng
cerning selector lever positions or shifting operations are trans‐

t.
yi Co
op
ferred to the gearbox control unit via a separate control unit in the
C py
t. rig
gh
selector mechanism and the CAN data bus. That is, gears are
ht
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shifted without any mechanical cables being involved. Only for
co lksw
by
cted agen
selector lever position “P” the parking lock is engaged mechani‐
Prote AG.
cally via the selector lever cable.
Gear change point variations for gradients
An additional gear change map automatically selects gear
changes for gradients dependent upon accelerator pedal position
and driving speed.
• Gear change map for extreme uphill stretches is matched to
engine output.
• Gear change map for extreme downhill stretches is matched
to the braking effect of the engine.
• If a gear is selected directly via the Tiptronic system, it is also
possible to use the braking effect of the engine in a specific
gear, e.g. when driving down a slope with a trailer attached.
3.2 Rules for cleanliness

♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ Seal open lines and connections immediately using clean
plugs or sealing caps from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ Make sure that no dirt can enter an »open« gearbox.
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
3. Repair notes 5
♦ If repair work cannot be performed immediately, cover opened

parts carefully.
♦ Protect disconnected electrical connectors from dirt and water,
and only reconnect them in dry condition.
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 general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
Guided fault-finding, vehicle self-diagnosis and test instruments
♦ Before performing repairs to the gearbox, determine the cause
of the fault as accurately as possible ⇒ Vehicle diagnostic
tester, Guided Fault Finding , Vehicle Self-Diagnosis
or Test Instruments .
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools" .
Gearbox
Always make sure that no dirt can enter an »open« gearbox. In
particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle. lkswage es n
Vo ot g
y ua
db ran
♦ First thoroughly clean connecting points and rissurrounding
e
tee
areas and then loosen bolts. utho or
a ac
ss
♦ When installing the gearbox, ensure that dowel sleeves be‐
ce
le
un
pt
tween the engine and gearbox are correctly located.

an
d
itte
y li
rm
Locking devices
ab
pe
ility
ot
♦ Do not overstretch retaining rings.

wit
, is n
h re
♦ Always renew retaining rings which have been damaged or

hole
spec
overstretched.
es, in part or in w
t to the co
♦ Retaining rings must locate properly in grooves.

Dual clutch gearbox oil
rrectness of i
The oil quality is of critical importance for the function of the gear‐
l purpos
box.
Shake oil bottle before opening.
nform
ercia
Do not mix additives in oil. Do not fill any other oil.

m
a
com
ti
Oil which has been drained out cannot be filled again.

on in
r
te o
thi
s
iva
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r
rp
cum
fo
en
ng
t.
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.

Oil drain and inspection plug

A plastic overflow pipe (with 8 mm hexagon socket head) is lo‐
cated behind this plug -arrow-. Its length determines the oil level
in the gearbox.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
3.4 Gaskets and seals tho eo
au ra
ss c
♦ Renew O-rings, seals and gaskets.
ce
le
un
pt
an
d
itte
♦ After removing gaskets and seals, always inspect contact sur‐
y li
rm
ab
face of housing or shaft for burrs resulting from removal or for
pe
ility
other signs of damage.
ot
wit
, is n
h re
♦ Before installing seals, lightly oil outer diameter and half-fill
hole
space between sealing lips -arrow- with sealing grease -
spec
G 052 128 A1- .
es, in part or in w
t to the co
♦ The open side of the oil seals faces toward the side with fluid
filling.
rrectness of i
♦ Only use dual clutch gearbox oil. Other lubricants will cause
problems in function.
l purpos
♦ Coat O-rings with dual clutch gearbox oil to prevent pinching

of rings during assembly.
nform
ercia
♦ After renewing gaskets, O-rings and seals, check oil level in

m
a
com
ti
gearbox and top up if necessary ⇒ page 162 .
on in
r
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thi
s
iva
3.5 Nuts and bolts
do
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rp
cum
fo
♦ Loosen and tighten securing bolts and securing nut for covers
en
ng
t.
yi Co
and housings diagonally. t. Cop py
rig
gh ht
♦ Specified torques given are for unoiled nuts, bolts and screws. pyri by
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co lksw
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♦ Clean threads of bolts which are to be installed with locking Prote AG.
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
♦ Always renew self-locking bolts and nuts.
3. Repair notes 7
4 Technical data
4.1 Allocation gearbox - engine
4.1.1 Passat 2015 ►, Passat Estate 2015 ►

Take account of the gearbox code if spare parts are required for
a repair.
Dual clutch gearbox 0DL, all-wheel drive
Codes QAX, RCG, SDR QBB, SDM
Engine 2.0 l - 176 kW TDI 2.0 l - 162 kW TSI
4.1.2 Tiguan 2016 ►

Take account of the gearbox code if spare parts are required for
a repair.
Codes QAY, QAY, SDK QBB, QBA,
RPN, SDK RPL, RPM
RPP, SDN
Engine 2.0 l - 105, 2.0 l - 130, 2.0 l - 132, 2.0 l - 176
110 140 162 kW kW TDI
kW TDI kW TDI TSI
Dual clutch gearbox 0DL, front-wheel drive

Codes QAZ, RPK
Engine 2.0 l - 110 kWgTDI
en AG. V
olkswagen AG
d
a oes
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Vol
4.1.3 Arteon 2018 ► by gu
d ara
e nte
ris
tho eo
Take account of thessgearbox code if spare parts are au required for ra
c
a repair.
ce
le
un
pt
an
d

itte
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erm
ab
Codes RWU
ility
ot p
wit
Engine 2.0 l - 176 kW TDI

is n
h re
ole,
spec
4.2 Capacities
urposes, in part or in wh
t to the co
Capacity Dual clutch gearbox 0DL

Initial filling 7.0 l ± 0.1 l
rrectne
Changing approx. 5.5 litres

♦ Change interval: ⇒ Maintenance manual and/
ss
or ⇒ service tables “ELSA”

o
cial p
f inform
Lubricant Dual clutch gearbox oil

mer
atio
m
The oil is available as a replacement part; part no. ⇒ Electronic

o
n
c
parts catalogue (ETKA) .

or
n thi
te
sd
a
Further information in the part number designates the container

iv
o
pr
size.
um
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

Capacity Front bevel box

Capacity of bevel box 0A6 0.9 l
⇒ page 34
Capacity of bevel box 0CP 0.75 l
⇒ page 34
Changing Filled for life, no change
Lubricant Gear oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) . AG. Volkswagen
a oes gen AG d
Further information in the part number ksw
Vol designates the container ot gu
n
by
size. ris
ed ara
nt ee
tho or
s au ac
s
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
en
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t.
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Cop py
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pyri by
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by c lksw
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Prote AG.
4. Technical data 9
5 Electrical components
5.1 Overview of fitting locations - electrical components
1 - Mechatronic unit for dual

clutch gearbox - J743-
❑ Removing and installing
⇒ page 26
2 - Gearbox input speed send‐
er - G182- and oil temperature
sender in multi-plate clutch -
G509-
❑ Both senders are com‐
bined in one component wage
es n
s
and can be renewed to‐ yV
olk ot g
ua
gether only. ir se
d b ran
tee
o
❑ Removing and installing auth or
ac
⇒ page 32 ss
ce
e
nl
❑ Before removal of the
pt
du
an
sender, the mechatronic
itte
y li
erm
unit for dual clutch gear‐
ab
ility
box - J743- must be re‐
ot p
wit
moved ⇒ page 26 .
, is n
h re
❑ Discontinued as of gear‐
hole
spec
box date 06/15
es, in part or in w
t to the co
3 - Selector lever - E313-
❑ With selector lever sen‐
sors control unit - J587- ,
rrectness of i
selector lever lock sole‐
l purpos
noid - N110- and selec‐

tor lever locked in posi‐
tion P switch - F319-
nform
ercia
❑ The components are in‐

m
tegrated into the printed

at
om
io
circuit of the selector

n
c
in t
r
mechanism and cannot

o
his
te
be renewed separately
a
do
priv
❑ Checking ⇒ vehicle di‐

um
for
en
g
agnostic tester
n
t.
yi Co
op
C py
t. rig
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selector mechanism ⇒ page 71
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pyri by
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co lksw
by
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Prote AG.

30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 11
⇒ “1.2 Removing and installing clutch end cover”, page 12
⇒ “1.3 Removing dual clutch”, page 15
⇒ “1.4 Installing dual clutch”, page 18
1.1 Assembly overview - dual clutch

Replacement parts
1 - Retaining ring for dual

clutch end cover
❑ Renew after removal
2 - Retaining ring for dual
clutch
❑ Renew after removal wage
e ks s no
Vol t gu
3 - Retaining ring efor
d b drive plate
y ara
is nte
or
4 - Dual clutch
au
th eo
ra
ss c
ce
le
un
pt
Caution
an
d
itte
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The
♦ drive plate has to re‐
rm
ab
pe
main engaged between

ility
ot
the teeth of the outer

wit
, is n
plate carrier.
h re
hole
spec
If♦the drive plate de‐

es, in part or in w
taches, the plates in the

t to the co
dual clutch can shift. It

may then not be possible
to adjust the clutch cor‐
rrectness of i
rectly when it is installed.

l purpos
5 - Shims
nform
ercia
❑ 10 shims having differ‐

ent »thicknesses«.
m
a
com
They are sized in

ion in
0.05 mm increments.
r
te o
thi
❑ Thickness of spacer ring

s
iva
do
r
must be determined
rp
cum
fo
when installing dual

en
ng
t.
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clutch.
Co
Cop py
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6 - Dual clutch end cover
gh ht
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by lksw
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Prote AG.
1. Clutch 11
Caution
♦ This figure is intended only to provide an overview of the

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

er
Special tools and workshop equipment required
♦ Clean assembly sleeve - T10459- before using. Do not use a wagen AG. Volkswagen AG doe
scratched sleeve. yV
olks s no
tg
b ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Brief description
rrectness of i
The cover is held in its seat by a retaining ring. After the retaining
ring has been removed, the cover can be levered out of its seat.
l purpos
Cover and retaining ring must always be renewed. Never install

a new cover with a hammer and never oil the centre seal or touch
nform
ercia
it with a hand! However, if this should happen, the cover is certain

to leak!
m
at
om
io
Removing
n
c
in t
or
his
e
The gearbox must be removed for work on cover.

at
do
priv
– Drain gear oil ⇒ page 164 .

um
for
en
ng
t.
yi
– Remove gearbox ⇒ page 89 .
Co
Cop py
t. rig
gh
– Secure gearbox to assembly stand ⇒ page 157 .
ht
pyri by
Vo
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by c lksw
Often, doubts arise as to whether the filter must be renewed or
cted agen
Prote AG.
not.
Note
It is not always necessary to change the oil filter ⇒ page 159 .
12 Rep. gr.30 - Clutch

– Remove filter if necessary ⇒ page 159 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Lever out retaining ring -2- of clutch end cover using screw‐
es, in part or in w
driver -1- -arrow- and remove.
t to the co
Cover can be levered out with a screwdriver.
rrectness of i
Note
l purpos
The removed cover and retaining may not be installed again.
nform
mercia
Install only a »new« cover. a

com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Installing
Caution
Cover and retaining ring must always be renewed.

Never grasp a new cover in centre seal. The centre hole of the
cover must not be touched, oiled or brought into contact with
other materials. Leaks will result.
Never install new covers with a hammer!
1. Clutch 13
– Only handle cover as shown -in this picture-.
Note
There must be no stickers on the inside of the cover. If, however,

stickers are present, remove them carefully.
– The running surface on the end of the shaft of the clutch

-arrow- must be free of oil and dry.
– If necessary, thoroughly clean running surface.
WARNING
The centre seal of the new cover must be »preformed« before

installing:
– Clean assembly sleeve - T10459- “before using”. Do not use

a scratched sleeve.
– Set sleeve on a flat surface.
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
– Guide cover horizontally and evenly over entire sleeve wit

is n
-as shown in this figure-. This will bring the sealing lip into in‐ h re
ole,
stallation position.
spec
– Remove sleeve upwards out of cover and set sleeve on end

t to the co
of clutch shaft.
– Moisten outer seal of cover with oil.
rrectne
Caution
ss o
cial p
f in
Moisten only the outer seal of the cover with oil. Oiling the inner
form
mer
seal will always cause leaks.

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
ed ra
Arteon 2018ho➤ r , Passat 2015 ➤ , Passat Variant 2015n➤
is tee , Tiguan 2016 ➤ , ...
t or
au 7-speed dual clutch gearbox 0DL ac - Edition 04.2017
ss
ce
le
un
– Guide cover horizontally over sleeve and press evenly onto its
pt
an
d
itte
seat.
y li
rm
ab
pe
ility
ot
Caution
wit
, is n
h re
hole
spec
Work carefully. Any sort of blow to the cover is certain to cause
es, in part or in w
leaks.
t to the co
rrectness of i
l purpos
nform
ercia
It is possible to lever cover carefully into its seat with a

-screwdriver- until »new« retaining ring can be installed.
m
a
com
tio
– Install new retaining ring.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
– Do not remove bush until retaining ring is installed.

– Installing gearbox ⇒ page 146
– Top up gear oil ⇒ page 164 .
WARNING
Do not start engine if there is no oil in gearbox.
1.3 Removing dual clutch

♦ 2 x hooks - 3438-
1. Clutch 15
♦ Puller - T10055-
♦ Puller - T10525-
Brief description
• The axial play of the clutch is readjusted during installation
procedure.
• To remove or install clutch, gearbox must be securely attached
to an assembly stand in vertical position ⇒ page 157 . Only
this way is it possible later to adjust axial play of the clutch
without error. G. Volkswage
A n AG d
agen oes
Removing ksw not
y Vol gu
b ara
ed
– Remove clutch end horiscover ⇒ page 12 . nte
eo
t
au ra
Important! Installation
ss location of drive plate c
ce
e
nl
pt
– Check that marking on drive plate -arrow- aligns with the mark‐
du
an
itte
ing on the outer plate carrier.

y li
erm
ab
ility
If there is no marking:
ot p
wit
, is n
– Mark installation position of drive plate relative to periphery of

h re
hole
outer plate carrier with permanent marker, as shown in illus‐

spec
tration.
es, in part or in w
t to the co
• During installation, drive plate must always be repositioned at

marked position.
rrectness of i
l purpos
Note
The retaining ring is renewed together with the clutch. If the clutch
nf
ercia
which is removed is reinstalled, the securing ring is to be used

rm
again as well.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
16
cted agen
Prote
Rep. gr.30 - Clutch
AG.
– Lever out retaining ring -2- of drive plate using screwdriver

-1- -arrow-.
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Apply puller - T10525- together with puller - T10055- on
splines and carefully pull drive plate off its seat -arrows-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove retaining ring -arrow- and save it for now.
Note
Do not dispose of the retaining ring yet because it will be needed

to measure axial clearance.
1. Clutch 17
– Remove shim -arrow-.
Caution
Carefully remove the dual clutch. Take care that no parts fall
out. Therefore, do not turn the clutch over!
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
– Remove dual clutch using hooks - 3438- .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.4 Installing dual clutch

nf
ercia
orm
m
atio

om
n in
or c
♦ Universal dial gauge holder - VW 387-

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Dial gauge - VAS 6079-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
♦ Retaining pins - T10524-
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
♦ Drift sleeve - 40-21-
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
♦ The drive plate has to remain engaged between the teeth

of the outer plate carrier.
♦ If the drive plate detaches, the plates in the dual clutch can
shift. It may then not be possible to adjust the clutch cor‐
rectly when it is installed.
♦ Do not lift (not even slightly) or remove plate carrier! The
plates could turn.
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
1. Clutch 19
Installing
– Take great care when removing the dual clutch from its pack‐
age.
– Turn piston rings by hand. They must move freely and must
not bind.
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
align. n AG. Volkswagen AG do
lkswage es n
o ot g
– The ring butts -arrows- of piston rings -2- and -4- should align byV ua
ed ran
and be offset 180° to the ring butts of piston rings -1- andor-3-.
is tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Important! Position of drive plate
t to the co
– Before installing, check if there is a marking -arrow- on dual
clutch.
rrectness of i
– If there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the outer plate carrier.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
– Insert retaining pin - T10524- .

f
en
ng
t.
yi Co
op
The retaining pin - T10524- should be held by a second mechanic C py
t. rig
while the dual clutch is being inserted.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Carefully insert -dual clutch-, ensuring it does not fall.

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

retaining pin - T10524- .
Note
♦ The retaining pin remains inserted until the clutch end cover
is installed.
♦ The dual clutch must now not be rotated any more, as this can
agen
AG. Volkswagen AG d
shift the position of the retaining pin - T10524- .
o es n
ksw
Vol ot g
d by ua
ran
e
ris tee
tho or
au ac
ss
ce
le
– Lever out retaining ring -2- of drive plate using screwdriver

un
pt
an
d
-1- -arrow-.
itte
y li
rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
This retaining ring will be used again. Do not dispose of it.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Clutch 21
. Volkswagen AG
gen AG does
– Apply puller - T10525- together with puller - T10055- onVolkswa not
gu
splines and carefully pull drive plate off its seat -arrows-.
ed
by ara
nte
ris
utho eo
ra
a c
ss
Note
ce
e
nl
pt
du
an
itte
The retaining pin - T10524- must be held by a second mechanic
y li
erm
ab
while pulling off.
ility
ot p
wit
, is n
– Carefully remove drive plate from dual clutch -arrows- and
h re
hole
place it on one side.
spec
es, in part or in w
t to the co
Caution
Do not lift (not even slightly) or remove plate carrier! The plates
rrectness of i
could turn.
l purpos
Determining shim for dual clutch:
nform
ercia
• The retaining pin - T10524- remains installed!

m
at
om
ion
c
in t
r
– Temporarily install “old” retaining ring -arrow-.

o
his
ate
do
riv
Before this ring is finally disposed of, 3 measurements must be

p
cum
or
made.
f
en
ng
t.
yi Co
First measurement (axial play of shaft) Cop py
t. rig
gh ht
yri
– Screw universal dial gauge - VW 387- to gearbox flange. p by
co Vo
by lksw
cted agen
Prote AG.
– Set -tip of dial gauge- on input shaft.

– Set -dial gauge- to 0 with preload.

– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.
Note
This value will be needed later for the check measurement so

save value “A” until the last measurement has been performed.
Second measurement
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Tip must not sit on retaining ring.
– Set -dial gauge- to 0 with preload again.

– Lift dual clutch with force to stop and note measurement.
– Call this value “B”.
Now calculate which shim must be fitted:
– Use this formula:
Value “B” minus value “A” minus 0.11 = thickness of shim to
be fitted. Volkswa gen AG
AG.
agen does
– Note result.
yV
olks
w not
gu
d b ara
The shims riseare sized in 0.05 mm increments. nte
tho eo
au ra
– Measure
ss the shims and determine which one is closest
c to the
result.
ce
le
un
pt
an
d
itte
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rm
ab
WARNING
pe
ility
ot
wit
, is n
Always use the next-largest shim, never the next-smallest.

h re
hole
spec
es, in part or in w
t to the co
Example:
Calculated dimension for shim New shim
rrectness of i
1.28 mm 1.3 mm
l purpos
1.26 mm 1.3 mm
nform
ercia
– Remove old retaining ring -arrow-.

m
a
com
tion in
Note
r
te o
thi
s
iva
do
Do not dispose of ring yet; it will be needed once more.

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Clutch 23
– Fit calculated shim.

Third measurement (check measurement)
To make sure that the shim is correct, a test measurement must
still be carried out. Proceed as follows:
– Install old retaining ring -arrow- once more.
– Set tip of dial gauge -on hub of large plate carrier-.
wage es n
Note yV
olks ot g
ua
d b ran
ir se tee
Set the tip of the dial gauge on the shim -1-. autho
or
ac
ss
ce
e
– Set -dial gauge- to 0 with preload again.

nl
pt
du
an
itte
y li
– Lift dual clutch with force to stop and note measurement.
erm
ab
ility
ot p
– Call this value “C”.
wit
, is n
h re
Now calculate which shim must finally be fitted:
hole
spec
– Use this formula:
es, in part or in w
t to the co
Value “C” minus value “A” = specification
This specification must lie between 0.05 and 0.12 mm.
rrectness of i
If the specification is not attained, then achieve the specification
l purpos
by fitting a thicker or thinner shim.

nform
ercia
– Install new retaining ring -arrow-.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Fit drive plate into dual clutch.

• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier -arrows-. If the markings were
subsequently make, align these.
– A second mechanic must hold retaining pin - T10524- in its
place and press outwards slightly.
– Carefully drive the drive plate onto its seat using press tool -
40-21- and a plastic hammer.
– Install drive plate retaining ring.
– Starting at the opening, press retaining ring in clockwise di‐
rection into its fitting position.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
and housing.
– Install clutch end cover ⇒ page 12 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Clutch 25
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox installed)”, page 26
⇒ “1.2 Removing and installing gearbox input speed sender G182
and oil temperature sender in multi-plate clutch G509 up to gear‐
box date 05/15”, page 32
1.1 Removing and installing mechatronic

unit for dual clutch gearbox - J743-
(gearbox installed)
♦ Up to gearbox date 05/15 release tool - T10465-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Torque wrench - V.A.G 1331-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
Always make sure that no dirt can enter an »open« gearbox.

fo
en
ng
t.
yi
In particular, dirt entering an »exposed« mechatronic unit for dual
Co
Cop py
clutch gearbox - J743- can lead to gearbox failure.
t. rig
gh ht
pyri by
Vo
o
Please also refer to the notes on the oil filter change regarding
c by lksw
cted agen
»dirty oil« ⇒ page 159 .
Prote AG.
Remove mechatronic unit.

– Move selector lever to position “P”.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
26 Rep. gr.34 - Controls, housing

Note
lkswage es n
Vo ot g
It is possible that parts having
ed
by nothing to do with the mechatronic ua
ra
unit must be removed.thoThis
ris depends on the vehicle's equipment. ntee
This will create enough au space to remove the mechatronic unit.
or
ac
ss
ce
le
un
pt
Vehicles with petrol engine
an
d
itte
y li
– Remove connecting hose between charge air cooler and
rm
ab
pe
ility
charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
ot
wit
overview - charge air system .
, is n
h re
hole
Continued for all vehicles
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Remove electrical wiring and retainer from front of sump
a
com
tio
-arrows- (2 x M6 nuts).
n in
r
te o
thi
– Raise wiring in area of sump and secure it.
s
iva
do
r
rp
c
– Place used oil collection and extraction unit - V.A.G 1782- be‐
um
fo
en
low gearbox.
ng
t.
yi Co
op py
– Drain oil ⇒ page 164 . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove securing clip -3-.

– Unscrew bolts -1- diagonally and remove.
– Remove cover -2- with seal.
Note
Always renew bolts, securing clips and the cover with seal.
1. Mechatronic unit 27
Before touching mechatronic unit, touch an earthed object again.
To gearbox date 05/15

– Release connector -1- of gearbox input speed sender - G182-
and oil temperature sender in multi-plate clutch - G509- using
release tool - T10465- .
Continuation for all:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
– Remove bolts -arrows- diagonally.

itte
y li
erm
ab
All 9 bolts have same length and are not allowed to be reused.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Arteon 2018 ➤ , Passatho2015 ➤ , Passat Variant 2015 ➤ , Tiguann2016
ris tee ➤ , ...
aut 7-speed dual clutch gearbox 0DL - Edition r04.2017
o
ac
ss
ce
e
nl
pt
– Remove mechatronic unit -1- carefully.
du
an
itte
y li
erm
ab
ility
Caution
ot p
wit
, is n
h re
• Lift or put down mechatronic unit only on housing and on
hole
spec
solenoid valves.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Lay mechatronic unit to side properly.
Co
Cop py
ht. rig
– Put down mechatronic unit so that sensors -arrows- are point‐ rig ht
py by
ing upwards.
co Vo
by lksw
cted agen
Prote AG.
Install mechatronic unit.
Install in reverse order of removal. During this procedure, observe
the following:
WARNING
Before installing the mechatronic unit, clean the sealing sur‐

face on the gearbox housing thoroughly without using cleaning
agents. Always make sure that no dirt can get into the inside.

– Before installation, check that »sender« -1- is installed
⇒ page 32 .
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant
agen AG. V 2015ag➤ , Tiguan
olksw en AG
does 2016 ➤ , ...
ksw not
7-speed dual clutch gearbox 0DL b-yEdition
Vol
04.2017 gu
a
ed ran
oris tee
Before touching mechatronic unit, touch
au
th
an earthed object again. or
ac
ss
ce
e
nl
pt
Caution
du
an
itte
y li
erm
ab
• Lift or put down mechatronic unit only on housing and on
ility
ot p
solenoid valves.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
– Carefully insert mechatronic unit -1- into gearbox.
do
priv
cum
or
– Screw in new bolts -arrows- diagonally until finger-tight.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Tighten bolts in specified sequence to 8 Nm + 45°.


– Push on connector g-1- and
en AG. Voengage.
lkswagen AG
a does
lksw n
– After this, check
db
y V that fastener -2- is not damaged.
o ot g
ua
e ran
ris tee
utho or
ss
a Caution ac
ce
le
un
pt
• Work with great care. The fastener of the connector -2-
an
d
itte
y li
can break. If this has happened, the connector will no
erm
ab
longer hold and the damaged part, e.g. mechatronic unit
ility
ot p
for dual clutch gearbox - J743- must be renewed.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f i
– Renew seal -arrow-.
nform
mer
A new mechatronic unit already has a new oil seal.
atio
om
n
– Moisten seal with oil.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Set new cover with seal -2- in place and tighten with new bolts
-1- diagonally in several stages to 10 Nm + 45°.
– Install new securing clip -3-.
– Attach wire retainer to cover and tighten nuts to 10 Nm.
– Push on connector for mechatronic unit for dual clutch gearbox
- J743- and engage lock by turning.
– Do not start engine!

– Fill with oil ⇒ page 164 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
– Conduct basic adjustment of mechatronic unit for dual clutch
gearbox - J743- . wage
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
1.2 Removing and installing gearbox input
speed sender - G182- and oil tempera‐
rrectne
ture sender in multi-plate clutch - G509-
s
up to gearbox date 05/15
s o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n
♦ As of gearbox date 06/15, the gearbox input speed sender -
thi
te
sd
a
G182- and the oil temperature sender in multi-plate clutch -

iv
o
r
G509- have been discontinued.

p
cum
r
fo
en
ng
t.
♦ If a sender is fitted, a sender must be reinstalled after it has
yi Co
op
been removed.
C py
t. rig
gh ht
yri by
♦ The following procedure applies only to gearboxes in which a
cop Vo
by lksw
sender is fitted.
cted agen
Prote AG.
Brief description
Both senders are combined in one component and can be re‐
newed together only. They are in the gearbox near the multi-
clutch. Before removal, the mechatronic unit for dual clutch
gearbox - J743- must be removed.
Removing
– Remove mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
Do not pull on line!
– Unscrew and remove bolt -2- and pull out sender -1-.
Installing
the following:
Reinstall »old« sender only if:
• The sender has no defect
• The cable was not pulled on when it was removed
– Moisten sender with dual clutch gearbox oil and install.

– Tighten bolt -2- to 10 Nm.

– Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2 Bevel box
⇒ “2.1 Distinguishing between different types of bevel boxes”,
page 34
⇒ “2.2 Removing and installing bevel box”, page 35
⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
page 57
2.1 Distinguishing between different types

of bevel boxes
The bevel box installed in the vehicle could be “0A6” or “0CP”.
Bevel boxes can be identified by means of the following:
Distinguishing feature with bevel box installed:
Determine version of bevel box by recess -arrow- in right area of
subframe.
Remove following components if necessary:
– Noise insulation ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation .
– Centre underbody cladding ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody cladding; Removing and installing
underbody cladding .
. Volkswagen AG
Area denoted by -arrow- is marked with “0A6” or “0CP”.
ksw
agen
AG does
not
ol
yV gu
edb ara
ris nte
tho eo
au ra
c
ss ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Additional distinguishing feature with bevel box removed:

rrectne
Output flange on bevel box “0A6” is secured with a nut -A- ⇒ As‐
sembly overview - bevel box, “0A6” ⇒ page 186 .
ss
Disregard -B- and -arrows-.

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

Output flange on bevel box “0CP” is secured with a retaining ring

-A- ⇒ Assembly overview - bevel box, “0CP” ⇒ page 188 .
Located behind retaining ring -A- is a washer -B-.
2.2 Removing and installing bevel box

⇒ “2.2.1 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat Estate 2015 ►, Tiguan 2016 ►, Arteon 2018 ► vehiclesagenwith
AG. Volkswagen AG d
oes
2.0 l - 176 kW TDI and bi-turbocharger”, page 35y Volksw not
g b ua
ed ran
⇒ “2.2.2 Removing and installing bevel box,hoPassat
ris 2015 ►, Pas‐ tee
sat Estate 2015 ►, vehicles with petrol engine”,
s aut page 40 or
ac
s
⇒ “2.2.3 Removing and installing bevel box, Tiguan 2016 ►”, page
ce
e
nl
pt
du
48
an
itte
y li
erm
ab
2.2.1 Removing and installing bevel box, Passat 2015 ►, Passat Estate 2015 ►,
ility
ot p
Tiguan 2016 ►, Arteon 2018 ► vehicles with 2.0 l - 176 kW TDI and bi-
wit
, is n
h re
turbocharger
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Bevel box 35
Special tools and workshop wage

es n
equipment required yV
olks ot g
ua
d b ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Multi-purpose tool - VW 771-

♦ Hexagon key extension, 8 mm - 3247-
♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Puller - T 10472-
Removing
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
Note
After loosening centre bolt, do not lower vehicle to ground again.

The right drive shaft will be removed in a later step.

– Do not loosen the front flange bolt -arrow- more than 90° while
the vehicle is still standing on its wheels, or the wheel bearing
will be damaged. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
Note
So that the propshaft can be turned later in order to loosen it:
– Move selector lever to »N« position.

– Remove exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
haust gas recirculation; Removing and installing exhaust gas
recirculation cooler .
The engine support - T10533- -A- remains in the forward position

after the cooler has been removed. This makes it easier to remove
the bevel box later.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
lkswage es n
o ot g
byV ua
ed ran
– Unscrew bolts -A and B-, and remove tgearbox
horis
carrier -1- for tee
or
bevel box. au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove upper securing bolts -arrows- securing bevel box to

l purpos
gearbox.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Bevel box 37
– Loosen lower securing bolts securing bevel box to gearbox

and unscrew only as far as dimension -a-.
Dimension -a- = 15 mm.
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Prepare multi-purpose tool - VW 771- with a washer -a- and 2
es, in part or in w
sleeves from the supplementary set for engine and gearbox
t to the co
support - VW 540/1 B- as shown in the illustration.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
– Bolt multi-purpose tool - VW 771- onto puller - T10472- and

fo
en
g
loosen bevel box from gearbox.

n
t.
yi Co
Cop py
– Remove multi-purpose tool - VW 771- and puller - T10472-
t. rig
gh ht
yri
from bevel box. p by
co Vo
by lksw
cted agen
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– Unscrew lower securing bolts -arrows- and remove bevel box.

Installing
When installing, note the following:
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– Grease splines of differential with grease for clutch plate
ce
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splines - G 000 100- .
pt
du
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– Install new retaining ring -arrow A- and new O-ring -arrow B-
erm
ab
on right stub shaft.
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– Insert bevel box and press against gearbox as far as it will go.
h re
hole
spec
es, in part or in w
t to the co
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot
rrectness of i
be pressed to stop against gearbox).
l purpos
– If splines are correctly positioned and shafts are centred, then

bevel box will slide to stop against gearbox.
nf
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orm
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Caution
om
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To ensure that the retaining ring of the stub shaft engages

thi
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a
properly in the differential bevel gear, strike the face of the

iv
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spline stub with a plastic hammer. Do not pull bevel box force‐
o
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f
fully against gearbox by turning securing bolts. Damage to

en
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gearbox or bevel box could result.
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– Screw on bevel box with new bolts -arrows- until finger-tight,
then tighten. Specified torque: ⇒ page 88 .
2. Bevel box 39
– Unbolt gearbox carrier for bevel box. Observe installation lo‐

cation and tightening sequence of bolts ⇒ page 88 .
– Install exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
haust gas recirculation system; Removing and installing ex‐
haust gas recirculation cooler .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Check gear oil in bevel box ⇒ page 170 .
– Following installation, check oil level in gearbox
⇒ page 162 .
gr. 66 ; Noise insulation .
Specified torques: ⇒ page 88
2.2.2 Removing and installing bevel box, Passat 2015 ►, Passat Estate 2015 ►,
vehicles with petrol engine
Special tools and workshop

equipment required
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♦ Supplementary set for engine and gearbox
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ua
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♦ Engine support - T10533-
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Removing
height.
Note

Note
– Move selector lever to »N« position.

– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation
2. Bevel box 41
– Disconnect connector -1- from oil level and oil temperature

sender - G266- .
– Remove right drive shaft ⇒ Running gear, axles, steering;
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– Remove drive shaft heat shield -1-, if present, from bevel box
ce
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pt
du
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
an
itte
y li
shaft .
erm
ab
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Caution
h re
hole
spec
Risk of damage to decoupling element.
es, in part or in w
t to the co
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
rrectness of i
– Remove front exhaust system from engine, raise it and tie it in
l purpos
place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly

overview - silencer .
nform
ercia
If fitted, remove heat shield for propshaft.

m
at
om
ion
c
– Unscrew bolts -A- and -B- from bevel box, and remove heat
in t
or
his
shield -1-.
ate
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for
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– Mark position of propshaft with flexible coupling relative to

output shaft of bevel box -arrows-.

– Unbolt front propshaft from bevel box -arrows-.
– If necessary, counterhold at rear final drive when loosening or

tightening propshaft.
Note
To loosen »next« bolt, turn propshaft further by turning rear

wheels at same time.
– Unscrew pendulum support bolts -1- from gearbox.

– Place a cloth on subframe to avoid damaging paint of prop‐
shaft when it is placed on subframe. AG. Volkswagen A n G do
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– Push font propshaft back to stop. Make sure not to damage

spec
seal -arrow- in centring bush.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
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2. Bevel box 43
– Guide propshaft upwards into tunnel, and use a suitable piece

of wood to support it on subframe.
– Set up engine support - T10533- as shown in figure and tighten

bolts hand-tight.
• -A- thin end
• -B- thick end
Bolt -3- = original pendulum support bolt
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded
hole for noise insulation.
It may be necessary to push the gearbox forwards slightly in order
to attach the engine support - T10533- .
– Force engine/gearbox as far forwards as possible by turning
spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
– Unbolt gearbox carrier.
AG. Volkswagen AG d
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– Unscrew bolts -1- and -2-, and remove carrier from bevel
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es, in part or in w
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rrectness of i
gearbox.
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om
ion
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ate
do
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for
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AG. Volkswagen AG d
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wit
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from bevel box.

hole
spec
es, in part or in w
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om
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2. Bevel box 45

Installing

splines - G 000 100- .
Note


AG. Volkswagen AG d
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Caution d by
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To ensure that the retaining ring of the stub shaft sengages
t
au ra
c
properly in the differential bevel gear, strike the face
s of the
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nl
pt
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erm
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ility
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– Install gearbox carrier. Observe installation location and tight‐ t to the co

ening sequence of bolts ⇒ page 88 . rrectness of i
l purpos
nform
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om
ion
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ate
do
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for
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t.
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pyri by
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cted agen
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– Mount drive shaft heat shield -1-, if present, on bevel box

shaft .
– Fit propshaft on bevel box.
Note
When removing and installing the bevel box, do not damage the
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
– Join bevel box and propshaft by turning spindle of engine sup‐

port - T10533- .
– Remove engine support - T10533- .
lkswage es n
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pt
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ab
ility
ot p
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– Bolt propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Propshaft;

hole
spec
Removing and installing propshaft .

es, in part or in w
t to the co
– If present, install heat shield for propshaft.

rrectness of i
l purpos
nf
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orm
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2. Bevel box 47
Version 1:
Version 2: AG. Volkswagen AG d

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spec
es, in part or in w
t to the co
– Secure pendulum support to gearbox using new bolts -1-.
Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
rrectness of i
l purpos

– Install parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/
nform
ercia
silencers .
m
at
om
i
on
c
in t
or
his
ate
⇒ page 162 .
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or

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t.
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Prote AG.
2.2.3 Removing and installing bevel box, Ti‐
guan 2016 ►
Note
The following procedure does not apply to vehicles with bi- tur‐
bocharger.
Removing and installing bevel box - vehicles with 2.0 l - 176 kW

TDI engine and bi-turbocharger ⇒ page 35

AG. Volkswa7-speed
gen AG
do dual clutch gearbox 0DL - Edition 04.2017
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mer
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c
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or
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te
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pr
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by lksw
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♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Puller - T 10472-
2. Bevel box 49
♦ Engine support - T10533-
AG. Volkswagen AG d
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Removing
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height.
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Note
t to the co
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ercia

m
a
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tion in
r
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s
Note
iva
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fo

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– Move selector lever to »N« position. rig ht
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co Vo
by lksw
– Remove noise insulation below engine and gearbox. ⇒ Gen‐ cted agen
Prote AG.
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation
Vehicles with petrol engine:
– Remove connecting hose between charge air cooler and

charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
overview - charge air system .
Vehicles with diesel engine:

– Disconnect connector -1-.

– Unscrew bolt -2- and push auxiliary pump for heating - V488-
to right side. Do not disconnect any lines ⇒ Rep. gr. 19 ;
Coolant pump, regulation of cooling system; Assembly over‐
view - electric coolant pump .
Continued for all vehicles:
– Disconnect connector -1- from oil level Aand

G. Vooil
lkswtemperature
agen AG
agen does
sender - G266- . Volksw not
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– Remove right drive shaft ris ⇒ Running gear, axles, steering;
e nte
tho Removing and installing drive shaft .
Rep. gr. 40 ; Drive shaft;
u
eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
shaft .
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Caution nf
ercia
Risk of damage to decoupling element.

rm
m
atio
m
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly

o
n in
c
overview - emission control .

or
thi
te
sd
iva
o
r
rp
cu
o
– Remove front exhaust system from engine, raise it and tie it in

m
f
en
ng
t.
place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly op
yi Co
overview - silencer .
C py
t. rig
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If fitted, remove heat shield for propshaft. cop Vo
by lksw
cted agen
Prote AG.
– Unscrew bolts -A- and -B- from bevel box, and remove heat
shield -1-.
2. Bevel box 51

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– Unbolt front propshaft from bevel box
ss a -arrows-. c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
a
Note
com
tion in
r
te o
thi
To loosen »next« bolt, turn propshaft further by turning rear
s
iva
wheels at same time. do

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew pendulum support bolts -1- from gearbox.

– Place a cloth on subframe to avoid damaging paint of prop‐
shaft when it is placed on subframe.

– Push font propshaft back to stop. Make sure not to damage

seal -arrow- in centring bush.
– Place front propshaft on heat shield or on subframe as appro‐
priate.
– Set up engine support - T10533- as shown in figure and tighten

bolts hand-tight.
• -A- thin end
• -B- thick end
Bolt -3- = original pendulum support bolt
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded
hole for noise insulation.
It may be necessary to push the gearbox forwards slightly in order
to attach the engine support - T10533- .
– Force engine/gearbox as far forwards as possible by turning
spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
– Unbolt gearbox carrier for bevel box.
Diesel engine:
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
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bevel box. swa
gen AG does
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spec
Petrol engine:
t to the co
– Unscrew bolts -1- and -2-, and remove carrier from bevel box.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
2. Bevel box 53

gearbox.


AG. Volkswagen AG d
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y V gu
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au ra
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nl
pt
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es, in part or in w
t to the co

rrectness of i
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nform
mercia
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om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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t. rig
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AG. Volkswagen AG d
agen oes
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Arteon 2018 ➤ d by, Passat 2015 ➤ , Passat Variantgu2015
V
ara ➤ , Tiguan 2016 ➤ , ...
e nte
thoris 7-speed dual clutch gearbox e or
0DL - Edition 04.2017
s au ac
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nl
pt
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from bevel box.
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Installing
m
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c
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ate
do
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for
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o
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cted agen
Prote AG.

splines - G 000 100- .
Note


Caution
To ensure that the retaining ring of the stub shaft engages

properly in the differential bevel gear, strike the face of the
2. Bevel box 55

– Unbolt gearbox carrier for bevel box. Observe installation lo‐
cation and tightening sequence of bolts ⇒ page 88 .
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
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ab
ility
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is n
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ole,
– Mount drive shaft heat shield -1-, if present, on bevel box
spec

shaft .
t to the co
– Fit propshaft on bevel box.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
Note
en
ng
t.
yi Co
Cop py
When removing and installing the bevel box, do not damage the
t. rig
gh ht
yri by
seal in the propshaft flange -arrow-. Renew propshaft if damaged. cop Vo
by lksw
cted agen
Prote AG.
– Join bevel box and propshaft by turning spindle of engine sup‐

port - T10533- . Take note of seal in propshaft flange when
doing this.
– Remove engine support - T10533- .

– Bolt propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Propshaft;

Removing and installing propshaft .
– If present, install heat shield for propshaft.
AG. Volkswagen AG d
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y V gu
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nl
pt
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ility
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hole
spec
– Secure pendulum support to gearbox using new bolts -1-.
es, in part or in w
t to the co
Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
rrectness of i
l purpos
– Install parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/

silencers .
nform
ercia
Continue installation in reverse order of removal.

m
at
om
ion
c
in t
or
his
ate
⇒ page 162 .
do
priv
cum
or

f
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2.3 Detaching bevel box from gearbox -
AG.
gearbox removed
2. Bevel box 57
AG. Volkswagen AG d
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♦ Hexagon key extension, 8 mm - 3247- olksw
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♦ Puller - T 10472-
rrectness of i
l purpos
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mercia
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com
tion in
r
te o
thi
s
iva
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t.
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Cop py
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rig ht
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Removing by c lksw
cted agen
Prote AG.
– Remove gearbox with bevel box ⇒ page 89 .
– Secure gearbox with bevel box to assembly stand
⇒ page 157 .
In the following illustrations the bevel box is shown in installed
condition.
gearbox.


AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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– Fit puller - T 10472- to bevel box. ss c
ce
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nl
pt
du
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
l purpos
– Bolt multi-purpose tool - VW 771- onto puller T10472 and

nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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for
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Cop py
t. rig
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pyri by
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Installing
2. Bevel box 59

splines - G 000 100- .
– Insert bevel box and press against gearbox.
Note

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gen AG does
swa
– If splines are correctly positioned by V and shafts are centred, then t gua
o lk no
bevel box will slide againstricontact
sed surface on gearbox. ran
tee
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ss
Caution
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le
un
pt
an
d
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Retaining ring on stub shaft must engage correctly in differen‐
y li
rm
ab
tial bevel gear. If retaining ring is not engaged, there is a risk
pe
ility
that stub shaft might move outwards.
ot
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Also, bevel box is not allowed to be bolted onto gearbox force‐
hole
fully. Damage to gearbox or bevel box could result in both
spec
cases.
es, in part or in w
t to the co
– To ensure that the retaining ring engages properly in the dif‐
rrectness of i
ferential bevel gear, strike the face of the spline stub several
times with a plastic hammer (weight 1000 - 2000 g).
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– Screw on bevel box with new bolts -arrows- until finger-tight, nform
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com
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– After installing gearbox, check oil level and top up

te o
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⇒ page 162 .
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3 Selector mechanism
⇒ “3.1 Assembly overview - selector mechanism”, page 61
⇒ “3.2 Emergency release from position P”, page 64
⇒ “3.3 Removing and installing selector lever handle”,
page 65
⇒ “3.4 Moving push button in the handle to installation position”,
page 70
⇒ “3.5 Removing and installing selector mechanism”, page 71
⇒ “3.6 Removing and installing selector lever cable”, page 78
⇒ “3.7 Checking selector mechanism”, page 83
⇒ “3.8 Checking and adjusting selector lever cable”, page 83
⇒ “3.9 Renewing oil seal for selector shaft”, page 85
3.1 Assembly overview - selector mecha‐

nism
⇒ “3.1.1 Assembly overview- selector mechanism, Passat 2015
►, Passat Estate 2015 ►, Arteon 2018 ►”, page 61
⇒ “3.1.2 Assembly overview- selector mechanism, Tiguan 2016
►”, page 63
3.1.1 Assembly overview- selector mechanism, Passat 2015 ►, Passat Estate

2015 ►, Arteon 2018 ►
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61
Prote AG.
3. Selector mechanism
7-speed dual clutch gearboxa0DL - .Edition
gen AG
Volkswag04.2017
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1 - Handle with selector cover
ris
ed
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❑ Do not remove handle
au
t or
ac
without reason.ssFor
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emergency release, on‐ un
pt
ly the cover needs to be
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unclipped ⇒ page 64 .
erm
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⇒ page 65
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2 - Bolt
spec
❑ Qty. 4
t to the co
❑ 8 Nm
3 - Selector mechanism
rrectne
❑ With integrated selector
lever sensor control unit
ss
- J587- with selector lev‐
o
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f
er - E313- , Tiptronic
inform
switch - F189- , switch
mer
for selector lever locked
atio
m
in P - F319- and selector

o
n
c
lever lock solenoid -
i
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N110-
t
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⇒ page 71
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4 - Selector lever cable
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⇒ page 78
❑ Checking ⇒ page 83
❑ Adjusting ⇒ page 83
5 - Securing clip
6 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
7 - Selector housing
8 - Cover
9 - Bolt
❑ For selector cable support bracket to gearbox
❑ Qty. 2
❑ 20 Nm + 90°
10 - Gearbox
11 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm

3.1.2 Assembly overview- selector mechanism, Tiguan 2016 ►
1 - Handle with selector cover

⇒ page 65
2 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid -
N110-
⇒ page 71
3 - Bolt
❑ Qty. 4
❑ 8 Nm
4 - Plug
5 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
6 - Selector housing
7 - Gearbox
8 - Bolt AG. Volkswagen AG d
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❑ 20 Nm + 90°
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9 - Bolt
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❑ Adjuster screw for selector lever cable

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spec
❑ 13 Nm
es, in part or in w
t to the co
10 - Securing clip
❑ Always renew after removing.
❑ Installation position: offset side points forwards towards front end.
rrectness of i
11 - Selector lever cable

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❑ Selector lever cable is not greased

❑ Removing and installing ⇒ page 80
nf
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❑ Checking and adjusting ⇒ page 83

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3. Selector mechanism 63
3.2 Emergency release from position P

⇒ “3.2.1 Emergency release from position P, Passat 2015 ►, Pas‐
sat Estate 2015 ►, Arteon 2018 ►”, page 64
⇒ “3.2.2 Emergency release from position P, Tiguan 2016 ►”,
page 64
3.2.1 Emergency release from position P,

Passat 2015 ►, Passat Estate 2015 ►,
Arteon 2018 ►
Do not remove handle
– Depress brake pedal or set handbrake.
– Open lid of storage compartment.
olks
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– Grasp under selector riselever
d cover with one hand, and unclip ran
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cover by pulling itutupwards.
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– Push selector cover to one side.
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rrectne
– Using a screw driver, from right side, press yellow plastic part
and hold in this position.
ss
Selector lever can now be moved from position »P«.

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3.2.2 Emergency release from position P, Ti‐
cted agen
Prote AG.
guan 2016 ►
♦ -T10383/2-

Do not remove handle

– Depress brake pedal or set handbrake.
– Fit wedge - T10383/2- at front between centre console and
selector cover, and lever selector cover off centre console by
carefully pushing wedge downwards.
– Push selector cover to one side.
– Push yellow plastic lever backwards in direction of arrow and

hold in this position.
Selector lever can now be moved from position »P«.
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3.3 Removing and installing selector lever ss a c
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⇒ “3.3.1 Removing and installing selector lever handle, Passat
erm
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2015 ►, Passat Estate 2015 ►, Arteon 2018 ►”, page 65
ot p
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⇒ “3.3.2 Removing and installing selector lever handle, Tiguan

h re
hole
2016 ►”, page 67

spec
es, in part or in w
3.3.1 Removing and installing selector lever t to the co
handle, Passat 2015 ►, Passat Estate

2015 ►, Arteon 2018 ►
rrectness of i
l purpos

♦ Hose clip pliers - V.A.G 1275-
nf
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Brief description
Handle is removed together with selector cover.
Removing
– Shift selector lever to position “D”.
The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Disconnect electrical connector.
AG. Volkswagen AG d
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– Cut open clamp -arrow- d byunder
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boot using side cutters. gu
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– Pull handle upwards
ut
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possible to install the handle.

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spec
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Installing
t to the co
Install in reverse order of removal, observing the following:

• Selector lever is in position “D”.
rrectness of i
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Note
♦ There is a chance that the button could be pressed into the

handle. Never install a handle with the button pressed in.
♦ Move push button to installation position ⇒ page 70 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
– Push on handle with new clamp -arrow- to stop. Do not tighten

AG. Volkswagen AG d
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– Press push
ris button after installation.
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If not installed correctly, the button remains inserted in the handle

rm
ab
after being pressed. If this happens, pull handle off again and
pe
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move push button to installation position again ⇒ page 70 . Then

wit
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fit the handle again.

h re
hole
spec
es, in part or in w
– If the press button moves back to its start position, the clamp
t to the co
can be tightened using the hose clip pliers - V.A.G 1275- .

– Connect electrical connector.
rrectness of i
– Clip cover in position.

l purpos
nform
ercia
3.3.2 Removing and installing selector lever

m
a
com
tio
handle, Tiguan 2016 ►

n in
r
te o
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67
AG.
3. Selector mechanism
♦ Hose clip pliers - V.A.G 1275-
♦ -T10383/2-
Brief description
Handle is removed together with selector cover.
Removing
– Shift selector lever to position “D”.
olkswagen AG
en AG. V
The push button -arrow- does not need to be pulledoout ksw by hand.
ag does
not
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Push button engages automatically in installation
ed
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spec
t to the co
– Fit wedge - T10383/2- at front between centre console and

rrectne
selector cover, and lever selector cover off centre console by

carefully pushing wedge downwards.
s
– Disconnect electrical connector.

s o
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mer
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AG. Volkswagen AG d
– Cut open clamp -arrow- under boot using
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– Pull handle upwards off selector ris
elever without pressing push
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button. utho eo
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Do not press button again after removal as it will no longer be
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Installing
es, in part or in w
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• Selector lever is in position “D”.
rrectness of i
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Prote AG.
Note
♦ There is a chance that the button could be pressed into the

handle. Never install a handle with the button pressed in.
♦ Move push button to installation position ⇒ page 70 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
lkswage es n
Arteon 2018 ➤ , Passat by 2015
Vo ➤ , Passat Variant 2015 ➤ u,aTiguan 2016
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– Push on handle with new clamp -arrow- to stop. Do not tighten
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If not installed correctly, the button remains inserted in the handle
t to the co
after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 70 . Then
fit the handle again.
rrectness of i
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– If the press button moves back to its start position, the clamp
can be tightened using the hose clip pliers - V.A.G 1275- .
nform
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– Connect electrical connector.

m
– Clip cover in position.
at
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3.4 Moving push button in the handle to in‐

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If the button was pressed by mistake, the installation position can cop Vo
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There are 2 ways of moving the push button into the installation
position, »with« and »without« installation guard. Both of them are
described here.
Place handle »with« installation guard in installation position:
When using the installation guard, make sure that it has an eyelet
-arrow- at the front. Other types of installation guard are not suit‐
able.
– Holding down push button, completely push in installation

guard with eyelet -arrow- until installation guard engages, then
release push button. When the installation guard is pulled out,
the push button engages in the installation position.
Place handle »without« installation guard in installation position:

– Carefully unclip handle trim -A- upwards.
– Using e.g. a screwdriver press small lever -1- for pull rod into
groove -2-. This action presses the push button -3- back into
installation position.
-I- = button pressed in
-II- = button in installationagposition
en AG. V
olkswagen AG
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♦ Press the lever only into the groove and no further.
ce
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♦ Do not clip the handle trim onto selector mechanism until the
itte
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handle has been fitted. This makes it possible to check wheth‐

ab
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er the small lever engages in the pull rod when the button is
ot
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pressed.
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spec
es, in part or in w
3.5 Removing and installing selector mech‐

t to the co
anism
rrectness of i
⇒ “3.5.1 Removing and installing selector mechanism with selec‐

tor lever cable”, page 71
l purpos
⇒ “3.5.2 Removing and installing selector mechanism without se‐

lector lever cable, Passat 2015 ►, Passat Estate 2015 ►, Arteon
nform
ercia
2018 ►”, page 73

m
a
com
⇒ “3.5.3 Removing and installing selector mechanism without se‐

tion in
lector lever cable, Tiguan 2016 ►”, page 75

r
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thi
s
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3.5.1 Removing and installing selector mech‐

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anism with selector lever cable

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Brief description
C py
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In the interior, the centre console must be removed.
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cted agen
Prote AG.
The heat shield beneath the vehicle must be removed.
Removing
– Remove selector lever handle ⇒ page 65 .
– Remove centre console with securing bracket ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Remove footwell air duct ⇒ Heating, air conditioning; Rep. gr.

87 ; Air duct; Assembly overview - air routing and air distribu‐
tion in passenger compartment .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove air filter housing.
Passat, Tiguan with diesel enginen AG. Volkswagen A
ge G do
swa es
– ⇒ Rep. gr. 23 ; Airbfilter;
yV
olk Removing and installing air
not
gfilter
ua
housing rised ran
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Tiguan with petrol
ss
au
engine ac
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e
– ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter

nl
pt
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an
housing
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ility
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– Pry selector lever cable -arrow- off lever using an open-ended
, is n
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spanner.
hole
spec
es, in part or in w
t to the co
Caution
Locks on selector lever cable break off very easily. If a locking
rrectness of i
lug has broken off, complete selector mechanism with selector
lever cable must be renewed.
l purpos
nform
ercia
– Carefully push locking mechanisms of selector lever cable to‐

gether -arrows- and remove selector lever cable upwards out
m
at
of cable support bracket.

om
ion
c
in t
r
– Do not bend or kink cable.

o
his
ate
do
riv
– Remove propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;

p
cum
or
Propshaft; Removing and installing propshaft .

f
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ng
t.
yi Co
– Install centre tunnel heat shield below selector mechanism ⇒ Cop py
t. rig
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/ yri
gh by
ht
extensions; Removing and installing floor heat shield .
op Vo
by c lksw
cted agen
Prote AG.

– If fitted, remove bracket -A-.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards.
Installing
the following:
Note
♦ Do not bend or kink gear selector cable.

♦ Do not grease selector lever cable.
♦ Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
– Install heat shield below selector mechanism ⇒ General body

repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– Install propshaft on all-wheel drive model ⇒ swRep. AG. Volkswagen AG d
agen gr. 39 ; oes
Propshaft; Removing and installing propshaft
by Volk
. not
gu
a d ran
ise
– Install footwell air duct ⇒ Heating, hoair conditioning; Rep. gr.
r tee
ut or
87 ; Air duct; Assembly overview
ss
a - air routing and air distribu‐ ac
tion in passenger compartment .
ce
le
un
pt
an
– Install centre console securing bracket and centre console ⇒
d
itte
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General body repairs, interior; Rep. gr. 68 ; Centre console;
erm
ab
Assembly overview - centre console .
ility
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– Install selector lever handle ⇒ page 65 .
h re
ole,
spec
– Adjust selector lever cable ⇒ page 83 .
t to the co
– Check selector mechanism ⇒ page 83 .
– Install air filter housing.
rrectne
Passat, Tiguan with diesel engine
ss
housing
o
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f inform
Tiguan with petrol engine

mer
atio
m

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c
housing
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Specified torques
iva
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♦ Selector housing to body

fo
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ng
⇒ “3.1 Assembly overview - selector mechanism”, page 61

t.
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Cop py
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p by
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by lksw
cted agen
anism without selector lever cable, Pas‐
Prote AG.
sat 2015 ►, Passat Estate 2015 ►,

Arteon 2018 ►
Brief description
Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove centre console vent ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Remove mounting bracket for centre console ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Removing and
installing centre console .
– Shift selector lever on selector mechanism to position “N”.
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐

moving.
AG. Volkswagen AG d
w agen oes
– Release the cable as shown with a screwdriver, andy Vpull
olks off not
gu
from the selector lever -arrows-. ise
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an
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ility
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h re
ole,
spec
t to the co
– Remove securing clip -arrow-.

rrectne
Always renew securing clip.

s
– Pull selector lever cable out of selector mechanism.

s o
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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pr
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fo
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Cop py
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Vo
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Prote AG.


– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
Install in reverse order of removal. During
n AG. Volkswagthis procedure, observe
en AG
the following: wage does
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Notes au ra
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ab
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h re
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spec
• Selector lever on selector mechanism must be set to position
t to the co
“N”.
– Insert cable into selector mechanism, attach to selector lever
and fit new securing clip.
rrectne
s
s o
cial p
– Install mounting bracket ⇒ General body repairs, interior; Rep. f inform

mer
atio
om
sole .
n
c
i
or
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e
– Install centre console vent ⇒ Heating, air conditioning; Rep.

t
sd
va
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
i
o
pr
cum
r
tribution in passenger compartment .

fo
en
ng
t.
yi Co
– Install centre console ⇒ General body repairs, interior; Rep. Cop py
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gr. 68 ; Centre console; Removing and installing centre con‐ yri
gh by
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sole .
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AG.

Specified torques
♦ Selector housing to body ⇒ page 61

anism without selector lever cable, Ti‐
guan 2016 ►
Brief description
Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
sole .
– If fitted, remove footwell air duct ⇒ Heating, air conditioning;

Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– If fitted, remove mounting bracket -2-. To do this, unscrew
bolts -1- on right and left.
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Install centre tunnel heat shield below selector mechanism age⇒
es n
olksw
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/ ot g
V
by ua
extensions; Removing and installing floor heatrisshield
ed . ran
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– Remove plug and securing clip -arrow-.
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– Fit a large screwdriver in grooves of locking element and turn
rm
m
atio
it 90° in direction of arrow.
om
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c
– Pull selector lever cable out of selector mechanism.

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– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
the following:
Note


“N”. Only in this position the selector lever cable can be en‐
gaged.
– Insert selector lever cable into selector mechanism until it is

visible in locking mechanism -arrow-.
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– With a large screwdriver, turn locking element 90° in direction

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ion
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ate
– The selector lever cable is properly engaged when the

do
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grooves in the locking element are at right angles to the se‐

um
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lector lever cable.

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– Install new securing clip -arrow- and insert plug.

– If previously removed, install mounting bracket -2- ⇒ General

body repairs, interior; Rep. gr. 68 ; Centre console; Removing
and installing centre console .
– If featured, install footwell air duct ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
Specified torques
♦ Selector housing to body ⇒ page 63
3.6 Removing and installing selector lever

cable olksw
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⇒ “3.6.1 Removing and installing selector lever cable, Passat
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s
⇒ “3.6.2 Removing and installing selector lever cable, Tiguan ce
le
un
2016 ►”, page 80

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2015 ►, Arteon 2018 ►

ole,
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Removing
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Diesel engine
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
rrectne
and installing air filter housing

ss o
cial p
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spanner.
Caution


– Remove parts of ⇒ exhaust system; Rep. gr. 26 .
– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew

agen
after
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– Release the cable as shown with a screwdriver, and pull off

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from the selector lever -arrows-.

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– Remove securing clip -arrow-.

– Pull cable out of selector mechanism and remove.
Installing
the following:
Note

♦ Following installation, selector lever cable must be checked
for ease of movement and be adjusted.

“N”.
– Install propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
– Check and adjust selector lever cable ⇒ page 83 .
Diesel engine:
– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
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cable, Tiguan 2016 ► thori ed ran
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Removing ss
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Diesel engine
an
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ab
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spec

housing
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cial p
f inform
mer
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Rep. gr.34 - Controls, housing

spanner.
Caution


– Remove plug and securing clip -arrow-.

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– Fit a large screwdriver in grooves of locking element and turn

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it 90° in direction of arrow.

t to the co
– Pull cable out of selector mechanism and remove.

rrectness of i
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♦ Ensure that selector lever cable moves freely after installing.

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“N”. Only in this position the selector lever cable can be en‐
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– Insert selector lever cable into selector mechanism until it is

visible in locking mechanism -arrow-.
– With a large screwdriver, turn locking element 90° in direction

of arrow.
– The selector lever cable is properly engaged when the

grooves in the locking element are at right angles to the se‐
lector lever cable.
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– Install new securing clip -arrow- and insert plug.

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es, in part or in w

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– Install propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;

rrectness of i
– Check and adjust selector lever cable ⇒ page 83 .

l purpos

nf
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– Install air filter housing.

orm
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3.7 Checking selector mechanism

The starter must not operate in the selector lever positions “R”,
“D” and “S” and in the Tiptronic position.
On right-hand drive vehicles, the starter must operate in selector
lever positions “P” and “N” only when the button in the selector
lever handle is not pressed.
Above 5 km/h:
wage e
When the selector levery Visolkshifted
s to “N”, the selectors lever
not
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solenoid must not lock ised bthe selector lever. Selector lever can
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Below 5 km/h:s
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When the selector lever is shifted to “N”, the selector lever lock
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solenoid must lock the selector lever only after approx. 1 second.
rm
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Selector lever cannot be shifted out of “N” position until brake
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Selector lever in “P” position and ignition switched on
hole
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• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “P” position
when the button is pressed. Solenoid for selector lever lock blocks
rrectness of i
selector lever.
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• Brake pedal is depressed:

Solenoid for selector lever lock releases selector lever. It is pos‐
nform
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sible to shift into a driving gear. Slowly shift selector lever from
m
“P” through to “S”, checking whether selector lever position in

a
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dash panel insert corresponds to selector lever position.

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

sible to shift into a driving gear.
Selector lever in position “Tiptronic”
• Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
When the selector lever is shifted into the Tiptronic gate, the se‐
lector lever position display in the dash panel insert must change
from “P R N D S” to “6 5 4 3 2 1”.
Ignition and light switched on
The respective symbol in the shift mechanism cover lights up.
Selector lever position indicator
Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
3.8 Checking and adjusting selector lever

cable
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Brief description
Selector lever cable must be removed from gearbox so that its
nf
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ease of movement can be checked. Put removed end down so it
rm
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Then the selector lever must be moved and after that, the Bowden
or
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Then the selector lever cable must be adjusted.
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Always adjust selector lever cable if the following applies:
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♦ The selector lever cable has been removed from the gearbox. cted agen
Prote AG.
♦ The engine and/or gearbox has been removed and installed.

♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
Check
– Switch selector lever to »P« position.
– Remove air filter housing.
Diesel engine
housing
housing


spanner.
Caution


– Shift selector lever several times from position »P« to »S« and
back to »P«. gen AG
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Adjusting
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– Move selector lever in vehicle to “P” position.
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– Selector shaft on gearbox is also in position “P”. To check,
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push lever opposite to driving direction to rear stop.
hole
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Note
Raise vehicle, to be sure that the gearbox is in “P” (parking lock
rrectness of i
engaged). It should not be possible to turn both front wheels to‐
l purpos
gether in the same direction.

nform
ercia
– Loosen bolt -2- of the Bowden cable -1-.

m
– Gently push knob of selector lever forwards and backwards

com
tion in
but under no circumstances must you shift out of “P”.

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– Tighten bolt -2- to 15 Nm.

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This completes the adjustment.

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– Install air filter housing. Cop py
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– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter Prote AG.
housing
housing
3.9 Renewing oil seal for selector shaft

Brief description
The seal can be renewed only with the gearbox removed.
♦ Tube - VW 423-
♦ Extractor hook - T20143-
♦ Not illustrated: Torque wrench - V.A.G 1331-

– Remove gearbox ⇒ page 89 .
– Remove selector lever cable from gearbox ⇒ page 71 .
– Unscrew securing nut -arrow- and carefully pull gearbox se‐
lector lever -A- off selector shaft.
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– Pry seal out -in direction of arrow-.

es, in part or in w
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– Lightly oil outer circumference of new oil seal.

rrectness of i
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Prote AG.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
AG. Volkswagen AG d
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– Drive new seal in onto limit stop. Do not cant oil seal in the
es, in part or in w
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• Closed side of oil seal -arrow- points towards tube - VW 423- .
rrectness of i
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– Install gearbox selector lever -A-, and tighten new nut

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-arrow-. Specified torque: ⇒ Item 21 (page 153) .
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Gearbox selector lever fits on splines in only one position
C py
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– Install gearbox ⇒ page 146 . cop Vo
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– Install and adjust selector lever cable on gearbox ⇒ page 83 .
4 Removing and installing gearbox

⇒ “4.1 Specified torques for gearbox”, page 88
⇒ “4.2 Removing gearbox”, page 89
⇒ “4.3 Installing gearbox”, page 146
⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
page 57 wage
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4.1 Specified torques
ris
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b ara
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⇒ “4.1.1 Gearbox carrier to engine
ss
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nl
Item Bolt Nm
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1, 2, 3 M12x55 80
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4 M12x65 80
5, 6, 7 M10x50 40
rrectness of i
8 M12×70 80
A Dowel sleeves for centring
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Component Nm
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Assembly mountings to gearbox (renew bolts after 60 Nm + turn 90° further
m
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each removal)
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Earth strap to assembly mounting 25

thi
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Heat shield for right drive shaft to bevel box 20

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Propshaft to bevel box ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - prop‐

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ng
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shaft
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Bevel box to gearbox 40 Nm + 90° further
♦ Renew bolts after re‐
moving.
4.1.1 Gearbox carrier to engine and bevel box

Installation location and tightening sequence:
Diesel engine
Item Bolt
A M10 x 21
B M10 x 45
Sequence Bolts Specified torque

1) -A- and -B- Screw in to contact by hand
2) Tighten -A- 40 Nm
3) Tighten -B- 40 Nm
Petrol engine

Installation location and tightening sequence:

Item Bolt
1 M10 x 21
2 M10 x 45 AG. Volkswagen AG d
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1) -1- and -2- Screw in to contact
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2) Tighten -2- s
40 Nm
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3) Tighten -1- 40 Nm
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♦ Bolt -A-: 20 Nm
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♦ Bolt -B-: 40 Nm
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4.2 Removing gearbox
i
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⇒ “4.2.1 Removing gearbox, Passat 2015 ►, Passat Estate 2015
o
pr
cum
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►, Arteon 2018 ►, vehicles with 2.0 l - 176 kW TDI and bi-turbo‐
en
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charger”, page 89 Cop
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⇒ “4.2.3 Removing gearbox, Tiguan 2016 ► vehicles with 2.0 l -
105 kW, 110 kW, 130 kW, 140 kW diesel engine, all-wheel drive”,
page 111
⇒ “4.2.4 Removing gearbox, Tiguan 2016 ►, vehicles with petrol
engine, all-wheel drive”, page 120
⇒ “4.2.5 Removing gearbox, Tiguan 2016 ►, vehicles with diesel
engine, front-wheel drive”, page 130
⇒ “4.2.6 Removing gearbox, Tiguan 2016 ►, vehicles with 2.0 l -
176 kW TDI”, page 137
4.2.1 Removing gearbox, Passat 2015 ►,

Passat Estate 2015 ►, Arteon 2018 ►,
vehicles with 2.0 l - 176 kW TDI and bi-
turbocharger
Brief description
The gearbox is removed downwards together with the bevel box.
»From above«
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Support engine and gearbox before left
subframe mounting is unbolted.
»From below«
The -subframe- is removed together with -pendulum support- and
-both suspension links-.
4. Removing and installing gearbox 89

Both drive shafts are disconnected from AGgearbox

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mer
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♦ Support - 10-222A-
♦ Shackle - 10 - 222 A /12-
♦ Support - 10 - 222 A /31-
♦ Engine support, basic set - T40091-
♦ Engine support supplement set - T40093-
♦ Gearbox support - 3282-

♦ Engine and gearbox

jack - V.A.G 1383 A-
or engine and gear‐
box jack - VAS 6931-
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♦ Adjustment plate -
3282/42 A-
rrectness of i
♦ Hose clamps to 25
mm - 3094-
l purpos
♦ Tensioning strap -
T10038-
nform
ercia
♦ Set of plugs for en‐

m
at
om
gine - VAS 6122-

on
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in t
or
♦ Insert tool, 18 mm -
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ate
T10179-
do
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f
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T10509-
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♦ Socket, multi-point bit

XZN 14 - T10061-

♦ Counter-hold tool -
T10172A-
♦ Support bridge -
T10323-
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♦ Adapter -
es, in part or in w
T40093/3-6- : qty. 2
t to the co
(check and modify as
necessary
⇒ page 92 )
rrectness of i
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agen
– If necessary, cut off

the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as -
T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be fitted onto longitudinal
members with adapters -
T40093/3-6A- .

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Removing:
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rrectness of i
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So that the propshaft can
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– Remove complete air
yi Co
op
filter housing ⇒ Rep.
C py
t. rig
gh
gr. 23 ; Air filter; Re‐
ht
pyri by
Vo
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moving and installing by c lksw
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air filter housing . Prote AG.
Battery in engine com‐

partment
– Remove battery and
battery tray ⇒ Electri‐
cal system; Rep. gr.
27 ; Battery; Remov‐
ing and installing bat‐
tery tray .
Battery in luggage com‐
partment
– Remove air filter housing bracket ⇒ Rep. gr. 23 ; Air filter;

Removing and installing air filter housing .
The bracket is similar to the one shown.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .

– Pry selector lever cable off selector shaft lever -arrow- using
an open-ended spanner.
Caution


olksw
– Clamp off coolant hoses using hose clamps ageto
n A40
G. Vmm -a3093-
gen AG
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– Seal connecting necks of gear
tho oil cooler using suitable plugs
ri e or
from engine bung set - VAS
s 6122- .
au ac
s
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ility
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ole,
spec
t to the co
– Disconnect connector -1- for mechatronic unit for dual clutch
gearbox - J743- . To do this, turn rotary locking mechanism
rrectne
anti-clockwise -arrow-.
– Remove charge air pipe ⇒ Rep. gr. 21 ; Charge air system; ss
Assembly overview - charge air system .
o
cial p
f inform
mer
atio
om
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or
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Cop py
.
– Unscrew upper engine/gearbox connecting bolts using insert
ht rig
rig ht
by
tool 18 mm - T10179- or insert tool 18 mm - T10509- . copy Vo
by lksw
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A bolt is located in the starter motor hole -arrow-. This bolt can be
removed using socket - T10061- .
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222A- , remove these now.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
– Install support bracket - 10-222 A- as follows:

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Required material: Volksw
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♦ Adapter - 10 - 222 A /31-2- ss a c
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♦ Adapter - T40093/3-6- : qty. 2 (check and modify as necessary
hole
spec
⇒ page 92 )
es, in part or in w
t to the co
♦ or adapter - T40093/3-6A- : qty. 2
– Detach cover caps on bolted connections for suspension
struts (front).
rrectness of i
– Fit adapter - 10 - 222 A /31-1- and adapter - 10 - 222 A /31-2-
l purpos
-A- onto suspension strut mountings.

The webs -arrow- must face towards front end.
nf
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atio
– Slide connector - T40091/3- onto support bracket - 10-222 A- .
om
n in
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– Bolt support bracket - 10-222 A- to adapter - 10 - 222 A /31-1-

thi
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and to adapter - 10 - 222 A /31-2- .

iva
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-A- = adapter - T40093/3-6A- (⇒ next figure)

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Cop py
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– Remove fuel filter and lay to side. Do not open pipe/hose sys‐
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
– Position adapter - T40093/3-6A- on left longitudinal member

directly behind filler pipe for washer fluid reservoir.
• Each of the adapters - T40093/3-6A- locks with pin -A- behind
the web of the longitudinal member -arrow-.
– Screw on spindle from engine support supplement set -
T40093 /3- , connect it via square tube - T40091/1- to engine
support bracket - 10-222 A- and fasten connection (⇒ previous
fig.).
• The square tube - T40091/1- must be flush with the connecting
piece - T40091/3- and the engine support supplement set -
AG. Volkswagen AG d
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– Then attach spindles to engine support db
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– Take up weight of engine/gearboxs auassembly and support ac
bracket on spindles . s
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le
un
pt

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ab
sulation .
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ility
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– Remove lower part of front left wheel housing liner ⇒ General

h re
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐

hole
spec
sembly overview - front wheel housing liner .

es, in part or in w
t to the co
– Remove electrical wiring and retainers from sump at front

-arrows-.
rrectness of i

l purpos
nform
mercia
a
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tion in
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te o
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Prote AG.


sender - G266- .
Remove subframe. ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe
shaft .
– Disconnect both drive shafts from gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft: Removing and in‐
stalling drive shafts .
Secure both drive shafts to suspension struts using tensioning

straps - T10038- .
The surface protection of the shafts must not be damaged.
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– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
an
d
itte
box.
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4. Removing and installing gearbox
olkswagen AG
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– Mark position of propshaft with flexible coupling
ss
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c
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nl
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spec
es, in part or in w
t to the co
rrectness of i
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– Unbolt propshaft from bevel box -arrows- ⇒ Rep. gr. 39 ;

nf
ercia
orm
m
atio
om
n in
or c
thi
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– Secure support - T10323- with a bolt on inside rear threaded

hole for subframe.
– A securing bolt from the subframe is suitable for this.
– Place cloth -A- on support and put propshaft on that.

Note
♦ When removing and installing, do not damage seal in the

propshaft flange -arrow-.
♦ Renew propshaft if damaged. ⇒ Rep. gr. 39 ; Propshaft; Re‐
moving and installing propshaft
♦ All parts of propshaft which have been marked relative to each
other must be reinstalled in the same positions.

AG. Volkswagen
– Remove all but one »easily accessible«
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bolt
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– Remove securing bolts
au -arrows- of assembly mounting for en‐ ac
ss
gine ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview
ce
le
- assembly mountings .
un
pt
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pe
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es, in part or in w
t to the co
rrectness of i
l purpos
– Remove securing bolts -arrows- of assembly mounting for

gearbox. nform
mercia
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tion in
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– Then use spindles of support bracket - 10 - 222 A- to lower
engine/gearbox »only« on gearbox side as far as dimension
-a-.
Dimension -a- = about 110mm
The gearbox is separated from the engine in this position.
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐
box support - 3282- under gearbox.

– Mount safety support -1- and hook -2- on gearbox as shown.
AG. Volkswagen AG d
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– Mount safety support -3- and pin -4- on gearbox as shown.
hole
spec
es, in part or in w
– Remove »last« connecting bolt between engine and gearbox.
t to the co
– Push gearbox off engine and lower it carefully, ensuring
»clearance« to other components.
rrectness of i
Transporting gearbox ⇒ page 151 .
l purpos
Secure gearbox to assembly stand ⇒ page 157 .

Install gearbox ⇒ page 146 .
nform
mercia
a
com
tion in
r
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4.2.2 Removing gearbox, Passat 2015 ►,
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Passat Estate 2015 ►, vehicles with pet‐
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Brief description
op Vo
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Prote AG.
The gearbox is removed downwards separately.
»From above«
The battery is disconnected and, if located in engine compart‐
ment, removed. The air filter and starter are removed. The engine
and gearbox must be supported before the left subframe mount‐
ing is removed.
»From below«
-Subframe- is removed together with -pendulum support- and
Both drive shafts are disconnected from gearbox and left installed
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.


equipment required
AG. Volkswagen AG d
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rrectness of i
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c
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ate
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♦ Support - 10 - 222 A-
AG.
♦ Adapter - 10 - 222 A /29-

♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- qty. 2
♦ Pin - 3282/29-
♦ Engine and gearbox jack - V.A.G 1383 A- or engine and gear‐

box jack - VAS 6931-
♦ Adjustment plate - 3282/67-
♦ Hose clamps to 25 mm - 3094-
♦ Tensioning strap - T10038-
♦ Set of plugs for engine - VAS 6122-

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♦ Insert tool, 18 mm - T10179-
nl
pt
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es, in part or in w
t to the co
rrectness of i
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nf
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♦ Socket, multi-point bit
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ab
XZN 14 - T10061-
pe
ility
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es, in part or in w
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rrectness of i
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nform
ercia
♦ Square tube -
m
a
com
ti
T40091/1- , qty. 2
on in
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♦ Connecting piece -
T40091/3- , qty. 2
♦ Spindle - T40093 /3-
from engine support
supplementary set -
T40093- , qty. 2
♦ Adapter -
T40093/3-6- : qty. 2
(check and modify as
necessary
⇒ page 104 )
♦ or adapter -
T40093/3-6A- : qty. 2

Check adapters -
T40093/3-6- and modify
as necessary
– If necessary, cut off
the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as -
T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be fitted onto longitudinal
members with adapters -
T40093/3-6A- .
• To prevent damage
to the longitudinal
members, wrap the
front section of the
adapters -
T40093/3-6A- with n AG. Volkswagen AG do
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textile-reinforced ad‐ byV
olk ot g
ua
hesive tape ⇒ Elec‐ ir se
d ran
tee
tronic parts catalogue utho
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a ac
stances) .
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Removing
itte
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– Raise vehicle. All 4
ility
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supports of lifting
wit
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platform must be at
h re
ole,
same height.
spec
– Move selector lever
t to the co
to position »P«.
– Remove engine cov‐
rrectne
er panel ⇒ Rep. gr.
10 ; Engine cover
s
panel; Removing and
installing engine cov‐ s o
cial p
f in
er panel .
form
mer
Battery in engine com‐

atio
m
partment
o
n
c
i
or
n thi
e
– Remove battery and

t
sd
va
battery tray ⇒ Electri‐

i
o
pr
cum
cal system; Rep. gr.

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fo
en
ng
27 ; Battery; Remov‐
t.
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ing and installing bat‐ C py
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Battery in luggage com‐ Prote
cted AG.
agen
partment
– Disconnect battery ⇒
Electrical system;
Rep. gr. 27 ; Battery;
Disconnecting and
reconnecting battery .

– Remove air filter housing and bracket located beneath ⇒ Rep.

gr. 24 ; Air filter; Assembly overview - air filter housing .
Caution


– Remove charge air pipe ⇒ Rep. gr. 21 ; Charge air system;
Assembly overvieww-agcharge
en AG. V air system
olkswagen AG.
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– Lay lint-freeedcloths
by on gear oil cooler and gearbox
gu
arato catch
escapingthorcoolant.
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nl
Note
pt
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♦ On a warm engine, the cooling system is under high pressure.

ility
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♦ Before pulling off the coolant hoses, cover the cap on the
, is n
h re
coolant expansion tank with a cloth and open carefully.

hole
spec
es, in part or in w
t to the co
– Clamp off coolant hoses using hose clamps, up to 25 mm in

diameter - 3094- , and detach them.
rrectness of i
– Seal connecting necks of gear oil cooler using suitable plugs

from engine bung set - VAS 6122- .
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
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en
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– Disconnect connector -1- for mechatronics unit for dual clutch
ce
e
nl
pt
du
an
itte
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erm
ab
– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
ility
ot p
wit
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h re
It is advisable to remove the lower bolt first.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew all upper bolts securing engine to gearbox.
nf
ercia
orm
m
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om
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thi
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Cop py
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– Install support bracket - 10-222 A- as follows:
Required material:
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- : qty 2 (required if spindles of support
bracket cannot be hooked into lifting eyes of engine).
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Square tube - T40091/1- , qty. 2
♦ Connecting piece - T40091/3- , qty. 2
♦ Spindles - T40093 /3- qty 2
♦ Adapter - T40093/3-6- : qty. 2 (check and modify as necessary
⇒ page 104 )
♦ or adapter - T40093/3-6A- : qty. 2
– On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐

tween wing mounting flange and sheet metal for mounting
wing underneath it.
♦ Installation position:
“L” = -1- adapter is to be used on “right” side of vehicle ( adapter
engages in recess of wing).
“R” (not shown in figure) adapter is to be inserted on “left” side of

vehicle.
Arrow -2- always points in direction of travel.

– Push adapter - 10 - 222 A /18- and two connecting pieces -

T40091/3- onto support bracket - 10-222 A- .
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
29- .
-A- = adapter - T40093/3-6A- (⇒ next figure)
– If present, pull off wires in front area of web on both longitudinal

members -arrow-. Do not disconnect pipe/hose system.
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
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– Position adapter - T40093/3-6A- on left longitudinal member

ab
pe
ility
directly behind filler pipe for washer fluid reservoir.
ot
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• Each of the adapters - T40093/3-6A- locks with pin -A- behind h re

hole
the web of the longitudinal member -arrow-. spec

es, in part or in w
– Screw in spindles - T40093 /3- .

t to the co
– Connect spindles - T40093 /3- via square tubes - T40091/1-

to engine support bracket - 10-222 A- , and tighten (⇒ previous
rrectness of i
illustration).
l purpos
– Then attach spindles to engine support eyes.

– Take up weight of engine/gearbox assembly and support
nform
ercia
bracket on spindles .
m

com
tion in
Rep. gr. 66 ; Noise insulation .

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– Remove electrical wiring and retainers from sump tatho front
ris
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-arrows-. au ra
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ss
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ility
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h re
ole,
spec
t to the co
rrectne
sender - G266- .
ss o
cial p
f
– Remove subframe ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
inform
view - subframe .
mer
atio
m
– Unbolt drive shafts from gearbox ⇒ Running gear, axles,

o
n
c
steering; Rep. gr. 40 ; Drive shaft .
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bevel box.

– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.


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Install gearbox ⇒ page 146 . h re

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4.2.3 Removing gearbox, Tiguan 2016 ► ve‐

t to the co
hicles with 2.0 l - 105 kW, 110 kW, 130

kW, 140 kW diesel engine, all-wheel
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Brief description
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»From above«
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nform
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♦ Pin - 3282/29-
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Removing
height.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
– Remove battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .

Caution


– Clamp off coolant hoses using hose clamps to 40 mm - 3093-

or hose clamps to 25 mm - 3094- and remove.
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port eyes for support bracket - 10 - 222 A- , remove these now.
– Remove gas strut of bonnet from bottom ball-head pin and
prop up bonnet using workshop means ⇒ General body re‐
pairs, exterior; Rep. gr. 55 ; Bonnet; Removing and installing
gas strut .
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Required material:
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♦ Adapter - 10 - 222 A /18-
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• First, slide adapter - 10-222A/16- onto left side of support

bracket ⇒ page 116 .
• Adapter - 10-222A/16- serves to secure support bracket dur‐
ing subsequent work routine.
• Once support bracket is complete, adapter - 10-222A/16- is
located between adapter - 10 - 222 A /18- and left adapter -
10 - 222 A /29- .
– Push adapter - 10 - 222 A /18- and adapter - 10 - 222 A /3-
onto support bracket - 10-222 A- .
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spec
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-arrows-.


sender - G266- .
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4.2.4 Removing gearbox, Tiguan 2016 ►, ve‐

h re
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hicles with petrol engine, all-wheel drive

spec
t to the co
Brief description
The gearbox is removed downwards separately.
rrectne
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The battery is disconnected and, if located in engine compart‐

s o
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cial p
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and gearbox must be supported before the left subframe mount‐

form
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equipment required
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♦ Adapter - 10 - 222 A /29- , qty. 2

♦ 2 × -T40091/1- and -T40091/3- from engine support basic set
- T40091-
♦ 2 × swivel joints - T40093/3- from engine support supplemen‐
tary set - T40093-


♦ Shackle - 10 - 222 A /12-
AG. Volkswagen AG d
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panel; Removing and installing
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♦ On a warm engine, the cooling system is under high pressure.

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coolant expansion tank with a cloth and open carefully.
– Clamp off coolant hoses using hose clamps, up to 25 mm in

diameter - 3094- , and detach them.


– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
It is advisable to remove the lower bolt first.
– Unscrew all upper bolts securing engine to gearbox.
Supporting engine
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– On both
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tween wing and mounting plate for wing located underneath.
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A- .
rrectness of i
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l purpos
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nform
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– Unscrew bolts -arrows- for lock carrier bracket on left and right.
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replace them with adapters -10-222 A /28-2- .
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carrier from adapter - 10-222 A /28-2- .
– Bolt adapter - 10-222 A /28-2- to lock carrier using securing

bolt -1-. Specified torque: 8 Nm

– Set-up square tubes - T40091/1- with one spindle each as

shown.
– Engage spindles in support eyes of engine. Use shackle - 10
- 222 A /12- if necessary.
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Rep. gr. 66 ; Noise insulation .
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l purpos
view - subframe .
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gearbox.
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Note
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at
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♦ Adapter - 10 - 222 A /29-

♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-

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Assembly overview - charge air system

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Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .

-arrows-.

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erm
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40 ; Subframe; Assembly overview - subframe
ility
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straps - T10038- .
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gearbox.


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The following diagrams show the gearbox in the all-wheel drive
h re
hole
version. The procedure for supporting the weight of the gearbox
spec
is the same as that for front-wheel drive.
es, in part or in w
t to the co
rrectness of i
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hicles with 2.0 l - 176 kW TDI
Brief description
»From above«
The battery, air filter and starter are removed. Wiring harness of
steering rack is disconnected and »moved clear«. This allows it
to be lowered together with subframe and steering rack. The en‐
gine and gearbox must be supported before the left and right
assembly mounting is removed.
»From below«
Remove noise insulation beneath engine and cover in front left
wheel housing.
-steering rack-.


equipment required
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♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-


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♦ Support bridge - T10323-
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♦ Adapter - 10 - 222 A /16-

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Removing
height.

Caution


of cable support bracket. . Volkswage
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th clamps to 40 mm - 3093- eo
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ss and remove. c
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Assembly overview - charge air system atio

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ra ➤ , ...
ss 7-speed dual clutch gearbox 0DL - Edition 04.2017
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rrectness of i
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Required material:
♦ Adapter - 10 - 222 A /3-
nform
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♦ Adapter - 10 - 222 A /18-

m
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♦ Shackle - 10 - 222 A /12-
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ing subsequent work routine.
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tery tray.
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sulation .

-arrows-.


sender - G266- .
view - subframe
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straps - T10038- .
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– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
box.



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Propshaft; Re‐ tee
moving and installing propshafts aut or
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gearbox. by c lksw
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-a-.


4.3 Installing gearbox

Install in the reverse order of removal observing the following:
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– Renew needle bearing in crankshaft
au
th ⇒ Rep. gr.
o
13 ; Crank‐ e or
ac
shaft; Renewing needle bearing
ss in crankshaft .
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Note
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If the needle bearing in the crankshaft is damaged, the gears
wit
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cannot be selected properly any more because the clutch is sup‐
h re
ported on this bearing. hole
spec
es, in part or in w
t to the co
– Lightly grease journal and splines on gearbox.
– Check for proper seating of both dowel sleeves between en‐
rrectness of i
gine and gearbox.
l purpos
– Check for proper seating of intermediate plate.

It must be possible to guide the engine and gearbox together by
nform
ercia
hand until the engine flange and gearbox flange make contact all
around.
m
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tio
– If necessary, readjust gearbox support until engine and gear‐
n in
r
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box are »aligned with each other«.
thi
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– Turn crankshaft slightly if necessary.
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Install gearbox, taking care not to pinch any lines.

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– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐ by c lksw
cted agen
moving and installing starter . Prote AG.
– If engine and gearbox were removed, install them ⇒ Rep. gr.

10 ; Removing and installing engine; Installing engine
Pay attention to selector lever cable when installing. Guide cable
as soon as possible into cable support bracket.
– Install subframe. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Assembly overview - subframe
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shafts .
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant .
gr. 66 ; Noise insulation; Removing and installing noise insu‐
lation .

5 Assembly mountings
⇒ “5.1 Assembly overview - assembly mountings”, page 148
5.1 Assembly overview - assembly mountings
1 - Bolt
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly n AG. Volkswagen AG do
mountings; Assembly lkswage es n
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overview - assembly byV ua
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mountings ir se tee
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2 - Engine support ss
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nl
❑ ⇒ Rep. gr. 10 ; Assem‐
pt
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bly mountings; Assem‐
itte
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bly overview - assembly
erm
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mountings
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3 - Engine mounting
h re
hole
spec
❑ ⇒ Rep. gr. 10 ; Assem‐
es, in part or in w
bly mountings; Assem‐
t to the co
bly overview - assembly
mountings
rrectness of i
4 - Bolt
l purpos
gr. 10 ; Assembly
mountings; Assembly
nform
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overview - assembly
mountings
m
at
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5 - Bolt
n
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gr. 10 ; Assembly
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mountings; Assembly
um
for
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mountings t. Cop py
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6 - Bolt yri
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❑ Specified torque ⇒ Rep. cted agen
Prote AG.
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
7 - Bolt
❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
8 - Pendulum support
9 - Bolt
❑ For pendulum support to subframe
10 - Bolt
❑ For pendulum support to gearbox
❑ Gearbox with threaded insert ⇒ page 149
11 - Bolt
❑ For pendulum support to gearbox
❑ Gearbox with threaded insert ⇒ page 149

12 - Bolt
❑ For securing gearbox mounting to gearbox console.
❑ Tightening sequence ⇒ page 150
❑ 60 Nm +90°
13 - Bolt
❑ For securing gearbox mounting to gearbox console.
❑ Qty. 2
❑ Tightening sequence ⇒ page 150
❑ 60 Nm +90°
14 - Gearbox mounting
❑ Check adjustment ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - checking adjustment of
assembly mountings
❑ Adjust ⇒ Rep. gr. 10 ; Assembly mountings; Adjusting assembly mountings
15 - Bolt
❑ Gearbox mounting to body
16 - Bolt
❑ For securing gearbox console to gearbox. n AG. Volkswagen AG do
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❑ Tightening sequence ⇒ page 150hor is tee
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❑ 40 Nm +90° ss
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17 - Gearbox bracket
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❑ Illustration does not correspond to version in vehicle.
y li
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18 - Bolt
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❑ For securing gearbox console to gearbox.
h re
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spec
es, in part or in w
❑ Tightening sequence ⇒ page 150 t to the co

❑ 40 Nm +90°
rrectness of i
Gearbox with threaded insert (e.g. “Heli-Coil”) for securing pen‐

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Note
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♦ Distinguishing feature: shoulder along beginning of thread

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5. Assembly mountings 149

Install left assembly mounting as follows:

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– The gearbox bracket -A- can be levered into its seat with a
un
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screwdriver while bolts -2- are being tightened.
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6 Transporting gearbox
AG. Volkswagen AG d
Special tools and workshop equipment required agen oes
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♦ Workshop hoist - VAS 6100-
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Always secure heavy parts when transporting them.
Also remember there is oil in the gearbox. Do not turn gearbox
with breathers downwards during transport or while on repair
stand. Oil will run out.
Note
If necessary, pull off breather cap and close using suitable plugs
to achieve an oil-tight seal.
Transporting gearbox
Gearbox can be lifted with lifting tackle - 2024 A- .
6. Transporting gearbox 151

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⇒ “7.1.1 Renewing bleeder”, page 154
⇒ “7.1.2 Renewing sealing cap”, page 154
rrectne
1 - Retaining ring
ss
❑ Renew
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2 - Clutch end cover
form
mer
❑ A cover which has been
atio
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removed must not be in‐

o
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stalled again.
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❑ Lubricate external seal

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with dual clutch gearbox
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oil - G 052 182 A2- be‐
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⇒ page 12
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3 - Retaining ring
❑ Renew
4 - Shim
❑ Determine thickness
again if a new clutch has
been fitted ⇒ page 11
5 - Tapered ring
6 - Clutch
⇒ page 11
7 - Seal, right
⇒ page 184
8 - Breather pipe
⇒ page 154
9 - Breather cap
10 - Plug
11 - Seal
❑ Renew
12 - Gear oil cooler
❑ Removing and installing gear oil cooler ⇒ page 158
13 - Bolt, 20 Nm + 45°
❑ Renew
14 - Filter housing, 20 Nm
15 - Seal
❑ Renew

16 - Heat shield
17 - Oil filter
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18 - Bolt, 5 Nm + 90° Volkswa not
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❑ Renew ris
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19 - Cable support
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❑ For selector lever cable to gearbox
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20 - Gearbox selector lever
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21 - Bolt, 10 Nm + 90°
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❑ Renew
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22 - Gearbox
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23 - Seal, left
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24 - Seal
❑ Renew
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25 - Oil drain plug, 20 Nm
nform
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❑ For mechatronic unit

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

ferent lengths and colours.
♦ If the oil level pipe is renewed, it
is essential that the oil level pipe
appropriate for the gearbox is in‐
stalled ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Do not install the oil level pipe
from another gearbox! The oil
level pipe determines the oil level
in the gearbox.
♦ Fitting a different oil level pipe
can result in the oil level in the
gearbox being too high or too
low.
❑ Drain and fill oil ⇒ page 164
27 - Seal
❑ Renew
28 - Oil drain plug, 45 Nm
29 - Bolt, 10 Nm
30 - Gearbox input speed sender - G182- and oil temperature sender in multi-plate clutch - G509-
7. Dismantling and assembling gearbox 153

31 - Mechatronic unit for dual clutch gearbox - J743-

32 - Bolt, 8 Nm + 45°
❑ Renew
33 - Cover
❑ With seal
❑ Renew
34 - Bolt, 10 Nm + 45°
❑ Renew
35 - Securing clip
❑ Renew
36 - Seal
❑ Renew
7.1.1 Renewing bleeder

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

pipe -2-.
rrectness of i
– Pry off breather pipe -2- with screwdriver -1-.

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Installing
– Push on breather pipe -2- powerfully by hand.
nf
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or
Breather pipe must be heard and felt to engage.

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– Put on cap.
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7.1.2 Renewing sealing cap C py
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♦ -1- Internal puller - Kukko 21/2-
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♦ -4- Counter support - Kukko 22/1- auth eo
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♦ Special wrench - T40297-
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♦ Knife, commercially available
inform
mer
Removing
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om
n
c
i
or
n
height.
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– Remove front left wheel.

t.
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Cop py
– Remove front left wheel housing liner ⇒ General body repairs,
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exterior; Rep. gr. 66 ; Wheel housing liners; Removing and
p by
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installing front wheel housing liner . Prote
cted AG.
agen
– Pierce centre of cap with a knife -1- and remove rubber coating
around it. Diameter of opening approx. 15 mm.
7. Dismantling and assembling gearbox 155

– Pull sealing cap out of gearbox housing using internal puller

14 … 19 mm -B-, e.g. -Kukko 21/2- , and counter support
-A-, e.g. -Kukko 22/1- .
– Thoroughly clean sealing surface on gearbox housing with a
lint-free cloth.
Installing
– Using key - T40297- , drive new sealing cap into gearbox

housing to stop. Take care not to cant sealing cap.
– Check gear oil level ⇒ page 162 .
– Install front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– Install front left wheel ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres; Changing wheels .
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Prote AG.

8 Installing to engine and gearbox sup‐

port
Keep in mind that there is oil in the gearbox. Do not turn gearbox
with breathers downwards during transport or while on repair
stand. Oil will run out.
Note
If necessary, pull off breather cap and close using suitable plugs
to achieve an oil-tight seal.
Example: securing gearbox to assembly stand.
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8. Installing to engine and gearbox support 157

9 Gear oil circuit
9.1 Removing and installing gear oil cooler

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♦ Not illustrated: Torque wrench d by-VV.A.G 1331- gu
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Removing utho eo
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– Move selector lever to position “P”. s
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and installing air filter housing y li

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– Remove battery and battery tray ⇒ Electrical system; Rep. gr. wit
, is n
27 ; Battery; Removing and installing battery . h re

hole
spec
– Lay lint-free cloths on gear oil cooler and gearbox to catch

es, in part or in w
escaping coolant.
t to the co
– Clamp off coolant hoses using hose clamps -3094- and re‐
move from cooler.
rrectness of i
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ion
c
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do
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for
en
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– Remove bolts -A- and remove gear oil cooler -B-.
Caution
No coolant must be allowed to drip into gearbox!
Installing
the following:
– Renew O-rings -C-. n AG. Volkswagen AG do

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– Set gear oil cooler -B-
ir se
d in place. When doing this, note O-rings
b ua
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-C-. tho tee
or
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– Screw in new bolts -A- and tighten to 20 Nm + 45°.
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– Attach coolant hoses to gear oil cooler and remove hose

com
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clamps -3094- .
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– Install battery with battery tray ⇒ Electrical system; Rep. gr.

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27 ; Battery; Removing and installing battery .

n
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– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
t. rig
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and installing air filter housing . p by
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– Check coolant level and top up with coolant as needed ⇒ Rep. Prote AG.
gr. 19 ; Cooling system, coolant; Draining and filling coolant .
– Checking and adjusting oil level ⇒ page 162 .
9.2 Removing and installing gear oil filter

Oil filter change – »yes or no?«
The oil filter does not have to be changed as a matter of course.
Do not change the filter if:
♦ The gear oil cooler or its O-rings have been renewed and no
coolant has got into the oil.
9. Gear oil circuit 159

♦ The oil seal for the selector shaft has been renewed.
♦ The oil seal for the flange shaft was renewed.
♦ Leaking covers in the mechatronic unit, dual clutch or oil pump
have been renewed. gen AG
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The filter must be changed if: byV gu
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♦ Coolant has got into the oil. tho eo
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♦ Metal particles have been found in the oil.s
ce
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♦ The clutch is burnt out or has a mechanical defect.
an
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Note
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Refer to general repair instructions ⇒ page 6 .
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Removing
rrectne
Note
ss
The gear oil filter cannot be removed with the gearbox installed.
o
cial p
f
The gearbox must be separated from the engine beforehand.
inform
mer
atio
– Removing gearbox ⇒ page 89
om
n
c
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Note
iv
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♦ A residual amount of oil remains in oil filter. It runs out when

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filter housing is unscrewed. C py
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♦ Before unscrewing the filter housing, cover the area around copy Vo
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the oil filter with a sufficient number of cloths. cted agen
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– First loosen filter housing -1- by about 7 turns.

– Wait about 10 seconds.
This allows the oil to flow from filter housing back into gearbox.
– Now remove filter housing with filter.
– Renew missing or damaged heat shield -2-.
Installing
the following:
– Thoroughly clean oily areas on gearbox.

– Insert new oil filter with collar -arrow- downwards.

– Screw in filter housing and tighten to 20 Nm.
– Check oil level and top up ⇒ page 162 .
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9. Gear oil circuit 161

10 Gear oil
10.1 Checking gear oil level

If DSG oil must be added, use only oil listed in ⇒ Electronic parts
catalogue “ETKA” .
♦ Vehicle diagnosis, testing and information system - VAS
5051B-
AG. Volkswagen AG d
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♦ Used oil collector and extractor - V.A.G 1782-
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♦ Adapter for oil filling - VAS 6262 A-

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Conditions
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed
5051B- is connected.
♦ At start of work, oil temperature must not be above 45°C.
♦ Test temperature: 35 - 45°C

Check
– Connect vehicle diagnosis, testing and information system -
VAS 5051B- and identify the vehicle in Guided functions .
– Select Dual clutch gearbox .
– Select Check oil level .
Note
If the oil temperature is above 45°C, allow the gearbox to cool

down.
Engine is running at idling speed with selector lever in “P”.

– Remove oil drain plug -arrow-.
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– Renew oil seal -arrow- of bolt.
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Note an
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Even if oil level is too low, a small amount of oil will initially run out
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of oil level pipe because pipe fills up during operation.
, is n
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hole
spec
– Let surplus oil flow out.

es, in part or in w
t to the co
– When excess oil has run out (when it begins only to drip), in‐
stall plug with new seal.
rrectness of i
– Top up oil if no oil flows out.

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Topping up
nform
mercia
at
om
ion
c
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or
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ate
do
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for
en
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Prote AG.
10. Gear oil 163

– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a-, and
shorten it as necessary.
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- .
– Screw adapter of adapter for filling oil - VAS 6262 A- hand-

tight into inspection hole.
WARNING
Shake bottles thoroughly before opening to ensure that sedi‐

ment at the bottom of the bottle mixes well with the oil.
– Fill 1.0 litres of oil.

– Pull off adapter for oil filling - VAS 6262- at plug-in connector
and check:
If oil now flows out of hole in adapter:
Oil does not need topping up.
– Allow surplus oil to drain out.
– When excess oil has run out (when it begins only to drip), re‐
move adapter for filling oil - VAS 6262 A- and install plug with
new seal.
If no oil drips out of inspection hole:
– If a further litre has to be added ⇒ page o162
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An oil level whichssisa too low or too high will impair the function c
of the gearbox.
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Torque setting for drain plug: 45 Nm

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10.2 Draining and filling gear oil

hole
spec
es, in part or in w
If DSG oil must be added, use only oil listed in ⇒ Electronic parts
t to the co
catalogue “ETKA” .
Please also refer to the notes on the oil filter change regarding
rrectness of i
»dirty oil« ⇒ page 159 .

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Brief description
First read the oil temperature. If it is above 50°C, allow the gear‐
nform
ercia
box to cool down.

m
With engine stopped, unscrew and remove overflow pipe and let
a
com
tio
the oil drain out. Then reinstall overflow pipe and »overfill« gear‐
n in
r
box with oil.

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Then start engine and drain excess oil until oil level attains level
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of overflow pipe.
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Special tools and workshop equipment required t. Cop py
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164
Prote AG.

5051B-
♦ Used oil collector and extractor - V.A.G 1782-
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♦ Adapter for oil filling - VAS 6262 A- yV
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Conditions
rrectne
♦ Engine switched off

ss o
♦ Vehicle level, all mountings of lifting platform evenly at same

cial p
f i
height
nform
mer
♦ Noise insulation removed if previously fitted

atio
om
n
c
♦ Selector lever at “P”

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or
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5051B- is connected.
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♦ At start of work, oil temperature must not be above 45 °C.
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– Comply with rules for cleanliness when working on gearbox Prote
cted AG.
agen
⇒ page 5 .
– Only gear oil available as spare part is allowed to be used for
dual clutch gearbox. Other oils will lead to malfunctions or fail‐
ure of the gearbox ⇒ Electronic Parts Catalogue (ETKA) .
10. Gear oil 165

olkswagen AG
ag 2015 ➤ , Tiguando en AG. V
Arteon 2018 ➤ , Passat 2015 ➤ , PassatVoVariant
lksw 2016
es n ➤ , ...
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7-speed dual clutch gearbox 0DL - Edition
sed by
04.2017 ua
ran
ri tee
ho
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ac
ss
WARNING
ce
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nl
pt
du
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itte
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Danger of injury from hot gear oil!
erm
ab
ility
ot p
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– Connect vehicle diagnosis, testing and information system -
h re
hole
VAS 5051B- and identify the vehicle in Guided functions .
spec
es, in part or in w
– Select Dual clutch gearbox .
t to the co
– Select Check oil level .
rrectness of i
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Note
If the oil temperature is higher than 45°C, allow gearbox to cool
nf
ercia
o
down.
rm
m
atio
om
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or c
WARNING
thi
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sd
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Do not start engine if there is no oil in gearbox.
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– Engine switched off - do not start engine! rig ht
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– Remove oil drain plug -arrow-. cted agen
Prote AG.
– Renew oil seal -arrow- of bolt.

– Remove oil level pipe -arrow- and allow oil to run out.
– Remove oil drain plug -arrow- from mechatronic unit.
Note
A further approx. 1.2 litres of oil will run out.
– Renew seal -arrow- and reinstall oil drain plug of mechatronic

agen
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unit, tightening to 20 Nm. yV
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♦ Normally, there is no need to remove oil filter.

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♦ Oil filter change “Yes or no?” ⇒ page 159
ility
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hole
spec
es, in part or in w
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– Screw oil level pipe -arrow- in to stop and tighten to 3 Nm.

rrectness of i
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nform
mercia
at
om
ion
c
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ate
do
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cted agen
Prote AG.
10. Gear oil 167

– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a-, and
shorten it as necessary.
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- .
– Screw adapter of adapter for filling oil - VAS 6262 A- hand-

tight into inspection hole.
WARNING
Shake bottles thoroughly before opening to ensure that sedi‐

ment at the bottom of the bottle mixes well with the oil.
During filling, the adapter for oil filling - VAS 6262 A- and bottle
must always be held higherwthanagen the gearbox.AG doe
AG. Volkswagen
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– Fill 5.5 litres of oil.
ed
by ara
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– When changing
au
th bottles, close tap on adapter. ra
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– Close tap on adapter when 5.5 litres of oil have been added
ce
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to gearbox.
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– Start engine. The adapter for filling oil - VAS 6262 A- may re‐
ab
ility
main connected.
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– Depress brake pedal, and select each selector lever position

h re
ole,
for about 3 seconds, then move lever back to »P«.

spec
– Do NOT switch off engine.

t to the co
– Then check oil level and top up. ⇒ page 162

rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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Cop py
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Prote AG.

35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
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39 – Final drive - differential

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⇒ “1.1 Checking gear oil level”, by Vpage 170 gu
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aut gear oil”, page 172
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hole
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♦ Used oil collector and extractor - VAS 6622A-
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♦ The bevel box is bolted to side of the gearbox and has its own
oil supply.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue “ET‐
KA”
Requirement
• Bevel box must be in installation position.
height.
sulation .
Caution
The following work instruction only applies to the bevel box

“0A6”.
– Before starting work, check which bevel box is installed

⇒ page 34 .
– Put used oil collection and extraction unit - VAS 6622A- un‐
derneath.
170 Rep. gr.39 - Final drive - differential

– Unscrew oil filler plug -1-.

Renew oil filler plug after each removal.
Oil level is correct when bevel box is filled to lower edge of filler
hole.
Note
♦ Clean bevel box thoroughly to remove any remains of the

emerged oil.
♦ Disregard -item 2-.
– If necessary, top up gear oil ⇒ page 172 .

– Screw in new oil filler plug -1-.
– Tighten bolt to specified torque ⇒ page 186 .
1.1.2 Checking gear oil level, bevel box “0CP”

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ss
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Caution

“0CP”.

⇒ page 34 .
1. Gear oil 171

– Put used oil collection and extraction unit - VAS 6622A- un‐
derneath.
Renew oil filler plug after each removal.
• On current bevel boxes, the oil level is beneath the oil filler
hole and can therefore not be checked.
• Should the oil level be up to the lower edge of the oil filler hole,
extract 100 ml of gear oil ⇒ page 175 .
Note
♦ Clean bevel box thoroughly to remove any remains of the

emerged oil.
♦ Disregard -item 2-.
– If necessary, top up gear oil ⇒ page 172 .

– Screw in new oil filler plug -1-.
– Tighten bolt to specified torque ⇒ page 188 .
1.2 Draining and filling gear oil

⇒ “1.2.1 Draining and filling gear oil, bevel box 0A6 ”, page 172
⇒ “1.2.2 Draining and filling gear oil, bevel box 0CP ”, page 175
wage
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♦ The gear oil in the bevel box must only be drained in the event
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hole
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue spec

es, in part or in w
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♦ Filling device - VAS 6291 A-
♦ Adapter for oil filling - VAS 6291/3-
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ss must be used as c
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Requirement
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Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐ op
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sulation .
C py
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– If fitted, remove right drive shaft heat shield from bevel box
op Vo
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-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
cted agen
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shaft; Removing and installing drive shaft .
Caution

“0A6”.
1. Gear oil 173


⇒ page 34 .
– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
WARNING
Risk of injury from hot gear oil.

♦ Wear safety goggles.
♦ Wear acid-resistant gloves
– Unscrew oil drain plug -2-, and drain gear oil.

– Screw in new oil drain plug.
Note
To collect escaping gear oil, leave used oil collection and extrac‐
tion unit - VAS 6622- underneath.
AG. Volkswagen AG d
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– Screw adapter for oil filling -VAS 6291/3- in to stop.

– Engage angled piece of filling device for Haldex coupling 2 -
VAS 6291 A- with adapter for oil filling -VAS 6291/3- .
• Do not allow hose to sag. AG. Volkswagen AG d
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– Top up with oil. d by ara
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– After bevel box has been properly filled, unscrew adapter -
es, in part or in w
VAS 6291/2- .
t to the co
– Screw in »old« oil drain plug and tighten slightly.
rrectness of i
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
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– Turn off engine and unscrew plug from oil filler hole.
nform
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– Check oil level, if necessary top up gear oil again to lower edge
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– Screw in new oil filler plug.
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– If present, install heat shield above right drive shaft ⇒ Running Prote AG.
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and

installing drive shaft .
tion .
1.2.2 Draining and filling gear oil, bevel box

“0CP”
Note
♦ The gear oil in the bevel box must only be drained in the event
of repairs. The oil is not intended to be changed on a regular
basis.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue
1. Gear oil 175

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♦ Filling device - VAS 6291 A-
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♦ Adapter for oil filling - VAS 6291/3-

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♦ For some oil bottles adapter - VAS 6262/6- must be used as

well.

Requirement
• Vehicle is level.
height.


sulation .
– If fitted, remove right drive shaft heat shield from bevel box agen
AG. Volkswagen AG d
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⇒ page 34 .
es, in part or in w
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– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
rrectness of i
WARNING
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ercia
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m
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com
tion in
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– Screw in new oil drain plug.
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Note cop Vo
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To collect escaping gear oil, leave used oil collection and extrac‐
tion unit - VAS 6622- underneath.
1. Gear oil 177

7-speed dual clutch gearbox o0DL
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• Do not allow hose to sag. itte
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rrectness of i
♦ Continue with filling procedure if no oil has run out yet.
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The correct oil level is beneath the oil filler hole and cannot be
ht
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checked.
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If an elevated level is not rectified after filling, oil could escape
through the breather while the vehicle is being driven.
The correct oil level can only be achieved by extracting 100 ml
of gear oil after filling.
– Extract 100 ml of gear oil from the bevel box using a commer‐
cially available syringe with hose measuring max. ∅ 6 mm.
– Screw in new oil filler plug.
Note
Clean bevel box thoroughly to remove any remains of the

emerged oil.
– If present, install heat shield above right drive shaft ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
tion .

2 Oil seals
⇒ “2.1 Overview of fitting locations - seals”, page 179
⇒ “2.2 Renewing left oil seal”, page 179
⇒ “2.3 Renewing right oil seal”, page 182
⇒ “3.2 Renewing bevel box seals”, page 190
2.1 Overview of Gfitting locations - seals

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1 - Stub shaftrisO-ring
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❑ Renew au
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2 - Seal right, bevel box
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⇒ page 193
erm
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3 - Stub shaft
wit
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4 - Right oil seal, stub shaft
hole
spec
❑ Item can be disregarded
es, in part or in w
t to the co
5 - Output shaft seal
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⇒ page 190
l purpos
6 - Deflector ring
❑ Item can be disregarded
nform
ercia
7 - Left oil seal, stub shaft

m

at
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io
⇒ page 190
n
c
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or
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8 - Seal left, bevel box

at
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⇒ page 190
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9 - Seal, right
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❑ Removing and instal‐ p by
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ling, front-wheel drive Prote
cted agen
⇒ page 182
AG.
❑ Removing and instal‐

ling, all-wheel drive
⇒ page 184
10 - Seal, left
⇒ page 179
2.2 Renewing left oil seal
2.2.1 Renewing oil seal for left flange shaft

2. Oil seals 179

♦ Puller - T10055-
AG. Volkswagen AG d
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♦ Thrust piece - T10457-
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♦ Drip tray for workshop hoist - VAS 6208-

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♦ Electric drill, commercially available

Removing
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shafts; Removing and installing drive shafts .
Note
Only drill through sheet metal ring (about 3 mm), otherwise bear‐
ing located behind it might be damaged.

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

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

hole drilled in oil seal. Do not screw in sheet metal screw too
far to avoid damaging bearing behind it.
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
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– Pull out oil seal usingVpuller
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Make sure no metal
au
th chips get into gearbox and into opening foror
ac
drive shaft. Vacuum
ss out metal chips first if necessary.
ce
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– Carefully remove cloths and make sure that no metal chips get
an
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into gearbox.
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– Carefully clean gearbox and opening for drive shaft.
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If only the sheet metal ring could be pulled out, carefully lever out h re
hole
rest of seal with a screwdriver. spec

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

the following:
rrectness of i
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Before installing the seal, apply sealing grease for oil seal - G 052
128 A1- to sealing lips and cavity, and apply oil to outer circum‐
ference.
nform
ercia
Installation position:
m
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tio
Open side of oil seal faces gearbox.

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te o
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– Drive oil seal in to stop with thrust piece - T10457- . Do not
cant oil seal in the process.
2. Oil seals 181

– Grease splines -arrow- of stub shaft with universal grease -

G 060 735 A2- .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
2.3 Renewing right oil seal

⇒ “2.3.1 Renewing seal on right of gearbox, front-wheel drive ve‐
hicles”, page 182
⇒ “2.3.2 Renewing seal on right of gearbox, vehicles with all wheel
drive”, page 184
⇒ “3.2.2 Renewing seal on right of bevel box”, page 193
2.3.1 Renewing seal on right of gearbox,

front-wheel drive vehicles
Special tools and workshop equipment
olks
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♦ Puller - T10055- db ran
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Prote AG.

♦ Drip tray for workshop hoist - VAS 6208-
♦ Electric drill, commercially available

Removing lkswage es n
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byV ua
– Remove right drive shaft ⇒ Running gear, axles, ed
ir ssteering;
ran
o tee
Rep. gr. 40 ; Drive shaft; Removing and installing
auth drive shaft . or
ac
ss
– Grease drill bit -3- so that metal chips adhere to it.
ce
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an
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– Drill only through sheet metal ring -1- (about 3 mm) because
itte
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– Seal drive shaft aperture on transmission with a clean cloth
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-2-.
h re
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spec
– Carefully drill a hole with a drill bit -3- (diameter 2 to 4 mm) into
es, in part or in w
outer sheet metal ring -1- of oil seal.
t to the co
rrectness of i
l purpos
– Screw a self-tapping screw, approx. 4 mm in diameter, into
nform
ercia
hole drilled in oil seal. Do not screw in sheet metal screw too
far to avoid damaging bearing behind it.
m
a
com
tio
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
n in
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te o
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– Pull out oil seal using puller - T10055- and adapter -
s
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Note
C py
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Make sure no metal chips get into gearbox and into opening for
by lksw
cted agen
Prote
drive shaft. Vacuum out metal chips if necessary.
AG.
– Carefully remove cloths. When doing this, make sure that no

metal chips get into gearbox.
– Carefully clean gearbox and opening for drive shaft.
If only the sheet metal ring could be pulled out, carefully lever out
rest of seal with a screwdriver.
Installing
Install in reverse order of removal. Observe the following:
– Apply ATF to circumference and sealing lips of oil seal.
– Press oil seal in straight as far as possible by hand.
2. Oil seals 183


– Then check oil level and top up ⇒ page 162 .
– Grease splines -arrow- of stub shaft with universal grease -

G 060 735 A2- .
2.3.2 Renewing seal on right of gearbox, ve‐

hicles with all wheel drive
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Vol
equipment
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♦ Extractor hooks
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ss o
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Cop py
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co lksw
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Removing
– Remove bevel box ⇒ page 35 .

– Lever out seal on gearbox using puller hook - T20143/1- or -

T20143/2- .
Installing
the following:
Before installing the seal, apply sealing grease for oil seal - G 052
128 A1- to sealing lips and cavity, and apply oil to outer circum‐
ference.

– Install bevel box ⇒ page 35 .
AG. Volkswagen AG d
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t.
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Cop py
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co lksw
by
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185
AG.
2. Oil seals
AG. Volkswagen AG d
agen oes
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan
Vol
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7-speed dual clutch gearbox 0DL - Edition 04.2017 rised ara
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3 Components of bevel box
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itte
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⇒ “3.1 Assembly overview - components of bevel box”,
erm
ab
page 186
ility
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⇒ “3.2 Renewing bevel box seals”, page 190
, is n
h re
hole
⇒ “3.3 Renewing needle bearing (polygon bearing) for stub shaft”,
spec
page 207
es, in part or in w
t to the co
3.1 Assembly overview - components of
bevel box
rrectness of i
⇒ “3.1.1 Assembly overview - components of bevel box, 0A6”,
l purpos
page 186
⇒ “3.1.2 Assembly overview - components of bevel box, 0CP”,
nf
ercia
o
page 188
rm
m
atio
m
3.1.1 Assembly overview - components of

o
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or c
bevel box, 0A6
thi
te
sd
iva
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r
rp
cu
(Seals, stub shaft bearing, output flange in bevel box)
o
m
f
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ng
t.
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Cop py
1 - Seal
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote
❑ Between bevel box and
AG.
bevel box
❑ To renew, remove bevel
box ⇒ page 35
2 - Seal
bevel box
box ⇒ page 35
3 - Plug
❑ With captive seal
❑ 15 Nm
4 - Sealing cover
❑ Drive in to stop with
spacer tube - VW 540
1B- .
5 - Seal
❑ For right stub shaft to
drive shaft
❑ Seal can be renewed
with bevel box installed
❑ Renewing ⇒ page 193
6 - Bevel box
⇒ page 35
7 - Cap
❑ To vent bevel box

8 - Breather pipe lkswage es n
o ot g
byV ua
❑ To vent bevel box ir se
d ran
tee
ho
❑ Press in until stop is reached aut or
ac
ss
9 - Retaining ring
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nl
pt
du
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erm
ab
❑ Insert in circumferential groove in stub shaft
ility
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wit
10 - O-ring
, is n
h re
hole
spec
❑ Insert in circumferential groove in stub shaft es, in part or in w
t to the co
11 - Right stub shaft
❑ To remove and install, remove bevel box ⇒ page 35
rrectness of i
l purpos
12 - Needle bearing (polygon bearing)

❑ Needle bearing (polygon bearing) is difficult to turn with stub shaft removed. The fact it is difficult to move
nform
ercia
does not mean that the bearing is defective. An acoustic test can only be performed with the bearings
installed.
m
at
om
i
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
on
c
in t
or
his
ate
do
riv
13 - Retaining ring
p
cum
for
en
ng
t.
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op
❑ For needle roller bearing (polygon bearing) C py
t. rig
gh ht
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❑ Insert in circumferential groove in stub shaft p by
co Vo
by lksw
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14 - Hexagon nut Prote AG.

❑ Removing ⇒ page 200
❑ Install using locking fluid - D 000 600-
❑ Installing ⇒ page 201
❑ 480 Nm
15 - Output flange
16 - Cover
❑ Not fitted in all bevel boxes
❑ Renew after removing output flange if damaged
❑ Engage with output flange
17 - Seal
❑ For output flange
❑ To renew, remove bevel box ⇒ page 35
18 - Bolt
❑ Tighten diagonally and alternately
❑ 25 Nm
19 - Pinion housing
❑ With shaft bevel gear and inner race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
20 - O-ring
❑ Renew after removing pinion housing
3. Components of bevel box 187

❑ To renew, unscrew bolts ⇒ Item 18 (page 187) and carefully lever off pinion housing at projecting webs
on outside edge
❑ Do not remove hexagon nut ⇒ Item 14 (page 187) and output flange ⇒ Item 15 (page 187)
3.1.2 Assembly overview - components of bevel box, 0CP

(Seals, stub shaft bearing, output flange in bevel box)
1 - Seal
bevel box
box ⇒ page 35
2 - Seal
❑ Renew after removal n AG. Volkswagen AG do
swage es n
❑ For right stub shaft to yV
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ua
gearbox ir se
d b ran
tee
o
❑ To renew, remove bevel auth or
ac
box ⇒ page 35 ss
ce
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nl
pt
3 - Plug
du
an
itte
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ility
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❑ With captive seal
wit
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❑ 15 Nm
h re
hole
spec
4 - Seal
es, in part or in w
t to the co
❑ For right stub shaft to
drive shaft
❑ Seal can be renewed
rrectness of i
with bevel box installed
l purpos

5 - Bevel box nf
ercia

orm
⇒ page 35
m
atio
om
n in
6 - Breather pipe
or c
thi
e
❑ To vent bevel box

t
sd
iva
o
r
❑ Press in until stop is

rp
cu
o
reached
f
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ng
t.
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op
7 - Cap
C py
t. rig
gh ht
yri
❑ To vent bevel box p by
co Vo
by lksw
cted agen
8 - Retaining ring Prote AG.

9 - O-ring
10 - Right stub shaft
11 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with stub shaft removed. The fact it is difficult to move
does not mean that the bearing is defective. An acoustic test can only be performed with the bearings
installed.

❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
AG. Volkswagen AG d
agen
❑ Renewing ⇒ page 207 Volksw
oes
not
g y ua
db ran
12 - Retaining ring ris
e
tee
tho or
❑ Renew after removal ss
au ac
❑ For needle roller bearing (polygon bearing)
ce
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nl
pt
du
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itte
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ab
13 - Retaining ring
ility
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, is n
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hole
spec
es, in part or in w
14 - Retaining ring
t to the co
rrectness of i
l purpos
15 - Shim
nf
ercia
o
16 - Output flange
rm
m
atio
m

o
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17 - Seal
thi
te
sd
iva
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cu
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❑ Renew after removing output flange
f
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ng
t.
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❑ Renewing ⇒ page 202 ht. Cop py
rig
rig ht
18 - O-ring py by
co Vo
by lksw
cted agen
Prote AG.
❑ Renew after removing output flange
19 - Bolt
❑ 38 Nm
20 - Pinion housing
❑ With shaft bevel gear and inner race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
21 - O-ring
❑ Renew after removing pinion housing
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
❑ Do not remove output flange

3.2 Renewing bevel box seals

⇒ “3.2.1 Renewing left seal between bevel box and gearbox on
bevel box”, page 190
⇒ “3.2.2 Renewing seal on right of bevel box”, page 193
⇒ “3.2.3 Renewing bevel box output flange seal, 0A6, bevel box
removed”, page 197
⇒ “3.2.4 Renewing bevel box output flange seal, 0CP, bevel box
removed”, page 202
3.2.1 Renewing left seal between bevel box

and gearbox on bevel box
♦ Multi-purpose tool - VW 771/37-
AG. Volkswagen AG d
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olksw not
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ab
pe
ility
ot
♦ Removal tool - T20143-

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
190
cted agen
Prote AG.
Rep. gr.39 - Final drive - differential
♦ Thrust piece -T10380-
Note
Seals (Qty. 2) can be renewed only with bevel box removed. Al‐
ways renew both seals. en AG. V
olkswagen AG
wag does
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Removing ed
b ara
nte
ris
tho eo
– Remove bevel box ⇒ page 35 . au ra
c
ss
ce
Remove »outer« seal.

le
un
pt
an
d
itte
– Lever out seal using puller hook - T20143/2- .

y li
erm
ab
ility
Remove »inner« seal.

ot p
wit
is n
h re
ole,
spec
Note
t to the co
So that new seal will not be damaged later on:

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

swage es n
– Remove retaining ring -1- from stub shaft. byV
olk ot g
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d ran
ir se
– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
tho tee
or
tion of arrow. ss
au ac
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le
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Pull out seal for stub shaft on gearbox side.
rrectness of i
Installing
l purpos
Drive in »outer« seal.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
yri by
– Half-fill space between sealing lip and dust lip of new seal cop Vo
by lksw
-arrow- with sealing grease - G 052 128 A1- . cted agen
Prote AG.
– Drive in seal to stop.

Drive in »inner« seal.

– Half-fill space between sealing lip and dust lip of new seal
-arrow- with sealing grease - G 052 128 A1- .
– Drive in seal to stop.

– Carefully use plastic mallet to drive in stub shaft to stop.
– Fit new retaining ring -1- on stub shaft.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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pt
an
d
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ility
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3.2.2 Renewing seal on right of bevel box wit

is n
h re
ole,

spec
♦ Removal tool - T20143-

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

♦ Hub grease cap puller - VW 637/2-
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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aut ra
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nl
pt
du
an
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erm
ab
ility
ot p
♦ Drip tray - V.A.G 1306-

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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♦ or drip tray for workshop hoist - VAS 6208-

thi
te
sd
iva
♦ Sealing grease
o
r
rp
cu
o
m
f
en
ng
♦ Grease for splines

t.
yi Co
Cop py
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) . ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Seal can be renewed with bevel box installed.
Removing
– Raise vehicle.
– Remove noise insulation beneath engine/gearbox ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assem‐
bly overview - noise insulation .

– If fitted, remove drive shaft heat shield -1- from bevel box
-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
The right drive shaft heat shield is secured with 2 or 3 nuts ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft .
– Remove right drive shaft. ⇒ Running gear, axles, steering;
– Place drip tray or used oil collection and extraction uniten-AV.A.G
G. Volkswagen AG d
1782- underneath. olks
wag oes
no
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db ara
rise nte
tho eo
au ra
c
ss
ce
le
– Remove retaining ring -arrow A- and O-ring -arrow B- from
un
pt
an
stub shaft.
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Note
atio
om
n
c
Some bevel boxes have protective cap -arrow- installed on right.
i
or
n thi
Renew protective cap each time after removing.
te
sd
iva
o
pr
cum
r
fo
Pull off protective cap.

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Position hub cap puller - VW 637/2- in recess -arrow- and lever

off protective cap.

. Volkswagen AG
7-speed dual clutch gearboxw gen AG
a0DL - Edition 04.2017
does
olks no
yV t gu
db ara
– Lever out seal. rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Installing
s
s o
cial p
f in
– Half-fill space between sealing lip and dust lip -arrow- with
form
mer
sealing grease .
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– Drive in seal to stop. Prote AG.
– Fit new retaining ring and new seal on stub shaft.

Bevel box with protective cap
– Drive on new protective cap to stop.

– Then install retaining ring -arrow A- and O-ring -arrow B-.

– Grease splines of stub shaft using grease for clutch plate

splines .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr. wage
es n
40 ; Drive shaft; Removing and installing drive shafts . yV
olks ot g
u b ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Install heat shield -1- for drive shaft ⇒ Running gear, axles,
es, in part or in w
t to the co
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
rrectness of i
tion .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
3.2.3 Renewing bevel box output flange seal,
fo
en
ng
t.
yi
0A6, bevel box removed
Co
Cop py
ht. rig
rig ht
The output flange is secured with a nut -A-.
py by
co Vo
by lksw
cted agen
Disregard -B- and -arrows-.
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Support clamp - VW 313-

♦ Tube - VW 516-
♦ Thrust plate - 40-105-
♦ Gearbox support - T10108-
♦ Support plate - T10108/1-

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Two-arm puller - VAS 251 001- or e.g. two-arm puller - Kukko
20/10-
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
♦ Extractor hook - VW 771/37-
♦ Sealing grease
♦ Universal grease
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ 2 bolts M10 x 30
♦ 4 nuts M12 x 10
Note
The bevel box oil seal for the output flange can only be renewed
with the bevel box removed.

– Fit bevel box on gearbox support - T10108- onto hole

-arrow- marked with the number -5-.
AG. Volkswagen AG d
agen oes
A - Lay nuts M12 x 10 (qty. 4) between bevel box and gearbox olks
w not
yV gu
support . Nuts function as spacers. ed b ara
nte
ris
ho eo
– Then align bevel box with hole opposite and secure. au
t ra
c
ss
– Place container underneath.
ce
e
nl
pt
du
an
itte
– Drain oil from bevel box.
y li
erm
ab
– Lock output flange for bevel box with stop plate - T10108/1- .
ility
ot p
Screw in M10 x 30 bolts -arrows- to do this.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing hexagon nut for output flange

m
A - 36 mm socket for 3/4" drive
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Swing bevel box so that output flange points upwards.

– Pull output flange off shaft bevel gear of bevel box.
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
– Pull out seal -A- for output flange.

– Clean residual locking fluid from thread of shaft bevel gear.
– Clean any oil seal residue away from area on shaft bevel gear.

Installing
– Drive in new oil seal to stop using thrust piece - T10049- .
– Half-fill space between sealing lip and dust lip with sealing
grease .
– Lightly lubricate splines of output shaft with universal grease .
– Pull in output flange using two arm puller -A-.

A - Two-arm puller - VAS 251 001- or e.g. two-arm puller - Kukko
20/10-
Please note the following:
• Use new or nearly new puller hooks!
• The output flange must not be canted.
• Fit puller hooks as far as they will go onto underside of pinion
housing.
• Take up slack on puller hooks fully with two arm puller
-arrows-.
• Puller hooks should not bend outwards.
• If necessary, halt pulling process, pull off output flange again
and restart pulling process.
. Volkswagen AG
gen AG d
Coat thread of new hexagon
Vol
ksw
a
nut with locking fluid
oes
D
not000 600
y gu
db ar
– Tightening new
ris hexagon nut for output flange to specified
e an
tee tor‐
que. tho or
au a c
ss
Specified torque ⇒ Item 14 (page 187)
ce
e
nl
pt
du
an
A - 36 mm socket for 3/4" drive

itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.07 mm.
– Check gear oil level in bevel box ⇒ page 170 .
Specified torques
♦ ⇒ “3.1.1 Assembly overview - components of bevel box, 0A6”,
page 186
3.2.4 Renewing bevel box output flange seal,

0CP, bevel box removed lksw
agen
AG. Volkswagen AG d
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n
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The output flange is secured with a retaining rring
ise -A-.
d ran
tee
tho or
Located behind retaining ring -A- is a washer
sa
u -B-. ac
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pt
du
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itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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om
n in
or c
thi
te
sd
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
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nl
pt
du
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
♦ Support clamp - VW 313-
orm
m
atio
♦ Gearbox support - T10108-
om
n in
or c
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -

thi
te
Kukko 45-2-
sd
iva
o
r
rp
cu
♦ Extractor hook - T20143-

o
m
f
en
ng
t.
yi Co
♦ Locking tool - T40265- Cop py
t. rig
gh ht
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♦ Drift sleeve - 40-21- p by
co Vo
by lksw
cted agen
Prote AG.

♦ Drip tray - V.A.G 1306-

♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealing grease
♦ Universal grease
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ 2 x bolts M10 x 30
♦ 4 nuts M12 x 10
Note
AG. Volkswagen AG d
The bevel box oil seal for the output flange can only be renewed ksw
agen oes
with the bevel box removed. ol not
y V gu
d b ara
rise nte
tho eo
– Remove bevel box ⇒ page 35 . s au ra
c
s
ce
– Fit bevel box on gearbox support - T10108- onto hole
le
un
pt
-arrow- marked with the number -5-.
an
d
itte
y li
rm
ab
A - Lay nuts M12 x 10 (qty. 4) between bevel box and gearbox
pe
ility
support . Nuts function as spacers.
ot
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– Then align bevel box with hole opposite and secure.
hole
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– Place container underneath.
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– Drain oil from bevel box.
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– Swing bevel box so that output flange points upwards.

– Pull output flange off shaft bevel gear of bevel box.
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
– Lever out seal -A- for output flange.

• Take care not to damage the seat for the oil seal in the hous‐
ing.
– Clean any oil seal residue away from area on shaft bevel gear.
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– Remove O-ring -A- from shaft. pt

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screwdriver.
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– Place new O-ring -3- on bevel gear shaft -2- in pinion housing
atio
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-1-.
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• O-ring must be located behind splines and in base of sur‐

rounding groove -arrow-.
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– Drive new seal in onto limit stop.
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– Half-fill space betweenrisealing
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– Lightly lubricate splines of output shaft -A- with universal
grease .
– Carefully drive output flange -A- onto shaft as far as stop using rrectness of i
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a plastic hammer.
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– Fit washer -A-. opyri
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– Secure output flange in position with retaining ring -B-. Prote
cted AG.
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– Retaining ring -B- features an uneven contour -arrow 1-.

• Retaining ring -B- must be located in base of surrounding
groove -arrow 2-.

Measure radial run-out on output flange/shaft bevel gear.
Note
After securing the output flange, the radial run-out on the centring
pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.07 mm.
– Check gear oil level in bevel box ⇒ page 170 .
Specified torques
♦ ⇒ “3.1.2 Assembly overview - components of bevel box, 0CP”,
page 188
3.3 Renewing needle bearing (polygon bearing) for stub shaft
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equipment required
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♦ Thrust plate - VW 401- rig ht
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♦ Thrust plate - VW 402- cted agen
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♦ Press tool - VW 407-

♦ Press tool - VW 412-
♦ Assembly tool - 3253/5-
♦ Tensioning device - T10047-

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♦ Thrust pieces for drive pinion bearing - VW 470-

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♦ Socket and extended bit 6 mm - T10107 A-

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♦ Counter-hold tool - T10371-

spec
es, in part or in w

t to the co
♦ Splitter - VAS 251 409- , or splitter 22 …75 mm , e.g. -Kukko

17/1-
rrectness of i
♦ 2 bolts M10 x 90
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♦ 2 x hexagon socket head bolts M12 x 80 with M12 nuts

nform
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Removing
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– Remove noise insulation beneath engine/gearbox ⇒ General

at
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– Align both parts of tool so that marks “B” are opposite one
another.
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– The shoulders -arrows- must then be below the bearing.
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– Now screw both halves together to stop.
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– Lever off retaining ring -A- for needle bearing.
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Installing
– Align both parts of tool so that marks “B” are opposite one
another.

– To avoid damage to running surface of bearing on shaft, turn

shaft during pressing procedure -arrow-.
– Secure needle bearing with a new retaining ring.
– Carefully use plastic mallet to drive in stub shaft to stop.
– Fit new retaining ring -1- on stub shaft.

– Install heat shield. Specified torque ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
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– Check oil level in bevel box ⇒ page k170
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– Install noise insulation ⇒ Generalised b body repairs, exterior; Rep. ara
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7 Speed Dual Clutch Gearbox 0dl

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7 Speed Dual Clutch Gearbox 0dl

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B804A300A

3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

struments during a road test”, page 2

1.1 General safety provisions

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

To prevent damage to the electronic components when dis‐

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

1.2 Safety measures when working on ve‐

Injury hazard as a result of automatic engine start in vehicles

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

1.4 Safety precautions when using testers

and measuring instruments during a

Observe the following if test and measuring equipment is required

Risk of accident due to distraction and inadequate securing of

2 Rep. gr.00 - Technical data

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

2.1 Gearbox identification

The gearbox code is also indicated on the vehicle data stickers.

4 Rep. gr.00 - Technical data

an automatic gearbox. In other words, the gears are engaged

sition is not transferred by mechanical means via the selector

as is the case for the automatic gearbox. The information con‐

cerning selector lever positions or shifting operations are trans‐

3.2 Rules for cleanliness

♦ If repair work cannot be performed immediately, cover opened

3.3 General repair instructions

tween the engine and gearbox are correctly located.

♦ Do not overstretch retaining rings.

♦ Always renew retaining rings which have been damaged or

♦ Retaining rings must locate properly in grooves.

Do not mix additives in oil. Do not fill any other oil.

Oil which has been drained out cannot be filled again.

6 Rep. gr.00 - Technical data

Oil drain and inspection plug

♦ After removing gaskets and seals, always inspect contact sur‐

space between sealing lips -arrow- with sealing grease -

♦ Coat O-rings with dual clutch gearbox oil to prevent pinching

♦ After renewing gaskets, O-rings and seals, check oil level in

3.5 Nuts and bolts

4.1 Allocation gearbox - engine

4.1.1 Passat 2015 ►, Passat Estate 2015 ►

4.1.2 Tiguan 2016 ►

Dual clutch gearbox 0DL, front-wheel drive

Dual clutch gearbox 0DL, all-wheel drive

Engine 2.0 l - 176 kW TDI

Capacity Dual clutch gearbox 0DL

Changing approx. 5.5 litres

or ⇒ service tables “ELSA”

Lubricant Dual clutch gearbox oil

The oil is available as a replacement part; part no. ⇒ Electronic

parts catalogue (ETKA) .

Further information in the part number designates the container

8 Rep. gr.00 - Technical data