Service

Service
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Workshop Manual
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ,
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Golf 2009 ➤ , Golf Plus 2005 ➤ ,
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Golf Plus 2009 ➤ , Passat 2006 ➤ ,
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Passat CC 2009 ➤ , Scirocco 2009 ➤ ,

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Sharan 2011 ➤ , Touran 2003 ➤
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6-speed dual clutch gearbox 02E

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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
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg K0458972220

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 DSG® oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Oil filter change - »Yes or no?« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Oil drain and inspection plug A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.8 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.9 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Fault findinggen. A.G. ..V.ol.ks. w. a.g.en. A. G. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 General ksw
Vol notes on fault finding . . . .ot. g.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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control unit in the event of a gearbox fault”
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2.3ss Special notes on fault finding . . . . . . . . . . . . .c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3 Identification of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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3.1 Reading gearbox code letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Code - engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Golf Plus 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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4.2 Golf Plus 2005 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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4.3 Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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4.4 Scirocco 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.5 Golf 2004 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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4.7 Passat 2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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4.8 Eos 2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.9 Passat CC 2009 ►; CC 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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4.10 Sharan 2011 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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5 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 Electrical and electronic components and their locations DSG® . . . . . . . . . . . . . . . . . . . . 31
1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
........................................................................ 31
1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
........................................................................ 40
1.3 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Renewing selector shaft lever oil seal with gearbox removed . . . . . . . . . . . . . . . . . . . . . . 55
5 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Contents i
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus A2005
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7 Selector mechanism up to 02.2009 . . . . . a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or a 62
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7.1 Overview of selector mechanism up to 02.2009
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7.2 Removing and installing selector lever cable up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 63
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7.3 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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7.4 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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8 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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8.1 Selector lever in “P” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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8.2 Selector lever in “N” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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8.3 Selector lever in position “Tiptronic” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.4 Ignition and light switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.5 Selector lever position indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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9 Selector mechanism from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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9.1 Overview of selector mechanism in vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 73
9.2 Removing and installing selector mechanism, from 03.2009 . . . . . . . . . . . . . . . . . . . . . . . . 74
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10 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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10.1 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 2.0 l petrol engine . . . . . . . . . . . . 78
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10.2 Removing gearbox, Golf 2009 ►, Golf Plus 2009 ► with 2.0 l petrol engine . . . . . . . . . . . . 85
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10.3 Removing gearbox, Golf Plus 2005 ► with 1.4 l petrol engine . . . . . . . . . . . . . . . . . . . . . . 94
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10.4 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine . . . . . . . . . . . . . . . . . . 101
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10.5 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with diesel engine, all-wheel drive . . 111
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10.6 Removing gearbox, Golf Plus 2009 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . 120
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10.7 Removing gearbox, Golf 2009 ► 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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10.8 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 3.6 l - V6 engine (all-wheel drive) by c lksw
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10.9 Removing gearbox, Golf 2004 ▸ with 1.9 l and 2.0 l diesel engine . . . . . . . . . . . . . . . . . . 142
10.10 Removing gearbox, Golf 2004 ► with 125 kW - 2.0 l diesel engine . . . . . . . . . . . . . . . . . . 149
10.11 Removing gearbox, Eos 2006 ►, with 3.2 and 3.6 l - V6 engine . . . . . . . . . . . . . . . . . . . . 155
10.12 Removing gearbox, Golf 2004 ► with 1.4 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.13 Removing gearbox, Golf 2004 ► with 2.0 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.14 Removing gearbox, Golf 2004 ►, with 3.2 l - V6 engine (R32 all-wheel drive) . . . . . . . . . . 174
10.15 Removing gearbox, Golf Plus 2005 ► with 1.9 l and 2.0 l diesel engine, with 2.0 l petrol engine
...................................................................... 183
10.16 Removing gearbox, Eos 2006 ► with 2.0 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . 190
10.17 Removing gearbox, Eos 2005 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . 197
10.18 Removing gearbox, Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
10.19 Removing gearbox, Passat 2006 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 212
10.20 Removing gearbox, Passat 2006 ► with 2.0 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . 220
10.21 Removing gearbox, Passat 2006 ► with 3.6 l - V6 engine (all-wheel drive) . . . . . . . . . . . . 225
10.22 Removing gearbox, Scirocco 2009 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . 231
10.23 Removing gearbox, Scirocco 2009 ► with 2.0 l petrol engine . . . . . . . . . . . . . . . . . . . . . . 240
10.24 Removing gearbox, Sharan 2011 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 249
10.25 Removing gearbox, Sharan 2011 ► with 1.8 l and 2.0 l petrol engine . . . . . . . . . . . . . . . . 257
10.26 Removing gearbox, Sharan 2011 ► with 1.4 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . 266
10.27 Install gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
11 Torque settings »gearbox to engine« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
11.1 Torque settings (ELSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
12 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
13 Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► . . . . . . . . . . . . . . . . . . 284
14 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine . . 289
14.1 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
15 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3.6 l V6 engine . . 297
16 Oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
16.1 Oil filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
16.2 Checking oil level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
ii Contents
16.3 Draining and filling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

1 Overview - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
1.1 Renewing seals for right flange shaft or stub shaft - front-wheel drive . . . . . . . . . . . . . . . . 311
2 Renewing oil seal for left flange shaft - front and all-wheel drive . . . . . . . . . . . . . . . . . . . . 313
2.1 Renewing oil seal for right flange shaft - all-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . 314
2.2 Dismantling and assembling flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3 Renewing oil seal for propshaft drive flange at bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . 318
4 Assembly overview - Flange shafts and seals on bevel box . . . . . . . . . . . . . . . . . . . . . . . . 324
4.1 Renewing seal on gearbox between bevel box and gearbox . . . . . . . . . . . . . . . . . . . . . . . . 325
4.2 Removing and installing right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.3 Renewing seal for right flange shaft on outside of bevel box . . . . . . . . . . . . . . . . . . . . . . . . 328
4.4 Renewing needle bearing (polygon bearing) for right output shaft drive flange . . . . . . . . . . 329
4.5 Renewing seal on bevel box between gearbox and bevel box . . . . . . . . . . . . . . . . . . . . . . 331
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5 Checking and topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
5.1 Checking gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
5.2 Topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
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Contents iii
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤olk, sGolf
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iv Contents
olkswagen AG
en AG. V dual
ag6-speed clutchdoegearbox 02E - Edition 01.2018
ksw ol sn ot g
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00 – Technical data
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1 General repair instructions
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(VRL011359; Edition 01.2018)
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1.1 Tools , is n
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A summary of the special tools and workshop equipment used in
t to the co
the workshop manual precedes each repair procedure and can
be found in “Special tools/Workshop equipment” binder.
The catalogue is also available on ⇒ CD-ROM and can be ordered
rrectness of i
the usual way from Bertelsmann.
l purpos
Uncertainty often occurs with smaller bolts having low tightening

forces. Torque wrench - V.A.G 1783- can be used with these
nform
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bolts.
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1.2 Gearbox
Always make sure that no dirt can enter an »open« gearbox. In
particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
♦ 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.
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
1.3 Overview
1. General repair instructions 1

1 - Filter ⇒ page 301

❑ Notes on filter change
⇒ page 3
2 - Inspection plug
⇒ page 3
❑ Near pendulum support.
3 - Drain plug
❑ ⇒ page 3
❑ Plug was discontinued
as of September 2004.
The oil can be drained
via the inspection plug AG. Volkswagen AG d
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4 - Gearbox oil cooler d by
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⇒ page 48 orise nte
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5 - Mechatronic unit for dual ss a c
clutch gearbox - J743-
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⇒ page 31
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6 - Gearbox input speed send‐
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er - G182- and oil temperature
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sender in multi-plate clutch -
, is n
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G509- ⇒ page 31
hole
spec
7 - Oil pump ⇒ page 51
es, in part or in w
t to the co
8 - Cover (end cover) for dual
clutch
rrectness of i
9 - Dual clutch ⇒ page 16
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1.4 Seals
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♦ After removing gaskets and seals, always inspect contact sur‐ yri
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face of housing or shaft for burrs resulting from removal or for by c lksw
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other signs of damage.
Prote AG.
♦ Before installing seals, lightly oil outer diameter and half-fill

space between sealing lips -arrow- with sealing grease -
G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Only use dual clutch gearbox oil. Other lubricants will cause
problems in function.
♦ After renewing gaskets, O-rings and seals, check oil level in
gearbox and top up if necessary ⇒ page 302 .
2 Rep. gr.00 - Technical data

1.5 ⇒ DSG® oil

Shake before opening.
The oil is available as a Genuine part. Therefore the Genuine part . Volkswagen AG
number for it can be found in the ⇒ Electronic parts catalogue kswagen AG does
not
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“ETKA” . by Vo gu
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The oil quality is of critical importance for the function ofuthe
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Do not mix additives in oil. Do not fill any other oil.
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Oil which has been drained out cannot be filled again.
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Caution
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spec
Be careful when working with oil. Dispose of drained oil ac‐ urposes, in part or in wh
cording to regulations. Remember: one drop of oil will contam‐
t to the co
inate 600 litres of water.
rrectne
1.6 Oil filter change - »Yes or no?«
satelettronica
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The oil filter does not have to be changed as a matter of course.
inform
mer
Do not change the filter if:
atio
om
♦ The gear oil cooler or its O-rings have been renewed and no
n
c
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or
n
coolant has got into the oil.
thi
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♦ The oil seal for the selector shaft has been renewed.
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♦ The oil seal for the flange or stub shaft has been renewed.
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♦ Leaking covers in the mechatronic unit, dual clutch or oil pump
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♦ The gearbox input speed sender - G182- with oil temperature Prote AG.
sender in multi-plate clutch - G509- has been renewed.
The filter must be changed if:
♦ The 60,000 kilometre service interval has been reached.
♦ Coolant has got into the oil.
♦ Metal particles have been found in the oil.
♦ The clutch is burnt out or has a mechanical defect.
1.7 Oil drain and inspection plug -A-

To gearbox manufacture date “20 September 2004”, gearboxes
were constructed with 2 plugs.
The second plug was then discontinued, and oil could be drained
and the level checked with only one plug -A-.
A plastic overflow tube (with 8 mm hexagon socket head bolt,
torque setting 3 Nm) is located behind the plug. Its length deter‐
mines the oil level in the gearbox.
1. General repair instructions 3

1.8 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid
AMV 185 100 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.
♦ Always renew self-locking bolts and nuts.
1.9 Electrical components

You have certainly felt an electric shock when you have touched
something metallic. This is due to the electrostatic charge of the
human body. This charge can disturb the function of electrical
components of the gearbox and of the selector mechanism.
satelettronica
. Volkswagen AG
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– Before working on electrical components,
Vol
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o
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charge yourself (touch something d that is earthed). Do not
by ara
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directly touch connector contacts
thori or electronic components. eo
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CC 2010 ➤ , Eos 2006g➤ n A, G
Golf
. Volk2004
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y Volks 6-speed dual clutch ngearbox
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2.1 General notes on fault finding
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Before making repairs, determine the cause of the fault with the
, is n
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Initiate Guided fault finding using the vehicle diagnosis,
es, in part or in w
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testing and information system - VAS 5051- .
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2.2 Useful information about the “behaviour
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The control unit works with highly developed software. This soft‐
Prote AG.
ware is able to execute, monitor and control electronic functions

in milliseconds. This control unit »has everything« that a modern
gearbox electronics »has to offer«. This must also be considered
when looking for faults.
But no electronics can do something for which it was not de‐
signed. So it is just not possible to identify electronically, for
example, where oil is leaking from the gearbox housing. But it is
possible to detect the effects of »insufficient oil«. First a fault in
“gear monitoring” will be detected and finally the control unit will
react by opening both clutches (no power transfer).
You should be aware of this when looking for faults and working
with testers. There is a chance that the source of the fault cannot
be found with Guided fault finding .
As well as the more advanced software, a great deal has been
done to protect the gearbox in case of a malfunction (safety func‐
tions). Consequently, when a fault occurs, if it is necessary, the
fault is saved and a substitute program is started.
Behaviour of the control unit in the event of a fault
If a component in the gearbox malfunctions, the control unit re‐
sponds with a substitute function. Because the gearbox must be
protected, there are 4 fault responses:
1- The fault is so minor that travel may be continued with a
substitute program and driving safety will be preserved. The
driver will not be warned via the selector lever position dis‐
play - Y5- . The display indicates the selector lever position
as usual. It may be possible to notice changes in driving
behaviour.
2- Individual selector lever positions flash in the selected range
display - Y5- . The driver is being warned that it is not pos‐
sible to select this gear at the moment. For example, driving
in reverse: the lever is in “R” and the vehicle is travelling
backwards. If a gear is engaged in this situation “D”, the se‐
lector lever position display - Y5- flashes “D”. The control
unit prevents 1st gear from being engaged in this case to
2. Fault finding 5
prevent gearbox damage. The gear will not be engaged until

the vehicle has stopped moving.
3- The selected range display - Y5- is completely illuminated
and is flashing. The selected selector lever position is rec‐
ognisable or is highlighted. For example: the gear oil tem‐
perature is too high. Some possible causes may be the
towing of a trailer with too great a load or retrofitted compo‐
nents at the front of the vehicle leading to »insufficient air
cooling«.
4- The selected selector lever position is not recognisable. The
selected range display - Y5- flashes. Changes in driving and
gear-change behaviour are clearly apparent. Reversing wage
nisAG. Volkswagen AG do
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not possible. A »major fault« has occurred. Party Vofo the gear‐
lks ot g
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box has been switched off and the gearboxisemust
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2.3 Special notes on fault finding
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Selector lever position display - no “R”

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Simultaneous illumination of all selector lever position display
ility
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segments indicates gearbox emergency running mode. The ve‐
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hicle cannot reverse.
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Touch function does not work - no gear change

Check securing clip on cable support bracket of selector lever
cable on top of gearbox. In particular, clip -B- must never be
reused.
Due to the loss of its »own tension«, this clip -B- may go lost. The
-arrow- points to the cable adjusting screw.
»Power transfer« inadequate - possibly insufficient fluid
First click here ⇒ page 3 .
Top up fluid only when it has been ascertained that fluid has es‐
caped. Anything else is »expensive fun« which will not help.
No faults have been saved:
AG . Volkswagen AG
In this case, the solution depends on you. Experience shows that agen does
lksw not
»faults« attributed to the gearbox often are caused by otherby com‐
Vo gu
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ponents or assemblies. ris
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It has occurred in the past that poor shifting behaviour
ss
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to insufficient air intake of the engine. Don't make the same sort
ce
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un
of mistakes.
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Only after such faults have been excluded can one work mean‐
rm
satelettronica
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ingfully with the VW tester.
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Faults have been saved:
h re
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spec
First consider what the saved faults indicate. The VW testers offer
es, in part or in w
Guided fault finding . Properly used, Guided fault find-
t to the co
ing will locate the sources of many faults.
If there are faults »not caused by the gearbox«:
rrectness of i
For example, if the fault “ABS signal missing” is saved in the
l purpos
gearbox memory and additionally another control unit reports

“ABS signal missing”, then the gearbox control unit is not likely to
be »faulty«.
nform
ercia
The entry means only that the gearbox (and possibly other control
m
a
com
t
units) are expecting a signal via the bus, but does not receive it.
ion in
In this case, it is more likely that the ⇒ ABS control unit has a
r
te o
thi
problem. In such a case, under no circumstances should the me‐
s
iva
do
chatronic unit for dual clutch gearbox - J743- be removed without
r
rp
cum
further consideration. The fault in this example indicates problems
fo
en
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in the ⇒ ABS.
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2. Fault finding 7
. Volkswagen AG
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CC 2010 ➤y ,V Eos 2006 ➤ , Golf 2004 ➤ s,nGolf
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, Golf Plus 2005 ➤ ...
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6-speed ris dual clutch gearbox 02E - Edition 01.2018
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Example -arrow-:
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GKF - Gearbox code
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10.05.2 - 10 May 2002
es, in part or in w
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14 - Factory code
14 15 - Time
rrectness of i
001 - Serial number
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Prote AG.
On some gearboxes, gearbox code is also located on the top of

the gearbox near the selector lever cable -arrows-.
The gearbox code is also included on the vehicle data stickers.
If there is no vehicle data sticker, if the installed gearbox does not
match the one indicated on the sticker or if the installed gearbox
cannot be definitively identified: read gearbox code off gearbox
⇒ page 8 .
3.1 Reading gearbox code letters

The code appears on every gearbox in at least two places.

Once on top of the gearbox close to the selector lever cable

-2 arrows-.
If it is not legible or is»upside down«, the gearbox code may also
be found under the bracket of the right assembly mounting.
To see the code directly on the gearbox behind the bracket, the
engine and gearbox must be supported. Bracket -A- for the left-
hand assembly mounting must be removed. In the process, it is
important to lower the engine and gearbox only enough so that
the bracket can be pushed back. If it is lowered further, the ⇒
pendulum support will be damaged. Following assembly, the se‐
lector lever cable must be adjusted ⇒ page 70 .
A detailed description of bracket removal will not be provided in
satelettronica
this chapter. Please refer to the respective chapter “Removing
and installing gearbox” for information on removing the bracket.
Brief description
Remove air filter and battery.
AG. Volkswagen AG d
agen oes
Set up support bracket - 10 - 222 A- and support engine withVolksw not
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gearbox. Do not raise. se
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– Remove all bolts -1- and -2- for bracket -A-. ss c
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– Then lower engine and gearbox slightly using spindles of sup‐
pt
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port bracket - 10 - 222 A- until bracket can be removed.
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In most cases, 2 turns of the spindle will be sufficient to remove

the bracket -arrow-.
nform
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– Always adjust selector lever cable after installing bracket

m
⇒ page 70 .
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3. Identification of gearbox 9
4 Code - engine allocation

Codes for Golf 2004 ► ⇒ page 11
Codes for Golf Plus 2005 ► ⇒ page 10
Codes for Touran 2003 ► ⇒ page 12
Codes for Passat 2006 ► ⇒ page 13
Codes for Eos 2006 ► ⇒ page 13
Codes for Passat CC 2009 ►, CC 2010 ► ⇒ page 14
Codes for Scirocco 2009 ► ⇒ page 11
Codes for Golf 2009 ► ⇒ page 11
Codes for Golf Plus 2009 ► ⇒ page 10
Codes for Sharan 2011 ► ⇒ page 14
4.1 Golf Plus 2009 ►

If Genuine parts are required for a repair, always refer to the
gearbox code.
satelettronica
Dual clutch gearbox (⇒ DSG®) 02E »front-wheel drive«
»LQV«, HJP, JPK, LQT LQZ MDJ
KQC, KPT,
LTE, MFL, HQM,
MSV KMY, LQV,
KQC,
LQW, AG. Volkswagen AG d
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LTG, HXT, byV
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HFQ, KCV, rised
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NJK, NLP, ss a c
PBF, PBY
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2.0 l - 81 2.0 l - 100, 2.0 l - 125 2.0 l - 147 2.0 l - 155
itte
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kW TDI 103 kW kW TDI kW TDI kW TDI
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KNF, JPL, LQS,
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KDC, JBT, KPQ,
JPS, HQN,
KMZ,
KCW, HXU
rrectness of i
1.4 l - 103 1.9 l -

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and 77kW TDI

125 kW
nf
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4.2 Golf Plus 2005 ►

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gearbox code.
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»HQN« »HQH« »HJP« »HQM« HVV, JPT, JPS,
rig ht
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»GPW«, HXU, JPL, »HQG«, »HQG«, KDC, KNF, JBT by c lksw
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KCW, KMZ, LQS, HXT, HBP, HXU, Prote AG.
KPQ, HQN, KMZ, GPU, GYM, GYQ,

KCW, KPQ, GYR GYR, JPT, JPK,
HFQ, KMY, KCV,
KPT

Dual clutch gearbox (⇒ DSG®) 02E

1.9 l - 77 kW TDI 2.0 l - 100 ⇒ or 1.4 l - 103 and
103 kW TDI 125 kW FSI turbo
4.3 Golf 2009 ►

gearbox code.
LQV, KQC LTE, LQV, LTD, LQT, LTL, LQZ, NJP, NLT,
»KQC«, MFM, MDJ, PBL
MFL, MSV, MSU, NJJ MMA,
NJK MSY,
NJR, NJL,
NLR
2.0 l - 81 2.0 l - 103 2.0 l - 125 2.0 l - 147 2.0 l - 173
kW TDI kW TDI kW TDI and kW FSI tur‐
155 kW bo
FSI turbo
4.4 Scirocco 2009 ►
satelettronica
gearbox code.
PQK, PDY KMX, LQT, LTD, LPY, LQZ, KNC,
KQC, LQV, MFM, MMD, KPV, LTL,
KMX, MSU, n NJJ,
AG. VolkswMTC,
agen AG MMA, MSY,
KCU, MFL, wage d s
Volks NLN NJP, NLT oeNJL,not NLR
LTE, MSV,ed
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2.0 l - 130 ss2.0
a
l -100 ⇒ 2.0 l - 125 2.0 l - 188 2.0 l - 147 ac
kW TDI or 103 kW kW TDI kW, and 155 kW
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TDI 195 kW FSI turbo

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4.5 Golf 2004 ►

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with » GPU »HBQ,
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plug HLH«, GYM
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4. Code - engine allocation 11


with‐ » HQN, » » HVV, HUS, JVG,
out JPS«, HZJ,HQL HYC »JBT HUT, »KFV«
drain JBT, JPL, «, «, «, HXW, , KFW,
plug »KDC HXU,JPJ, HTB, KDC JPP, KNB,
from «, KCW,HFQ JPQ, KCZ, LBK,
20 KNF, KMZ, , KDA, KNC, LRD
Sep‐ KPY, KPQ,HXS, KMW KPV
tem‐ LRC LQS KCU ,
ber , LQT,
2004 KMX LTD
,
KQC
,
LQV,
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1.4 l - 1.9 l - 2.0 l - 2.0 l - 1.4 l - 2.0 l - 2.0 l - Volkswa not
103 77 kW 100 120 125 k 147 k 169 ekd by gu
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and TDI ⇒ or and W W FSI WthoFSI
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125 k 103 k 125 k FSI turbo s auturbo ra
c
W TSI WT W turbo s
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DI TDI
nl
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satelettronica
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Instal‐ Golf 2004 ► individ‐
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ility
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gearbox code.
hole
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Dual clutch gearbox (⇒ DSG®) 02E »all-wheel drive«
t to the co
»HUV«, GUF,
GYB, HDD,
rrectness of i
HKA, HPZ,
HXZ, JUQ,
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KDE, JUQ,
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KQA, JYX,
nform
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KQA, LRF,
m
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at
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3.2 l - 184 kW
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4.6 Touran 2003 ► do

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gearbox code. Cop py
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Dual clutch gearbox (⇒ DSG®) 02E
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HZH, PSN HZH, GPV, MSV, GPQ, HTB, PDY,
AG.
JPS, JBT, GYR, NJK, GYP, HYC, PQK

KDC, JPS, GYQ, NLP, HQM, JPQ,
KNF, HVV, HLH, PBF, HQG, KDA,
KPY KDC, HQH, PPY HJP, KMW,
KNF, HQN, HXT, LQT,
KPY HXU, JPK, LTD,
JPL, KCV, MFM,
KCW, KMY, MSU,
KMZ KPT, NJJ,
LQW, PBE
LTG,
MLX,
MSV,
NJK,
PBE,
PBF,
PPX,
PPY

n AG. Volkswagen AG do
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,o Golf 2004 ➤ , Golf 2009 ➤s n,oGolf
lks
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d 6-speed dual clutch gearbox 02Eua-raEdition 01.2018
b
ir se nte
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Dual clutch gearbox (⇒ DSG®) 02E ss
ce
le
un
pt
1.4 l - 1.4 l - 1.4 l - 1.9 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l -
an
d
itte
103 k 110 125 k 77 kW 81 kW 103 k 125 k 130 k
y li
erm
ab
W FSI kW W TSI TDI TDI W TDI W TDI W TDI
ility
ot p
turbo Eco-
wit
is n
Fuel
h re
ole,
spec
4.7 Passat 2006 ►
t to the co
gearbox code.
rrectne
JPJ HQL, HFQ, HYC, HYC, »LQY«, HBR,
ss o
HXS GSS, HTB, HTB, LTK, HXX
cial p
f in
HQF, JPQ, JPQ, MLZ
form
mer
HQL, KDA, KDA,
atio
HXS, KPS, KMW,
om
JPJ, KMW »KPS«,
n
c
i
or
n
KCU, LQT,
thi
te
sd
a
KMX, LTD
iv
o
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KQC,
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fo
satelettronica
LTE,
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LTF,
Co
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2.0 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l - 3.2 l -
co Vo
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cted
88 kW 90 kW 100, 120 kW 125 kW 125, 184 kW
agen
Prote AG.
TDI TDI 103, TDI TDI 147 kW FSI
105 kW FSI tur‐
TDI bo
gearbox code.
»HXX«, JQZ, MKM,
HBR, KJL, MMH
JPY, KNM,
JVY, LHS,
JYW, LHQ,
KDF, KQB,
KPZ, LRH,
KNK, LTW
LRE,
LTT
3.2 l - 3.6 l - 2.0 l -
184 kW 220 kW 125 kW
FSI FSI TDI
4.8 Eos 2006 ►

gearbox code.
JPJ, HQL, HYD, JPR, LTK, HYE, HTG, LPW,
HXS, KCU, KDB, KNH, MLZ, JPN, KCY, LXZ,
KMX, KQC, LQY, KPU, MSX, KNJ, KPX, MHL
LQV, LTE, LTK, MLZ, NJM, LRB
MFL, MSV, MSK, NJM, NLQ,
NJK, NLP, NLQ, PBG, PBG,
PBF, PPY PPZ PPZ
4. Code - engine allocation 13


2.0 l - 100, 2.0 l - 2.0 l - 3.2 l - 3.6 l -
103 kW TDI 147 kW FSI 155 kW 184 kW pet‐ 191 kW
turbo FSI turbo rol engine⇒ petrol
SRE engine
4.9 Passat CC 2009 ►; CC 2010 ►

If Genuine parts are required for a repair,. Valways refer to the
AG olkswagen AG d
gearbox code. ksw
agen oes
n
Vol ot g
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Dual clutch gearboxris(⇒
ed DSG®) 02E »front-wheel drive« ran
tee
tho or
KMX, KMX,au KMW, LQY, MLZ, ac
ss
KQC KQC, KPS, LTK, MSX,
ce
e
nl
MSV, MFM, MLZ, NJM,
pt
du
an
MFL, MSU, MSX, NLQ
itte
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erm
NJK, NJJ, NJM,
ab
ility
NLP NLN NLQ,
ot p
wit
NNU
, is n
h re
2.0 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l -
hole
spec
100 k 103, 125 k 147 k 155 k
es, in part or in w
W TDI 105 k W TDI W FSI W FSI
t to the co
satelettronica
W TDI turbo turbo
rrectness of i
KSA, MKM,
l purpos
KSB, MMH,
LHT, MTZ,
nform
ercia
LHR, NJD
LRJ,
m
at
LTX,
om
ion
MTW,
c
in t
or
NHZ
his
ate
do
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3.6 l - 2.0 l -
p
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or
220 kW 125 kW
f
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t.
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engine engine
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LTQ, PBM, LTR, LTA, MFY, PDX,
NJF, PQE NJG, MSS, MST, PQJ
NLS, NLU, NJQ, NJR,
PBJ PBM NLL, NLM,
PBC, PBD
PPW
1.4 l - 1.8 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l -
110 kW 118 kW 147 kW 100, 125 kW 130 kW
TSI TFSI TFSI 103 kW TDI TDI
TDI

5 Capacity
Capacity Dual clutch gearbox 02E
Initial filling in factory 6.9 l –7.2 l
depending on vehicle and date of
gearbox construction
Change quantity approx. 5.2 litres
Change quantity only me‐ 3 – 4 litres
chatronic unit removal and
installation (gearbox instal‐
led)
Lubricant: ⇒ DSG® oil
Further information in the part number designates the container
size.
The oil is available as a genuine part in ⇒ Electronics parts cata‐
logue “ETKA” .
Capacity Front bevel box
satelettronica
Initial filling 0.9 l
Changing Filled for life, no change
Lubricant Gear oil - G 052 145-
Further information in the part number designates the container
size.
The oil is available as a genuine part in ⇒ Electronics parts cata‐
logue “ETKA” .
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5. Capacity 15
30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 16
⇒ “1.2 Removing and installing clutch end cover”, page 18
⇒ “1.3 Removing dual clutch”, page 24
⇒ “1.4 Installing dual clutch”, page 25
1.1 Assembly overview - dual clutch

Brief description
♦ The clutch has 2 sets of plates. The outer, larger set of plates
is called “C 1” (clutch 1). The “C 1” selects reverse gear and
gears »1«, »3« and »5«. The smaller inner “C 2” (clutch 2)
selects gears »2«, »4« and »6«.
♦ The assembly of the dual clutch requires special care because
all components were balanced together during manufacture.
satelettronica
If parts are rotated relative to each other during assembly, im‐
balances develop which are detrimental to ease of shifting and
service life.
Replacement parts
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16 Rep. gr.30 - Clutch

1 - Dual clutch with retaining

ring
2 - Retaining ring
❑ Qty. 10, of varying thick‐
ness for adjusting AG. Volkswagen AG d
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❑ The thickness ofedthe b re‐
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taining ring hashoristo be de‐ nte
eo
termined whenaut installing ra
c
the clutchs ⇒ page 28
s
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3 - Clutch end cover
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4 - Retaining ring for clutch end
pe
ility
cover
ot
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rrectness of i
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satelettronica
nform
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tion in
r
te o
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Individual parts of the disassembled dual clutch
Caution
♦ This figure is intended only to provide an overview of the

components. It is presently not permitted to dismantle the
dual clutch since all the plates have been balanced rela‐
tive to each other.
♦ If the drive plate is released, the plates in the dual clutch
can shift, as a result of which it may not be possible to
correctly adjust the clutch when it is installed.
1. Clutch 17
1 - Dual clutch/clutch housing

❑ Outer plate carrier
2 - Oil seals
❑ Qty. 4
3 - Inner plate carrier
❑ Do not remove
Caution
Under no circumstances
raise or remove the inner
plate carrier. The plates
could turn.
4 - Outer plates
❑ Qty. 4
5 - Inner plates
❑ Qty. 4
satelettronica
6 - Thrust washer AG. Volkswagen AG d
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7 - Retaining ring d by ara
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or
❑ If retaining ring was re‐ aut
h eo
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moved to insert new ss c
plates, it should be re‐
ce
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nl
pt
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newed with a new,
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equally thick ring.
erm
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8 - Retaining ring
wit
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❑ Determine thickness
h re
hole
again if a new clutch has
spec
been fitted ⇒ page 28
es, in part or in w
t to the co
9 - Drive plate
10 - Retaining ring
rrectness of i
l purpos
1.2 Removing and installing clutch end cov‐

nf
ercia
er
orm
m
atio
Special tools and workshop equipment required

om
n in
or c
♦ Assembly sleeve - T10302-

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Brief description
Cover seals off gearbox from atmosphere. Cover is held in its seat
by a retaining ring. After the retaining ring has been removed, the
cover can be levered out of its seat. Cover and retaining ring must
always be renewed. Never install a new cover with a hammer and
never oil the centre seal or touch it with a hand! However, if this
should happen, the cover is certain to leak!
To remove or install cover, gearbox must be securely attached to
an assembly stand in vertical position.
Removing
– Drain gear oil
– Remove gearbox.
– Secure gearbox to assembly stand.
– Remove the filter if necessary.

Often, doubts arise as to whether the filter must be renewed or
not.
The notes on the oil filter change can help you in reaching this
satelettronica
decision.
AG. Volkswagen AG d
agen oes
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y V gu
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– Insert newafilter with shoulder downwards and tighten coverorto
ut
ac
20 Nm. ss
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pt
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itte
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rm
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ility
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1. Clutch 19
– Following repair work, it is not necessary to change the filter

again when filling oil.
Removing clutch end cover
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
satelettronica
– Lever clutch end cover -2- out through opening for starter mo‐
tor using screwdriver -1- or tyre lever -arrow- and remove n AG. Volkswagen AG do
swage es n
clutch end cover. by
Volk ot g
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ed ran
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au ac
Note ss
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un
pt
Never reinstall a cover which has been removed.

an
d
itte
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ab
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ility
ot
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, is n
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hole
spec
es, in part or in w
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tion in
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te o
thi
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iva
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20
Prote AG.
Rep. gr.30 - Clutch
Installing
Caution
Cover and retaining ring must always be renewed. Never install

a new cover with a hammer and never oil the centre seal or
touch it with a hand! Leaks will result.
lkswage es n
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– Only handle cover as shown -inss this picture-.
a ac
ce
le
un
pt
an
d
itte
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Note
rm
ab
pe
ility
ot
There are 2 types of cover.
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
r
te o
thi
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♦ Covers supplied with a white bush.

♦ Covers supplied without a bush.
Observe the following before installing cover:
New cover must be free of oil and dry around centre seal!
1. Clutch 21
– If required, thoroughly clean sealing surface of drive plate

-arrow-.
There must be no stickers on the inside of the cover.
– If, however, stickers are present, remove them carefully.
Moisten only the outer edge of the seal with oil.
Installing covers supplied with bush
Caution
Do not remove bush!
AG. Volkswagen AG d
agen
satelettronica
oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
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an
– Install clutch end cover with bush.
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
o
Installing covers supplied without bush
rm
m
atio
m
– Clean assembly sleeve - T10302- “before using”. Do not use

o
n in
c
a scratched sleeve.
or
thi
te
sd
iva
– Set sleeve on a flat surface.

o
r
rp
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m
f
The centre seal of the new cover must now be »preformed«:

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– Guide cover horizontally and evenly over entire sleeve. This

will bring the sealing lip into installation position.
– Now remove sleeve upwards out of cover and set sleeve on
end of clutch shaft.
– Guide cover horizontally over sleeve and press evenly onto its
satelettronica
seat.
Continued for all covers:
Caution
Work carefully. Any sort of blow to the cover is certain to cause

leaks.
olksw
It is possible to lever cover carefully aginto its. Vseat awith
en AG a does
gen AG
ksw
-screwdriver- until »new« retaining
by
Vol ring can be installed. not
gu
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– Install new retainingthoring.
ri e or
au ac
ss
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nl
pt
du
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ility
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, is n
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spec
es, in part or in w
t to the co
– Do not remove bush until retaining ring is installed.

rrectness of i
– Install gearbox
l purpos
– Fill with gear oil

nform
ercia
WARNING
m
at
om
Do not start engine if there is no oil in gearbox.

ion
c
in t
or
his
ate
do
riv
– After installation of gearbox, initiate default settings by

p
cum
or
means of Guided Functions ⇒ vehicle diagnostic tester .

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1. Clutch 23
1.3 Removing dual clutch

Brief description
To remove or install clutch, gearbox must be securely attached
to an assembly stand in vertical position. Only in this way it is
possible later to adjust the axial clearance of the new clutch with‐
out error.
Removing
– Remove clutch end cover ⇒ page 18 .
– Lever out retaining ring -2- of drive plate using screwdriver
-1- -arrow-.
satelettronica
– Remove drive plate -arrows-.
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ility
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spec
– Remove and dispose of retaining ring -arrow-.

es, in part or in w
t to the co
Note
rrectness of i
During installation a new retaining ring must be measured and

l purpos
fitted.
nf
ercia
Caution
rm
m
atio
om
n in
Carefully remove the dual clutch. Take care that no parts fall
or c
out. Therefore, do not turn the clutch over!

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te
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– Remove dualVoclutch.
lksw
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not
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ility
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ole,
spec
t to the co
– Remove pump shaft -A-.
rrectne
– Pump shaft is not inserted until after new clutch is installed.
Set shaft aside until then.
ss o
cial p
– Install dual clutch ⇒ page 25
f inform
mer
atio
om
satelettronica
c
i
or
n thi
te
sd
iva
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pr
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1.4 Installing dual clutch
p by
co Vo
by lksw
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Prote AG.
♦ Retaining pins - T10303-
♦ Dial gauge - VAS 6079-
1. Clutch 25
♦ Universal dial gauge holder - VW 387-
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 olksposition.
wage Only this way ises it
not
possible later to adjust axial
d by play
V of the clutch without error. gu
ara
e nte
ris
satelettronica
• Inside the clutch, the ularge
tho plate carrier goes through all plates. eo
ra
a
It must not slip outs of the lowest plates.
s c
ce
e
nl
• The pump shaft of the oil pump is removed.

pt
du
an
itte
y li
• Do not install corrugated retaining rings.
erm
ab
ility
ot p
Installing
wit
, is n
– Remove new dual clutch from its packaging. 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
– Check that 4 hub seals on underside of dual clutch are cor‐

do
priv
rectly seated. If necessary, ensure that seals engage with

um
for
each other.
en
ng
t.
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op py
• The butt joints of the rings should be offset relative to each . C rig
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other, i.e. not above each other.
rig by
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cted
– Turn rings once. They must move freely and must not bind.
agen
Prote AG.

6-speed dual clutch
wage
ngearbox
AG. Volksw02E
agen -AG
Edition
doe 01.2018
ks s no
Vol t gu
by ara
Important! Installation location of drive plate ris
ed
nte
tho eo
– Please check whether projecting lug -arrow- of sdrive
s plate is au ra
c
positioned between colour-marked teeth of outer plate carrier.
ce
e
nl
pt
du
an
If there is no marking:
itte
y li
erm
ab
– Mark installation location of lug relative to periphery of outer
ility
ot p
plate carrier with permanent marker, as shown in illustration.
wit
, is n
h re
• During installation, the drive plate lug must always be reposi‐
hole
spec
tioned at this marked location.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
– Fit retaining pin - T10303- onto seat of clutch end cover as
his
e
satelettronica
t
shown in illustration.
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– Insert dual clutch in clutch housing, rotating and moving it in

and out as you do so, but do not let it drop into position.
• The retaining pin - T10303- should be held by a second me‐

chanic in the process.
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
shift the position of the retaining pin - T10303- .
1. Clutch 27
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ,wGolfagen 2009 ➤ , GolfAG
AG. Volkswagen Plus
does2005 ➤ ...
ks
6-speed dual clutch gearbox 02E - Edition
by Vol 01.2018 not
gu
ara
ed nte
oris
– Lever out retaining ring -2- for driveautplate using
h a screwdriver e or
ac
-1- -arrow-, and lay it to one side.ss
ce
le
un
pt
an
d
itte
Caution
y li
erm
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ility
ot p
Only this retaining ring may be reinstalled. Never reinstall »a
wit
different« retaining ring. 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
a
– Remove drive plate from »new« installed clutch -arrows-. If

iv
o
r
satelettronica
p
c
necessary, carefully lever it off teeth of outer plate carrier using
um
r
fo
a screwdriver.
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ng
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– Lay drive plate to side. t. C rig
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cted
Caution
agen
Prote AG.
Under no circumstances remove or raise the inner plate carrier.

The plates could turn.
Determining correct retaining ring for dual clutch

– Select 2 mm retaining ring from among rings supplied and in‐
stall it -arrow-.
Note
This retaining ring is used temporarily to measure the axial play.
First measurement:
• Retaining pin - T10303- remains in!
– Screw universal dial gauge - VW 387- to gearbox flange.

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

– Set -dial gauge- to »0« with preload.
– Raise clutch to stop and note result of measurement.
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Second measurement: Volks ot g
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• Retaining pin - T10303- remains in!thori tee
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– Set tip of dial gauge -on hub of large plate carrier-.
ss
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• Tip must not sit on retaining ring.
inform
mer
– Set -dial gauge- to »0« with preload again.
atio
om
– Raise clutch to stop again and also note this result.
n
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or
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Now it can be determined which of the remaining 9 rings will ulti‐

t
sd
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mately be installed:
i
o
pr
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2nd reading – 1st reading + 1.85 mm = thickness of retaining ht. rig
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– Write down this result. Prote AG.
The remaining 9 retaining rings are in increments of 0.1 millimetre.

– Measure all rings and determine which ring is closest to your
result.
Determined size for new retain‐ New retaining ring
ing ring
2.27 mm 2.3 mm
2.24 mm 2.2 mm
– Remove 2 mm thick ring and install calculated ring.

– Dispose of all remaining rings and the 2 mm ring.
1. Clutch 29
CC 2010 ➤ , Eos 2006 ➤en,AGolf
G. Vol2004
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g does
6-speed dual clutch
ol swa
kgearbox 02E - Edition 01.2018
not
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– Insert -pump shaft-.
tho or
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le
un
pt
Note
an
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itte
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erm
ab
Slightly raise and rotate the pump shaft in the process -arrow- so
ility
ot p
that it fully engages the gearing.
wit
is n
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ole,
spec
t to the co
rrectne
– Fit drive plate into dual clutch.
ss
• The projecting lug of the drive plate must be positioned be‐
o
cial p
f i
tween the colour-marked teeth of the outer plate carrier. If the
nform
markings were subsequently make, align these.
mer
atio
om
n
c
Caution
i
or
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Only the securing clip which was removed may be reinstalled.
pr
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Never reinstall »a different« retaining ring.

en
ng
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Cop py
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pyri by
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Prote AG.
– Install drive plate retaining ring.

• The retaining ring must be fitted so that the lug of the drive
plate -arrow- and the colour-marked teeth of the outer plate
carrier lie between the two ends of the retaining ring.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Now remove retaining pin - T10303- from between dual clutch
and housing.
– Install clutch end cover ⇒ page 18 .

34 – Controls, housing
1 Electrical and electronic components
and their locations ⇒ DSG®
The electrical components are located in the gearbox.
Only the selector lever sensors control unit - J587- and the se‐
lector lever lock solenoid - N110- are located on the selector lever.
1 - Mechatronic unit for dual

clutch gearbox - J743-
❑ Behind »large« sheet
metal cover
❑ Removing and installing
with gearbox installed
⇒ page 31 .
with gearbox removed
satelettronica
AG. Volkswagen AG d
⇒ page 40 lksw
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2 - Gearbox input speed send‐ rised ara
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er - G182- and oil temperature ut
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sender in multi-plate clutch - ss a c
G509-
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❑ Before sender can be
an
d
itte
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removed, mechatronic
erm
ab
unit for dual clutch gear‐
ility
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box - J743- must be re‐
wit
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moved ⇒ page 31 .
h re
ole,
spec
3 - Selector lever - E313-
t to the co
❑ For information about
selector lever, see
⇒ page 62 Selector
rrectne
mechanism
ss o
cial p
f inform
mer
atio
om
n
c
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te
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Cop py
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Prote
1.1 Removing and installing mechatronic
AG.
unit for dual clutch gearbox - J743-

(gearbox installed)
Removing and installing with gearbox removed is described in
⇒ page 40 .
1. Electrical and electronic components and their locations DSG® 31

lkswage es n
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf hor 2009 ➤ , Golf Plus 2005 ➤ ...
is tee
t or
6-speed dual clutch gearbox 02E - Editionau 01.2018 ac
ss
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nl
♦ Torque wrench - V.A.G 1331-
pt
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an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
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nf
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♦ Used oil collector and extractor - V.A.G 1782-
orm
m
atio
om
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thi
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satelettronica
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Prote AG.
♦ Adapter for oil filling - VAS 6262 A-
♦ Release tool - T10465-
Removing mechatronic unit

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.
32 Rep. gr.34 - Controls, housing

Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 3 .
The mechatronic unit can stick on the dowel pins when the gear‐
box is very warm. Then allow the gearbox to cool down.
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position “P”.
– Remove noise insulation and lower part of front left wheel
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
Removing and installing wheel housing liners; Front wheel
housing liners .
If present:
– Remove connecting hose between charge air cooler and
charge air pipe ⇒ Rep. gr. 21 ; Removing and installing parts
of charge air cooling .
Note
satelettronica
It is possible that parts having nothing to
agedo with the mechatronic
unit must be removed.lkThis a n AG. Volksw
gedepends on the vehicle's
n AG d
oes equipment.
sw
This will create enough Vo space to remove the mechatronic unit.
not
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nl
pt
du
an
♦ Depending on the vehicle, these parts may include, for exam‐

itte
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erm
ple,
ab
ility
ot p
♦ Radiator fan support

wit
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♦ Additional lines for air conditioner

hole
spec
es, in part or in w
♦ Charge air or air cooling pipes

t to the co
rrectness of i
l purpos
nform
ercia
– Release mechatronic unit connector -1- by turning and pull off

m
at
connector.
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
Item -A- can be disregarded.

n
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unbolt wiring retainer from front of »large« gearbox cover (2

nuts M6).
Specified torque: 10 Nm
– Raise lines near cover and tie.
– Position used oil collection and extraction unit - V.A.G 1782-
under gearbox in area of »large« cover.
Caution
Oil runs out of cover when bolts are unscrewed. Risk of injury
from hot gearbox oil.
– Loosen bolts -arrows- of cover diagonally and remove. Hold

cover when doing this.
– Allow oil to drain out and then remove cover with seal.
About 3 litres of oil will drain out.
satelettronica
Note
»Small« cover of oil pump, as well as seal and bolts of »large«

cover must always be renewed.
– Remove oil pump cover -A-.
AG. Volkswagen AG d
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or eo
h
aut ra
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nl
pt
du
an
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erm
ab
ility
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– Remove bolts -2, 3- of the pendulum support on gearbox ⇒

wit
, is n
h re
Rep. gr. 40 ; Assembly overview - subframe, anti-roll bar,

hole
suspension links .
spec
es, in part or in w
This allows the gearbox to be »pushed back« a little in order to

t to the co
remove the mechatronic unit.

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
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by c lksw
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Prote AG.

Before touching mechatronic unit, touch an earthed object n AG. Volkswagen AG do

⇒ page 4 . lkswage es n
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ho eo
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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
ercia
– Release connector -1- of gearbox input speed sender - G182-

m
at
satelettronica
om
and oil temperature sender in multi-plate clutch - G509- using
ion
c
release tool - T10465- and pull connector off.
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.
– First pull line out of lower clip -arrow I-.

– Then remove it from upper clip -arrow II- and lay to side. Do
not kink line.

6-speed dual clutch gearbox 02E - AEdition 01.2018
G. Volkswagen n AG do
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olks o
– Loosen securing bolts -1- through
ed
by
V
-10- in given order and re‐ t guara
move. oris nte
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th
au ra
c
ss
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
– Carefully pull mechatronic unit out of gearbox housing so that
in t
or
satelettronica
his
sender arm -B- on back is no longer in gearbox housing.
ate
do
priv
c
When handling mechatronic unit, pay special attention to the
um
for
»long« sender arm.
en
ng
t.
yi Co
op py
– Carefully swing mechatronic unit for dual clutch gearbox - t. C rig
gh ht
J743- downwards. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Laying mechatronic unit to side properly
Caution
Never lift mechatronic unit on »sender arm« or lay it on arm.

If »arm« is damaged, mechatronic unitVomust

lkswa
be renewed.
AG. gen AG
agen does
Installing mechatronic unitVolksw not
gu
by ara
ed
Before touching mechatronic
ris unit, touch an earthed object ntee
⇒ page 4 . utho 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
rrectness of i
l purpos
nform
ercia
– Carefully set mechatronic unit for dual clutch gearbox - J743-

m
satelettronica
a
in gearbox housing.
com
tion in
– Do not pinch wiring.
r
te o
thi
s
iva
do
– Carefully set mechatronic unit on dowel pins -arrow-. Ensure
r
rp
c
that »sender arm« locates in its -fitting position-.
um
fo
en
ng
t.
yi
– Look to see if mechatronic unit has made contact correctly.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Screw in new bolts -1- through -10- hand-tight.

– Tighten bolts in given order to 5 Nm + 90° (1/4 turn).
– Hook line -A- first in upper retaining lug, and then in lower
-arrows-.
– Push on connector and engage.

– Renew both -O-rings- if you reinstall the »old« mechatronic

unit.
Of course a »new« mechatronic unit already has »new« seals.
– Moisten O-rings with dual clutch gearbox oil.
– Clean cover seal and sealing surfaces on gearbox.
– Ensure proper seating of seal.
– Set cover over mechatronic unit, being careful not to pinch any
wiring.
lk swage es n
o ot g
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– Insert new bolts -arrows- and tighten diagonally d b in several ua
ran
ir se
satelettronica
stages to 16 Nm. tho tee
or
au ac
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Set new oil pump cover -A- in place and tighten bolts
-arrows- diagonally in several stages to 8 Nm.
l purpos
– Attach wire retainer to cover and tighten nuts to 10 Nm.

nf
ercia
– Push on connector for mechatronic unit for dual clutch gearbox

or
- J743- and engage lock by turning.

m
m
atio
om
– If present: install connecting hose between charge air cooler

n in
or c
and charge air pipe ⇒ Rep. gr. 21 ; Removing and installing

thi
te
parts of charge air cooling .

sd
iva
o
r
rp
cu
– Reinstall any parts which may have been removed from the
o
m
f
en
ng
vehicle.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Do not start engine!

– Please renew filter if oil is contaminated ⇒ page 301 .
– Connect ⇒ Vehicle diagnostic tester.
under gearbox in area of oil drain plug.
– Remove oil drain plug close to pendulum support -arrow-. AG. Volkswagen AG d
satelettronica
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Before screwing adapter for oil filling - VAS 6262 A- onto oil
m
at
om
bottle, measure length of breather pipe, dimension -a- and

ion
c
shorten ⇒ page 301 .

in t
or
his
ate
Dimension -a- = 210 mm

do
priv
cum
for
en
ng
t.
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Note . Cop py
rig
ht ht
rig by
py
The dimension -a- is measured from the shaft (green area in the co Vo
by lksw
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
cted agen
Prote AG.

– Screw adapter of adapter for filling oil - VAS 6262 A- hand-

tight into inspection hole.
– Shake bottles before opening.

– Fill 3 litres of oil.
– To change bottle, shut off tap or hold adapter for filling oil -
VAS 6262 A- higher than gearbox.
Next, start engine, check oil level and top up oil. Adapter for filling
oil - VAS 6262 A- remains installed initially.
satelettronica
– Check oil level and top up. ⇒ page 302
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation; Assembly overview - noise insulation
– Carry out basic setting.
1.2 Removing and installing mechatronic

unit for dual clutch gearbox - J743-
(gearbox removed)
Always make sure that no dirt can enter an »open« gearbox.
. Volkswagen AG
gen AG does
In particular, dirt entering an »exposed« mechatronic
Vol
ksw unit for dual
a
not
clutch gearbox - J743- and/or oil pump can lead
ed to gearbox failure.
by gu
ara
is nte
or eo
Please also refer to the notes on the oil
au filter
th change regarding ra
»dirty oil« ⇒ page 3 . ss c
ce
le
un
pt
Removing mechatronic unit

an
d
itte
y li
rm

ab
pe
ility

ot
wit
, is n
– Remove bolt -A- near pendulum support.

h re
hole
spec

es, in part or in w
torque setting 3 Nm) is located in this hole. Its length determines

t to the co
the oil level in the gearbox.

– Remove this oil pipe.
rrectness of i
– Drain oil.
l purpos
nform
ercia
– Screw overflow tube back in, torque setting: 3 Nm.

m
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 filter if necessary.

Often, doubts arise as to whether the filter must be renewed or
not.
The notes on the oil filter change can help you in reaching this
decision ⇒ page 3 .
– Insert new filter with shoulder downwards and tighten cover to
satelettronica
20 Nm.
– Following repair work, it is not necessary to change filter again
when filling oil.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Remove both -covers-. aut
ho eo
ra
ss c
»Small« cover of oil pump and bolts of »large« cover must always
ce
le
un
be renewed.
pt
an
d
itte
y li
Likewise, seal of »large« cover must be renewed.
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Before touching mechatronic unit, touch an earthed object

⇒ page 4 .
– Release connector -1- of gearbox input speed sender - G182-
satelettronica
and oil temperature sender in multi-plate clutch - G509- using
release tool - T10465- and pull connector off. AG. Volkswagen A n G do
wage es n
Volks ot g
by 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
– First pull line out of lower clip -arrow I-.
es, in part or in w
t to the co
– Then remove it from second clip -arrow II- and lay to side. Do
not kink line.
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.

– Remove -securing bolts- diagonally. Start with bolt -1-.

All 10 -securing bolts- must be renewed.
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
– Remove mechatronic unit for dual clutch gearbox - J743- .
satelettronica
l purpos
When handling mechatronic unit, pay special attention to the

»long« sender arm.
nform
mercia
Caution
at
om
ion
c
in t
r

o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
If »arm« is damaged, mechatronic unit must be renewed. cted agen
Prote AG.
– Lay mechatronic unit to side properly.

Laying mechatronic unit to side properly

Installing mechatronic unit
Caution
AG. Volkswagen AG d
agen oes
olksw not
byV gu
If »arm« is damaged, mechatronic unit must be renewed. rised ara
nte
ho eo
ut
satelettronica
a 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
– Before installation of mechatronic unit, make certain that gear‐

thi
te
box input speed sender - G182- with oil temperature sender sd

iva
o
r
in multi-plate clutch - G509- is installed.

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.

AG. Volkswagen AG d
agen oes
olksw CC 2010 ➤ , Eos 2006 not ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
byV gu
ara
rised
6-speed
nte dual clutch gearbox 02E - Edition 01.2018
ho eo
aut ra
– Renew
ss both -O-rings- if you reinstall the »old« mechatronicc
ce
le
unit.
un
pt
an
d
itte
(Of course a »new« mechatronic unit already has »new« seals.)
y li
rm
ab
pe
ility
– Moisten O-rings with dual clutch gearbox oil.
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
c
– Carefully set mechatronic unit on dowel pins -arrow-. Ensure
um
fo
satelettronica
en
g
that »sender arm« locates in its -fitting position-.

n
t.
yi Co
op py
– Do not pinch wiring.
. C rig
ht ht
rig by
py Vo
Be very careful: do not pinch wiring!
co lksw
by
cted agen
Prote AG.
All 10 -securing bolts- must be renewed.

– First start all -securing bolts- »by hand«.
– Then tighten all 10 -bolts- diagonally to 5 Nm. After this, turn
a further 90° in same sequence. Start with bolt -1-.

– First press wiring for gearbox input speed sender - G182- with
oil temperature sender in multi-plate clutch - G509- into clip
-II-. Then into clip -I-.
– Press connection onto mechatronic unit.
– Set cover over mechatronic unit, being careful not to pinch any
wiring.
– Insert new bolts -arrows- and tighten diagonally in several
satelettronica
stages to 16 Nm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
– Set new oil pump cover -A- in place and
ss atighten bolts c
ce
le
un
pt
an
d
After installing gearbox

itte
y li
rm
ab
– Top up oil, check level and top up ⇒ page 305 .

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
– Connect ⇒ Vehicle diagnostic tester.

– Carry out basic setting.
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.

1.3 Removing and installing gearbox input

speed sender - G182- and oil tempera‐
ture sender in multi-plate clutch - G509-
Brief description
Both senders are combined in one component and can be re‐
newed together only. They are »bathed in oil« in the gearbox near
the dual clutch. Before removal, the mechatronic unit for dual
clutch gearbox - J743- must be removed.
AG. Volkswagenn AG do
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It often occursythatVol the wiring for the sender is opulled.
n t
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will be damaged.
rised b
Consequently, if the cable is pulled
ara
n on, the
tee
senderumust
tho be renewed. or
sa ac
Removing
s
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un
pt
– Remove mechatronic unit for dual clutch gearbox - J743-
an
d
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⇒ page 31 .
rm
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ility
Do not pull on line!
ot
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– Remove bolt and carefully lever out sender with a screwdriver
spec
and/or pliers.
es, in part or in w
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t to the co
Installing
rrectness of i
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Reinstall »old« sender only if you know for certain:

• The sender has no defect.
• The cable was not pulled on when it was removed.
If this is not the case, install a »new« sender.
– Insert sender moistened with ⇒ DCG® oil.
– Tighten bolt to 10 Nm.
– Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 31 .
Never pinch mechatronic unit wiring during installation!

2 Removing and installing gear oil cool‐

er
♦ Hose clamps to 25 mm - 3094-
satelettronica
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Removing
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– Move selector lever to position “P”.
t to the co
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Lay lint-free cloths on gear oil cooler and gearbox to catch
rrectne
escaping coolant.
– Clamp off coolant hoses using hose clamps - 3094- and re‐
move from cooler. ss o
cial p
f inform
mer
atio
om
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– Remove bolts -A- and remove cooler -B-.
Caution
AG. Volkswagen AG d
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No coolant must be allowed to drip into gearbox! Volksw
oes
not
by gu
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or eo
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ut
Installing ss a ra
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– Renew O-rings -C- of gear oil cooler -B-.
satelettronica
– Set gear oil cooler -B- in place, observing O-rings -C-.
nform
ercia
– Screw in new bolts -A- and tighten to 20 Nm + 90° (1/4 turn).

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– Attach coolant hoses to gear oil cooler and remove hose

clamps - 3094- .
– Install battery tray and battery⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
2. Removing and installing gear oil cooler 49

– Check coolant level and top up with coolant as needed ⇒ Rep.

gr. 19 ; Removing and installing parts of cooling system .
– After repair, check oil level and top up ⇒ page 302 .
Caution
Do not start engine while checking coolant level if gear oil has
not yet been filled.
satelettronica
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3 Removing and installing oil pump

olkswagen AG
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♦ Torque wrench - V.A.G 1331- ir se nte
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satelettronica
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Removing oil pump
Brief description
The oil pump can be renewed without the gearbox being re‐
moved. The vehicle must be raised and any covers present
beneath the front part of the vehicle must be removed. The con‐
nection between suspension link and suspension strut does not
need to be separated. The drive shaft does not need to be re‐
moved. Do not “carry out basic adjustment” either. Only the ⇒
DSG® oil and pump cover must be renewed.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
sembly overview - front wheel housing liner .
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
3. Removing and installing oil pump 51

– Remove bolt -A- near pendulum support.

torque setting 3 Nm) is located in this hole. Its length determines
the oil level in the gearbox.
– Remove this oil pipe.
– Drain oil.
– Screw overflow tube back in, torque setting: 3 Nm.
lkswage es n
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– Renew seal -arrow- for plug. d by ua
ran
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– Used oil collection and extraction
auth unit - V.A.G 1782- remains or
ac
under gearbox. ss
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– Remove bolts -arrows- and remove oil cooler cover -A-.
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There will still be oil in oil pump cover.
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– Remove bolts -arrows- and pull oil pump -1- off dowel pins and
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pull out oil pump drive shaft.
agen
Prote AG.

It may be necessary to use socket - T10054- to remove upper

bolt.
Installing oil pump
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– Push input shaft -A- for oil pump into gearbox as far as stop.
itte
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Turn input shaft slightly whilst doing this.
ab
ility
– Always use a new metal seal -B-. ot p
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• The 2 dowel pins -C- must be located in gearbox housing.
hole
spec
es, in part or in w
– When fitting oil pump, observe splines of input shaft and prop‐
t to the co
er seating of dowel pins.
satelettronica
Various bolts for oil pump -1-
rrectness of i
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nf
ercia
o
All 4 bolts with flat heads
rm
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atio
m
Specified torque
o
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♦ 5 Nm + 90° (1/4 turn)
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3 bolts with flat heads, uppermost bolt with countersunk head

Specified torque
♦ Countersunk head bolt: 8 Nm (tighten with socket - T10054- )
♦ Flathead bolts: 8 Nm + 90° (1/4 turn)
3. Removing and installing oil pump 53

– Set new oil pump cover -A- in place and tighten new bolts
There is no oil in the gearbox. »New« oil must now be filled and
adjusted to the proper level ⇒ page 305 .
– Change oil and filter for dual clutch gearbox ⇒ page 301 .
– Install left wheel housing liner ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Wheel housing liners; Assembly overview -
front wheel housing liner . gen AG
. Volkswagen AG
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– Install noise insulation ⇒d byGeneral
Vo body repairs, exterior; Rep.
ot g
ua
gr. 50 ; Noise insulation;
or
is Assembly overview - noise insulation ante
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es, in part or in w
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4 Renewing selector shaft lever oil seal

with gearbox removed
♦ Tube - VW 423-
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♦ Extractor hook - T20143-
erm
ab
ility
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t to the co
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mer
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– Remove selector lever cable from gearbox ⇒ page 63 .

– Carefully pry lever -A- off selector shaft.
4. Renewing selector shaft lever oil seal with gearbox removed 55

– Lever out seal.

– Lightly oil outer circumference of new oil seal.
– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128- .
– Drive in new seal to stop, being careful not to cant seal.
satelettronica
– Set lever in place and tighten to 20 Nm.
Selector shaft lever fits on splines in only one position.
– Install and adjust selector lever cable on gearbox
⇒ page 63 .
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ate
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Rep. gr.34 - Controls, housing Prote AG.
5 Emergency release of selector lever

Do not remove knob.
– Depress brake pedal or set handbrake.
In an emergency:
– Grip leather bellows and pull trim upwards.
Vehicles through 02.2009 lkswage es n
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– Press yellow plastic wedge from right to left. ir se
d ran
tee
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satelettronica
– Unclip selector lever cover and hold aside.
rrectness of i
– Press yellow plastic wedge -arrow-.
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5. Emergency release of selector lever 57

6 Removing and installing selector lev‐

er handle
Brief description
Depending on the model, different handles may be installed.
It is possible with all knobs that the button is pressed into the knob.
Never install a knob with the button pressed in.
Handle is removed together with selector cover.
Removing:
– Shift selector lever to position “D”.
Handle with push-button on side:
– First pull button far enough out of handle that a small gap is
visible between handle and button. Button locks when re‐
leased.
– Hold button in this position with a cable tie or wire to prevent
it from being pressed in.
satelettronica
AG. Volkswagen AG d
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Handle with front push-button: d by ara
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Button does not need to be pulled out by hand.aThe
ut push-button ra
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engages in installation position -arrow- when the handle is pulled ss
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off.
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Continuation for all handles:

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– Unclip cover.
– Pull connector off selector cover.
nform
ercia
– Push sleeve upwards to release knob.

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– Pull handle off selector lever without pressing button.

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Do not press button again after removal as it will no longer be
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Installing
agen
Prote AG.
– Install in reverse order of removal, observing the following:

• Selector lever is in position “D”.

Handle with push-button on side:

• Button in handle is pulled out and secured against being
pressed in.
Handle with front push-button:

• Push-button is in installation position -arrow-.
If the button was pressed by mistake, the installation position can
be restored.
– Move push-button to installation position ⇒ page 60 .
AG. Volkswagen AG d
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satelettronica
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Note
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New handle is supplied with installation guard. Do not remove

guard until just before installing. To remove, pull it out.
nform
ercia
Handle with front push-button

m
at
om
io
If the button was pressed by mistake, the installation position can

n
c
in t
or
be restored. To do this, push installation guard fully in whilst but‐

his
ate
ton is pressed, release button and pull installation guard out

do
priv
again. Push-button engages in installation position.

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en
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Continuation for all handles
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– Push handle fully onto selector lever and lock. gh ht
pyri by
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– Push sleeve downwards to lock. Prote
cted AG.
agen
– After installation, press button in selector lever grip.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this has happened, handle will have to be
installed again. To do this, pull handle off selector lever, move
button into installation position using installation guard and install
handle again.
Continue installation in reverse order of removal.
6. Removing and installing selector lever handle 59

6.1 Moving push-button in the handle to in‐

stallation position
6.1.1 Handle with push-button on side

– First pull button far enough out of handle that a small gap is
visible between handle and button. Button locks when re‐
leased.
– Hold button in this position with a cable tie or wire to prevent
it from being pressed in.
AG. Volkswagen AG d
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6.1.2 Handle with front push-button
ot p
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With this kind of handle, the push-button cannot be pulled out.
hole
spec
There are 2 ways of moving the push-button into the installation
es, in part or in w
t to the co
position, »with« and »without« installation guard. Both of them are
described here.
Place handle »with« installation guard in installation position:
rrectness of i
When using the installation guard, make sure that it has an eyelet
l purpos
-arrow- at the front. Other types of installation guard are not suit‐
able. nf
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– Holding the button down, completely push in installation guard
AG.
with eyelet -arrow- until the installation guard engages, then

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

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– Carefully unclip handle trim -A- upwards.
itte
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ility
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es, in part or in w
t to the co
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– Using a screwdriver, press the small lever -1- for the tie rod
C py
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satelettronica
into the groove -2-. Doing this presses the push button -3- into rig ht
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the installation position.
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-I- = button pressed in
-II- = button in installation position
Note
♦ Press the lever only into the groove and no further.

♦ Do not clip the handle trim onto selector mechanism until the
handle has been fitted. This makes it possible to check wheth‐
er the small lever engages in the pull rod when the push-button
is pressed.
6. Removing and installing selector lever handle 61

7 Selector mechanism up to 02.2009
WARNING
Before working on vehicle with engine running, move selector

lever into position “P” and apply handbrake.
7.1 Overview of selector mechanism up to 02.2009
1 - Selector cover with knob

❑ Do not remove handle
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped ⇒ page 57 .
❑ Right knob in figure: first
pull button far enough
out of knob until a small
satelettronica
gap is visible between
knob and button. Button
locks in this position
when released. Hold
button in this position
with a cable tie or wire to
prevent it from being
pressed in.
❑ Left grip in figure: do not
press button in. Howev‐
er, if this should happen,
the knob must be dis‐
mantled and prepared
for installation
⇒ page 60 .
2 - Selector lever and selector agen
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❑ With selector lever lock orise nte
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❑ Emergency release s
ce
le
⇒ page 57 .
un
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❑ Brief instructions for re‐

rm
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moving and installing:

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ility
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– Remove centre console

, is n
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hole
spec
– Remove cable from

es, in part or in w
gearbox and separate

t to the co
selector mechanism
⇒ page 63 .
rrectness of i
– If necessary, disconnect or remove parts of ⇒ exhaust system; Rep. gr. 26 .

l purpos
– Remove heat shield beneath vehicle.

nform
ercia
– Adjust selector lever cable after installing ⇒ page 70 .

m
3 - Bolt with spring

com
tion in
❑ 3 Nm
r
te o
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4 - Pin
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❑ Removing ⇒ page 63
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❑ Do not grease
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Rep. gr.34 - Controls, housing Prote
cted AG.
agen
5 - Locking plate
❑ Always renew after removing
6 - Nut
❑ 9 Nm
❑ Qty. 4
7 - Selector housing
❑ With seal
8 - Selector lever cable
❑ Do not grease cable
❑ Removing and installing ⇒ page 63
❑ Checking ⇒ page 70
❑ Adjusting ⇒ page 70
9 - Securing clip
10 - Securing clip
satelettronica
11 - Hexagon nut with washer
❑ 8 Nm
❑ Qty. 4 n AG. Volkswagen AG do
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7.2 Removing and installing selector lever th or
au ac
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cable up to 02.2009
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ility
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Following installation, cable must be checked for ease of move‐
ole,
ment and be adjusted.

spec
t to the co
Removing
– Move selector lever to position “S” position.
rrectness o
cial p
f inform
mer
atio
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or
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7. Selector mechanism up to 02.2009 63

Loosen adjustment screw -arrow-.

– Remove securing clips -A- and -B-. Securing clips must be
renewed when cable is adjusted.
– Raise vehicle.
– To remove cable and/or selector mechanism, heat shield must
now be removed and, if necessary, parts of exhaust system.
– ⇒ Rep. gr. 26 ; Removing and installing parts of the exhaust
system
– Remove heat shield.
– Remove -selector housing- beneath selector lever.
satelettronica
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– Remove securing clip of cable support bracket. Always renew

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ab
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ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f i
satelettronica
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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fo
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ng
t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
-Selector housing- is pushed forwards slightly on cable.

To remove cable, securing tab must be pushed forwards -1-.

– At same time, push -pin- up with a screwdriver -2-.
AG. Volkswagen AG d
agen oes
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nl
pt
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Insert -screwdriver- from below.
satelettronica
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

Clarification:
♦ -1- Push tab forwards
♦ -2- Push pin up
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
– Remove selector lever cable.

ss
Remove selector housing from cable.

o
cial p
f in
Installing
form
mer
atio
Do not grease cable.

om
n
c
– Route selector lever cable without stress. Also insert into cable
or
n thi
e
support bracket on gearbox. Do not secure with securing clips

t
sd
iva
yet. Do not clip in ball head.

pr
cum
r
fo
en
ng
– Ensure that selector lever cable is properly routed during in‐

t.
yi Co
op
stallation. C py
t. rig
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yri
– Put selector housing onto cable.
p by
co Vo
by lksw
cted agen
Prote AG.

– Insert selector lever cable into selector mechanism.
– Insert cable into bearing and insert pin from above, down‐ AG. Volkswagen AG d
wards through eye. ksw
agen oes
not
satelettronica
Vol
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– Check selector lever cable for ease of movement rised ara
nte
⇒ page 70 . ut
ho eo
ra
s a c
– Then insert new securing clip. s
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Attach cable with new securing clip on cable support bracket
m
m
atio
of selector mechanism.
om
n in
or c
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Cop py
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6-speed dualoclutch
en AG. V
gearbox
lkswagen AG 02E - Edition 01.2018
ag does
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oris eo
th
au ra
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ss
ce
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un
pt
an
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
satelettronica
te
sd
iva
o
pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Install selector housing.

– Adjust selector lever cable ⇒ page 70 .
– Install heat shield.
If the sheet metal is bent downwards, it may cause noises. The
cable will »vibrate« against the sheet metal.

– Press sheet metal up in the tunnel during .installation

Volkswage -arrow-. n AG n AG d
wage oe
– Install exhaust system ⇒ Rep.y Vgr.
olks26 ; Removing and installing
s no
t gu
parts of exhaust system .ised b ara
n r tee
ho
aut or
ac
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un
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spec
t to the co
7.3 Checking selector lever cable
Brief description
rrectne
The ease of movement is checked on the cable. Selector lever
s
cable must be removed from gearbox so that its ease of move‐
s o
ment can be checked. Put removed end down so it does not rub
cial p
f in
against anything.
form
mer
satelettronica
atio
The selector lever must be moved and then the cable must be
om
reattached to the gearbox.
n
c
i
or
n thi
e
Then the selector lever cable must be adjusted.

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sd
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pr
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Do not grease connections of cable!
um
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fo
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t.
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Check
Co
Cop py
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– Move selector lever to position »P«.
rig ht
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– Remove cable from lever on gearbox.
cted agen
Prote AG.
– Move selector lever repeatedly from »P« to »S« and back to

»P«.
• Selector lever must move easily.
7.4 Adjusting selector lever cable


The selector lever cable must always be adjusted whenever

♦ The selector lever cable has been removed from the gearbox.
♦ 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.
Adjusting
– Move selector lever in vehicle to “P” position.
AG. Volkswagen AG d
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Shift lever on gearbox to position “P”. d byV
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Lever on gearbox must be pressed »all the wayut back«.
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– Pull lever forwards to check. s
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un
pt
– Then push lever »backwards«.
an
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itte
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erm
ab
“P” is in second detent.
ility
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Note
spec
t to the co
♦ Raise vehicle, to be sure that the gearbox is actually in
“P” (parking lock engaged). It should not be possible to turn
both front wheels together in the same direction.
rrectne
♦ Gearbox is also in “P” if vehicle cannot be pushed although its
wheels are free to turn.
ss o
cial p
f inform
mer
atio
om
n
– Install cable with loosened adjusting screw -arrow- and new
c
i
or
n
securing clips -A- and -B-.
thi
te
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– Gently push knob of selector lever forwards and backwards

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fo
but under no circumstances must you shift out of “P”.

en
ng
t.
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op
In this way the ⇒ inner cable of the Bowden cable finds it optimal C py
ht. rig
position. rig ht
py by
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– Tighten adjusting screw to 13 Nm. cted agen
Prote AG.
This completes the adjustment.

8 Checking selector mechanism

The starter must not turn in the selector lever positions “R”, “D” or
“S”.
On a right-hand drive vehicle, starter must only turn in selector
lever positions “P” and “N” when lock button is not pressed.
When selector lever is shifted to position “N” at speeds above
5 km/h, solenoid for selector lever lock must not engage and block
selector lever. Selector lever can be shifted into a driving range.
When travelling at speeds below 5 km/h (almost stationary) and
engaging selector lever position “N”, solenoid for selector lever
lock should only engage after about 1 second. Selector lever can‐
not be shifted out of “N” position until brake pedal is depressed.
8.1 Selector lever in “P” position and ignition

switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “P” position
with the lock button pressed. Solenoid for selector lever lock
satelettronica
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to selector lever position. gen AG
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8.2 Selector lever in “N” position and ignition ed
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• Brake pedal not depressed:
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un
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Selector lever is locked and cannot be shifted out of “P” position

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with the lock button pressed. Solenoid for selector lever lock
ab
pe
ility
blocks selector lever.
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• Brake pedal is depressed: h re

hole
spec
Solenoid for selector lever lock releases selector lever. It is pos‐
es, in part or in w
sible to shift into a driving gear.

t to the co
8.3 Selector lever in position “Tiptronic”

rrectness of i
• Shift selector lever into Tiptronic gate.

l purpos
The illumination of the “D” symbol in the selector mechanism cov‐

er must go out. “+” and “-” symbols must light up.
nform
ercia
When the selector lever is shifted into the Tiptronic gate, the se‐
m
lector lever position display in the dash panel insert must change
a
com
ti
from “P R N D S” to “6 5 4 3 2 1”.
on in
r
te o
thi
8.4 Ignition and light switched on

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The respective symbol in the shift mechanism cover lights up.

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8.5 Selector lever position indicator Cop py
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Simultaneous illumination of all selector lever position display cop Vo
by lksw
cted
segments indicates gearbox emergency running mode.
agen
Prote AG.

9 Selector mechanism from 03.2009

onwards
WARNING
Before working on vehicle with engine running, move selector

lever into position “P” and apply handbrake.
Selector mechanism in vehicles up to 02.2009 ⇒ page 62
9.1 Overview of selector mechanism in vehicles from 03.2009 onwards
1 - Selector cover with knob

❑ Do not remove handle
without reason. For gen AG
. Volkswagen AG
does
emergency release, on‐Volkswa not
ly the cover needs etod bbe y gu
ara
unclipped ⇒ page horis
57 . nte
eo
satelettronica
ut ra
❑ Right knob inssfigure: first
a c
pull button far enough
ce
le
un
pt
out of knob until a small
an
d
itte
gap is visible between
y li
erm
ab
knob and button. Button
ility
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locks in this position
wit
is n
when released. Secure
h re
ole,
button against being
spec
pressed in with a cable
tie or wire.
t to the co
❑ Left grip in figure: button
engages in installation
rrectne
position when handle is

pulled off. Do not press
button again after re‐
ss
moval as it will no longer

o
cial p
be possible to install the

inform
handle.
mer
atio

om
⇒ page 58
n
c
i
or
n thi
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2 - Selector lever and selector

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mechanism with selector lever

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❑ With selector lever lock Cop py
solenoid - N110-
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❑ Do not grease cable
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Prote
AG.
⇒ page 74
❑ Checking ⇒ page 70
❑ Adjusting ⇒ page 70
3 - Bolt
❑ 8 Nm
4 - Hexagon flange nut
❑ 8 Nm
❑ Qty. 4
5 - Selector housing
6 - Locking plate
9. Selector mechanism from 03.2009 onwards 73

7 - Locking plate
9.2 Removing and installing selector mech‐

anism, from 03.2009
⇒ “9.2.1 Removing and installing selector mechanism withgeselec‐
swa es n
tor housing”, page 74 yV
olk ot g
u b ara
ed nte
⇒ “9.2.2 Removing and installing selector mechanism
ho
ris without se‐ e
lector housing”, page 76 aut or
ac
s s
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e
9.2.1 Removing and installing selector mech‐

nl
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du
an
itte
anism with selector housing
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erm
ab
ility
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Brief description
wit
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Selector mechanism and selector lever cable are not allowed to
hole
spec
be separated from one another. Both are removed together with
es, in part or in w
the selector housing.
t to the co
In the interior, the centre console must be removed.
satelettronica
The heat shield beneath the vehicle must be removed.
rrectness of i
The selector mechanism with selector lever cable can be re‐
l purpos
moved and installed separately without removing and installing

the selector housing ⇒ page 76 .
nform
mercia
at
Note
om
ion
c
in t
or
his
Following installation of selector mechanism, selector lever cable
ate
do
riv
must be checked for ease of movement and be adjusted.

p
cum
for
en
ng
t.
yi
Removing
Co
Cop py
t. rig
gh ht
yri by
– Move selector lever to position “P”. op Vo
by c lksw
cted agen
Prote
– Remove selector lever handle ⇒ page 58 .
AG.
– Remove centre console ⇒ General body repairs, interior; Rep.

gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Separate electrical wiring connector -1- from selector mecha‐

nism to vehicle wiring harness.
– Remove complete air filter housing:
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
ling air filter housing
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐


renewed when selector lever cable is later adjusted.
Use pliers to remove the Asecuring
. Volkswaclip
gen A-B- on the cable support
bracket. Do not use wa gen G
asharp-edged lever. GThe
does selector lever cable
olks not
could otherwise
db
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a
e ran
ris t
– Removeut
ho heat shield for centre tunnel beneath selector
ee
or mech‐
anism
ss
a ⇒ General body repairs, exterior; Rep. gr. 66 a;cUnder‐
body cover; Assembly overview - underbody cover .
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
To remove selector mechanism, a 2nd mechanic is required un‐
h re
ole,
der the vehicle.
spec
t to the co
– Remove nuts -arrows- inside vehicle.
– If fitted, remove bracket -A-.
rrectne
– Remove selector mechanism -B- together with selector lever
satelettronica
s
cable and selector housing downwards.
s o
cial p
f
Installing
inform
mer
Install in reverse order of removal. atio

om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
♦ Do not bend or kink gear selector cable.

en
ng
t.
yi Co
op
♦ Do not grease selector lever cable. C py
t. rig
gh ht
yri by
♦ Specified torques ⇒ page 73 . op Vo
by c lksw
cted agen
Prote AG.
– Install heat shield beneath selector mechanism ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underbody cladding; As‐
sembly overview - underbody cladding .
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
– Install selector lever handle ⇒ page 58 .
– Check selector mechanism ⇒ page 72 .
– Install complete air filter housing:

9.2.2 Removing and installing selector mech‐

anism without selector housing
Brief description
Selector mechanism and selector lever cable are not allowed to
be separated from one another. Both are removed together.
In the interior, the centre console must be removed.
A cord must be attached to the Bowden cable before it is removed.
The cord is needed to guide the Bowden cable between the tunnel
and the heat shield.
The selector mechanism with selector lever cable can also be
removed and installed with the selector housing ⇒ page 74 .
Removing
– Remove selector lever handle ⇒ page 58 .
– Remove centre console ⇒ General body repairs, interior; Rep.
sole .
– Separate electrical connector from selector mechanism to ve‐
satelettronica
hicle wiring harness.
– Remove air filter housing.
. Volkswagen AG
a gen AG does
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and Vol instal‐
ksw not
gu
ling air filter housing ed
by ara
nte
is
or eo
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing
au
th and instal‐ ra
ling air filter housing ss c
ce
e
nl
pt
du
an
itte
y li
erm
renewed when selector lever cable is later adjusted.
ab
ility
ot p
wit
, is n
h re
Use pliers to remove the securing clip -B- on the cable support
hole
spec
bracket. Do not use a sharp-edged lever. The selector lever cable
es, in part or in w
could otherwise be damaged.
t to the co
– Then a long cord must be attached to the end of the Bowden
cable. The cord is needed to guide the Bowden cable between rrectness of i
the tunnel and heat shield during installation.
l purpos
nform
ercia
– Remove 4 bolts.
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.

– Carefully pull selector mechanism with Bowden cable out of

the centre tunnel. Ensure that the cord remains accessible
from the engine compartment after being pulled by the Bow‐
den cable.
– Remove cord from Bowden cable.
Installing
Install in reverse order of removal, observing the following:
A second mechanic is needed to guide Bowden cable from pas‐
senger compartment into engine compartment.
Note
♦ Do not bend or kink gear selector cable.

♦ Do not grease selector lever cable.
♦ Specified torques ⇒ page 73 .
– Attach Bowden cable to cord which was drawn into the pas‐
senger compartment during removal.
satelettronica
– Carefully guide selector mechanism with Bowden cable
through opening in centre tunnel.
– Have the second mechanic pull cord with Bowden cable
through tunnel from engine compartment until Bowden cable
can be attached to support bracket.
olkswagen AG
en AG. V
– Remove cord from Bowden cable.
olks
wag does
not
y V gu
d b ara
ise nte
– Secure selector mechanism
uthor
to selector housing using 4 bolts. eo
a ra
s c
Specified torque: 8 Nm s
ce
e
nl
pt
du
– Install centre console ⇒ General body repairs, interior; Rep.

an
itte
y li

erm
ab
sole .
ility
ot p
wit
, is n
– Install selector lever handle ⇒ page 58 .

h re
hole

spec
es, in part or in w
t to the co
– Check selector mechanism ⇒ page 72 .

– Install air filter housing:
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.

10 Removing and installing gearbox
10.1 Removing gearbox, Passat CC 2009 ►,

CC 2010 ► with 2.0 l petrol engine
Brief description
The gearbox is removed downwards separately.
gen AG
. Volkswag»From
en AG above«
a does
lksw n
The battery, air filter and starter
db
y V are removed. The coolant hoses
o ot g
ua
must be clamped off. Support
oris
e engine and gearbox before left rante
subframe mounting aisuthunbolted. eo
ra
ss c
»From below«
ce
le
un
pt
an
d
Remove -subframe- together with -pendulum support-,

itte
y li
-steering rack- and -both suspension links-.
rm
ab
pe
ility
ot
wit
, is n
h re
Special tools and workshop
hole
equipment required
spec
es, in part or in w
satelettronica
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/3-
♦ Adapter - 10 - 222 A /18-
♦ Gearbox support - 3282-

♦ Adjustment plate - 3282/42 A-

♦ Insert tool, 18 mm - T10179-
♦ Bracket - T10346-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
♦ Socket insert - T10035-
ot p
wit
is n
h re
ole,
satelettronica
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om

c
i
or
n thi
te
♦ Tools without illustration:

sd
iva
o
pr
cum
r
♦ 2 x tensioning straps - T10038-

fo
en
ng
t.
yi Co
♦ Adapter - 10 - 222 A /8- Cop py
t. rig
gh ht
yri
♦ If no hose clamps to 40 mm - 3093- are available, use hose p by
o Vo
by c
clamps to 25 mm - 3094- .
lksw
cted agen
Prote AG.
♦ Engine and gearbox jack - V.A.G 1383 A- or engine and gear‐
box jack - VAS 6931-
Removing:
height.
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
10. Removing and installing gearbox 79

– Remove battery and battery tray ⇒ Rep. gr. 27 ; Battery; Re‐

moving and installing battery .
satelettronica
connector.
– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
It is advisable to remove the »lower« bolt first.
– Unbolt earth strap from bracket.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– Remove selector lever cable from gearbox. orise nte
h eo
ut ra
Use pliers to remove the securing clip on the cable support
ss abrack‐ c
et. Do not use a sharp-edged lever, as the rubber grommet on the
ce
le
un
pt
cable could be damaged.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Always renew both securing clips.

s
– Remove cable with great care from cable support bracket on

s o
gearbox. Do not bend cable.

cial p
f inform
Cable can also be removed later on when gearbox is being low‐

mer
ered. Then observe cable whilst lowering gearbox.

atio
om
n
c
During later installation, do not clip »small« securing clips on until

i
or
n thi
e
cable has been checked and adjusted ⇒ page 70 .

t
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.

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

or hose clamps to 25 mm - 3094- and remove.
– Remove upper engine/gearbox connecting bolts.
satelettronica
These tools are appropriate for this.
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.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
satelettronica
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Pull connector -1- off oil level and oil temperature sender -
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Next remove -subframe- together with -pendulum support-, both

-suspension links- and -steering-.
⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and
installing subframe with steering rack
– Disconnect both drive shafts from gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Removing and installing drive
shaft .
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– Place support bracket - 10 - 222 A- onto upper longitudinal

member.
Caution
The support bracket must not be placed on the wings, other‐

wise these might be damaged.
– Support engine and gearbox with support bracket - 10 - 222

A- and hooks - 10 - 222 A /10- . Do not raise.
– Remove all bolts -1- and -2- for bracket -A-.

– Then lower engine/gearbox assembly to dimension -a- using

spindles of support bracket - 10 - 222 A- .
Dimension -a- = approx. 50 mm
– Remove gearbox bracket -arrow-.

– Remove all connecting bolts except one which is in an easily
accessible place between engine and gearbox.
It is advisable to leave an easily accessible bolt installed.
– Set up gearbox support - 3282- with adjustment plate -
3282/42 A- .
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– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
and support gearbox. Do not raise.
The gearbox is separated from the engine in this position.
– Remove last engine/gearbox connecting bolt.
– Press gearbox off engine while »observing selector lever ca‐
ble«, and lower gearbox.
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Transporting gearbox and securing to assembly stand olkswagen oes
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The gearbox is removed downwards separately. The engine re‐
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The battery, air filter and starter are removed. The coolant hoses t to the co
must be clamped off. Support engine and gearbox before left
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Their benefit is enormous.
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♦ Adapter - 10-222A/3-
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height.
– Remove both front wheels.
– Remove battery and -battery box- ⇒ Rep. gr. 27 ; Battery;
Removing and installing battery .

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

and installing starter
– Remove selector lever cable from gearbox.

Use pliers to remove the washer on the cable support bracket. Do
not use a sharp-edged lever, as the rubber grommet on the cable
could be damaged.
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Both securing clips must be later renewed when cable is adjusted.
Remove cable with great care from cable support bracket on
gearbox. Do not bend it. agen
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– Disconnect -wiring harness- coming »from below« from sub‐

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– Disconnect electrical connector -3-.
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steering and heat shield ⇒ Rep. gr. 40 ; Removing and installing

subframe with steering rack .
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– Remove all upper connecting bolts from engine and gearbox.
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Insert 18 mm - T10179- is especially good for this purpose.

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and installing steering rack to see what must be done.
In any case, return the steering wheel to the straight-ahead po‐
sition. Engage steering wheel lock. Notes on tightening the bolt
can also be found in these instructions.
– Separate steering box from steering column.
It is advisable to now do all the work which must be done »be‐
neath« the car. This will avoid having the weight of the engine
carried by the support bar and, consequently, by the body, for »a
long time«.
housing liners .
– Remove left wheel housing liner.

– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
– Unbolt both transverse links from suspension struts.

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– Unbolt both drive shafts from gearbox and carefully
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Secure both drive shafts to suspension struts using tensioning
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– Unbolt ⇒ pendulum support from gearbox.
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and reinstalled without subsequently causing increased tyre

wear, which may lead to customer complaints. It is recommended
to read this information »before« removing gearbox. Then the
position of the -subframe- can be properly fixed and the subframe
removed.
If the position of the subframe was not fixed, the wheels must now
be aligned.
⇒ Running gear, axles, steering; Rep. gr. 40 ; Locating subframe
and brackets .
When removing subframe, please remember:

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– After removing a bolt -1-, immediately screw in a locatingopinris
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– Fit retainer - T10346- on longitudinal member.
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(At rearmost of the 3 support points of the battery tray)

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– Support engine and gearbox. Do not raise.

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About 3 turns are sufficient to remove bracket -arrow-.
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3282/42 A- .
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Transporting gearbox and securing to assembly stand

⇒ page 283 .
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Install gearbox ⇒ page 273 .
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10.3 Removing gearbox, Golf Plus 2005 ►
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The gearbox is removed downwards separately. »From above« t. Cop py
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engine and gearbox supported.
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»From below«

removed.

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♦ Adapter - 10 - 222 A /8-
♦ Adapter - 10-222A/3-


♦ Pin - 3282/29-
♦ Bit - T10099/1-
♦ Support - 3282/59-
Removing:
height.
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– Remove battery and s-battery
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– Remove engine cover panel.
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could be damaged.

gearbox. Do not bend it.
Cable may also be pushed slightly backwards out of cable support
bracket and removed later when gearbox is lowered. But then
observe cable when lowering gearbox.
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– Clamp off coolant hoses ausing
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One bolt is located in hole for starter at the height of the solenoid.
Socket - T10061- , 18 mm insert - T10179- or insert tool -
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– Disconnect wire -1- from electronics box.

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– Position adapter - 10 - 222 A /8- :

• On longitudinal members, at top, directly before the elevation
(-arrow 1-) next to bolt (-arrow 2-)
– Connect left support eye on engine to support bracket .
– Connect bracket - T10346- to support bracket .
– Take up weight of engine/gearbox assembly and support
bracket on spindles.
port bracket - 10 - 222 A- so that bracket can be removed.

At most, 4 turns are sufficient to remove bracket -arrow-.

housing liners .
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removed.
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coolant circuit and charge air pipe do not need to opened or sep‐
arated, respectively.
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3282/42 A- .
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A lower connecting bolt can be loosened but need not be re‐

moved.
If this bolt needs to be renewed, the exhaust system must be
separated.
⇒ page 283 .

CC 2010 ► diesel engine
Brief description
The gearbox is removed downwards separately. »From above«
The battery, air filter and starter are removed. The coolant hoses
»From below«
⇒ Pendulum support and left drive shaft removed. The subframe
remains in the vehicle.


equipment required
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♦ Support - s10
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connector.
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A bolt is located in the starter motor hole -arrow-.

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nuts M6).

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ening torque ⇒ Rep. gr. 40 ; Repairing drive shafts .
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installed using socket V.A.G 1669 .
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counterhold flange shaft with a lever.
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a lever and screw in bolt.
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When moving engine/gearbox assembly, make sure that no con‐
necting lines, hoses or radiator are kinked or damaged.

3282/42 A- .
⇒ page 283 .

CC 2010 ► with diesel engine, all-wheel
drive
Brief description
The gearbox is removed downwards together with the bevel box.
»From above«
»From below«


-steering rack- and -both suspension links-. gen AG. Volkswagen AG d
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♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
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connector.
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3094- and remove.
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Only vehicles with auxiliary heater:

– Remove diesel particulate filter -A- from top of engine
-arrows-. Use suitable means to secure filter on plenum cham‐
ber bulkhead to prevent it from falling down⇒ Rep. gr. 26 ;
Removing and installing particulate filter .
Continued for all vehicles:
housing liners .

satelettronica
nuts M6).
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– Unbolt left and right drive shaft from gearbox ⇒ Rep. gr. 40 ;
h re
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Removing and installing drive shafts .

spec
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– Remove drive shaft heat shield from bevel box (-arrows-) ⇒

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shafts .
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– Remove lower bracket for diesel particulate filter ⇒ Rep. gr.
26 ; Removing and installing particulate filter .

– Unscrew coolant hoses of auxiliary heater from engine

-arrow-, pull off from threaded pins and push to one side until
gearbox carrier can be unscrewed ⇒ Auxiliary heater; Rep.
gr. 82 ; Removing and installing Thermo Top V auxiliary heat‐
er .
Do not open the pipe/hose system.
– Remove bolts -B- for gearbox carrier to bevel box.

– Loosen bolts -A-.
satelettronica
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Caution co Vo
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Do not place support bracket on the wings, as this may cause
damage.

– Then lower engine/gearbox using spindles of support bracket
- 10 - 222 A- until bracket -A- can be removed.
At most, 5 turns of each spindle should be sufficient to remove
bracket.

AG. Volkswagen AG d
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ce
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nform
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bevel box -A-.

m
at
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3282/42 A- .
c
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satelettronica
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Cop py
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lksw
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AG.
Some vehicles have an intermediate flange on flange shaft/bevel

box.
– Unscrew intermediate flange -arrows- if a »new« bevel box is

installed, because there is no intermediate flange on »new«
bevel box.
⇒ page 283 .

with 2.0 l diesel engine
Brief description
The battery, air filter and starter are removed. Wiring harness of
steering rack is disconnected and »laid clear«. This allows it to be
lowered together with subframe and steering rack. The engine
and gearbox must be supported before the left subframe mount‐
ing is removed.
»From below«


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.

removed. AG. Volkswagen AG d
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In any case, locating pins - T10096- are necessary. edb ua
ran
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equipment required
AG. Volkswagen AG d
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♦ Gearbox support - 3282- Prote
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agen

♦ Pin - 3282/29-
♦ Support - 3282/59-
Removing:
height.


satelettronica
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Both securing clips must be later renewed when cable is adjusted. wit
is n
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– Release mechatronic unit connector by turning and pull off C py
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frame.
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This wiring harness will later be removed together with the sub‐ cum
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heat shield. C py
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– Separate steering box from steering column. cop Vo
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Prote
AG.

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housing liners .
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– Unbolt drive shafts from gearbox and carefully
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Valuable information concerning the installation of the
-subframe- can be found in ⇒ Rep. gr. 40 . It is recommended to
rrectne
read this information »before« removing gearbox. Then it will be
clear how to fix the position of the -subframe- so it can then be
s
removed as shown in this figure.
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be aligned.
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– A small cover plate is located above the right drive shaft flange
on the intermediate plate for engine and gearbox. Remove
cover plate -A-.
3282/42 A- . AG. Volkswagen AG d
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⇒ page 283 .
ole,
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10.7 Removing gearbox, Golf 2009 ► 2.0 l
rrectne
diesel engine
satelettronica
Brief description
ss o
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mer
The battery, air filter and starter are removed. Wiring harness of
atio
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steering rack is disconnected and »laid clear«. This allows it to be

o
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c
lowered together with subframe and steering rack. The engine
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and gearbox must be supported before the left subframe mount‐
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Both drive shafts are disconnected from gearbox and left installed
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in wheel bearing housings. They are only swivelled to one side
and left on vehicle.

removed.

If the position of the -subframe- is not fixed with the pins,AGthe

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wheels must later be aligned. agen does
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equipment required
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mercia
at
satelettronica
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
yi Co
Cop py
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rig ht
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♦ Adapter - 10 - 222 A /18-


♦ Pin - 3282/29-
♦ Support - 3282/59-
Removing:
height.
AG. Volkswagen AG d
– Remove complete air filter housing ⇒ Rep. gr. 24 ; lRemoving
wage
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and installing air filter . db
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Removing and installing battery . s au ra
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M6 nuts).
connector.
satelettronica
AG. Volkswagen AG d
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un
pt
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d
frame.
itte
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spec
t to the co
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inform
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atio
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c
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pr
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olkswagen AG
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– Disconnect earth cable -2-. olkswag does
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heat shield.
pt
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tion in
satelettronica
r
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thi
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In any case, return the steering wheel to the straight-ahead po‐
sition. Then engage steering lock. Notes on tightening the bolt
AG. Volkswagen AG d
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satelettronica
ss c ce
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un
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an
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ab
pe
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wit
, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
a
com
tion in
r
te o
thi
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iva
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t.
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Cop py
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housing liners .
satelettronica
– Unbolt drive shafts from gearbox and carefully lay to side.
AG. Volkswagen AG d
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If the position of the subframe is not fixed with the pins, the wheels
rrectness of i
must later be aligned.

l purpos

and brackets .
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at
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ion
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- T10096- -2-.
must be supported.
satelettronica
cover plate -A-. wage
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– Set up gearbox support - 3282- with adjustment
ed
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3282/42 A- . horis nte
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– Move engine and gearbox jack - sV.A.G
s 1383 A- under gearbox c
ce
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nl
pt
du
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⇒ page 283 .
rrectness of i
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CC 2010 ► with 3.6 l - V6 engine (all-
nform
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wheel drive)
m
at
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Brief description
on
c
in t
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The gearbox is removed downwards together with the bevel box.

his
ate
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equipment required
satelettronica
AG. Volkswagen AG d
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nl
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du
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hole
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c
♦ Support - 10 - 222 A-
in t
or
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te

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♦ Gearbox support - 3282- Prote
cted AG.
agen


♦ Adapter - 10 - 222 A /18-
Removing:
height. wage
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– Move selector lever to eposition
db
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– Disconnect battery
au ⇒ Rep. gr.
th 27 ; Battery; Disconnecting and ra
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ss . c
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nl
pt
du
an
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and installing air filter , and remove bracket beneath that.
y li
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connector. orm
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satelettronica
– Unbolt coolant line from engine -1- and -2-.
AG. Volkswagen AG d
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– Insert bracket - T10013- in eye of crankcase.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
yi Co
Cop py
ht. rig
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– Remove all upper engine/gearbox connecting bolts. n AG. Volkswagen AG do

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The following tools are appropriate for this:
rrectne
s
housing liners .
s o
cial p
f inform
mer
atio
satelettronica
om
n
c
i
or
n thi
te
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pr
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fo
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co lksw
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– Unbolt wiring retainer from front of »black« gearbox cover

-arrows- (2 nuts M6).
– Unbolt left and right drive shaft from gearbox ⇒ Rep. gr. 40 ;
– Secure both drive shafts on suspension strut with tensioning

belts - T10038- .



bevel box flange with paint. gen AG
. Volkswagen AG
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– Unbolt propshaft from bevel box -arrows-
db
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– Push front propshaft tube to sstop.
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pt
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The -seal- in the propshaft must not be damaged. If seal is dam‐
aged, propshaft must be renewed.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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– Remove heat shield above right drive shaft -1- ⇒ Rep. gr. 40 ;
t.
yi Co
op
Heat shields for drive shafts . C py
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– Remove bolts -1- for gearbox carrier to bevel box.

– Loosen bolts -2-.
Specified torque
40 Nm
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pt
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cial p
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mer
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c
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t.
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Cop py
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Vo
co lksw
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member.
Caution
The support bracket must not be placed on the wings, other‐

wise these might be damaged.


AG. Volkswagen AG d
agen oes
olksw not
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b ara
– Then lower engine/gearbox assembly to dimension rise
d -a- using nte
spindle of support bracket - 10 - 222 A- . ut ho eo
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Dimension -a- = about 20mm
ce
le
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pt
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ility
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Remove bracket -arrow-.
l purpos

nform
ercia

m
3282/42 A- .
a
com
tion in
r
te o
thi
s
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rp

um
fo
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t.
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Cop py
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Prote AG.
⇒ page 283 .
10.9 Removing gearbox, Golf 2004 ▸ with

1.9 l and 2.0 l diesel engine
Brief description
»From below«



removed.
satelettronica
AG. Volkswagen AG d
agen oes
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If the position of the rise-subframe- is not fixed with the pins, the
d ara
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wheels must later uthobe aligned. eo
ra
s a c
s
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un
pt
an
d
expense!
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cial p
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mer
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c
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pr
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t.
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 age➤ , .Golf
n AG VolksPlus 2005
wagen AG
doe➤ ...
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6-speed dual clutch gearbox 02E - Edition b01.2018
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Special tools and workshop au
th or
ac
equipment required ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
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es, in part or in w
t to the co
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l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
satelettronica
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
♦ Adapter - 10-222A/3-
♦ Additional hook - 10-222A/13-
♦ Pin - 3282/29-
♦ Support - 3282/59-
Removing:
height.

Note
– Depress brake pedal to remove bolt for left drive shaft

-arrow- (2nd mechanic).
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
d b ara
– rise
Remove battery and h-battery box- ⇒ Rep. gr. 27 ; Battery; nte
o
satelettronica
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Removing and installing
s aut
battery . ra
c
s
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e
nl
pt
du
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nf
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t. rig
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pyri by
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co lksw
by
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nuts M6).
connector. wage
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Vol t gu
– Remove all upper engine/gearbox connecting
db
y bolts. Insert
satelettronica
ara
18 mm - T10179- is especially goodrisefor this purpose. nte
ho t eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
frame.
wit
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hole
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nform
mercia
at
om

on
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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co lksw
by
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frame. This will save time-consuming work on the steering
AG. Volkswand
agen AG
agen does
heat shield. V olksw not
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– Remove all upper engine/gearbox ris connecting bolts. Insert
e
tee
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18 mm - T10179- is especially
au good for this purpose.
t or
ac
ss
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e
nl
pt
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du
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satelettronica
nf
ercia
o
rm
m
atio
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n in
or c
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A- , adapter - 10 - 222 A /3- , hooks - 10 - 222 A /10- and
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adapter - 10 - 222 A /13- . Do not raise.
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by c lksw
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housing liners .
The surface protection of the shafts must not be damaged. Plastic
very good for this.
If the subframe is removed now, the left drive shaft may be re‐
satelettronica
moved.
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Next remove -subframe- together
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or
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-both suspension links-ssand ac
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es, in part or in w
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and brackets .
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- T10096- -2-.
nform
ercia
m
at
must be supported.
om
ion
c
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or
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ate
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co lksw
by
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cover plate -A-.
3282/42 A- .
⇒ page 283 .
10.10 Removing gearbox, Golf 2004 ► with

125 kW - 2.0 l diesel engine
satelettronica
Brief description . Volkswagen AG
gen AG does
swa
The gearbox yisV removed downwards separately.
olk not
gu »From above«
edb ara
nte
The battery,
horis
air filter and starter are removed. The coolant
eo hoses
ut clamped off. Left subframe mounting is removed
musts abe r a and
c
s
ce
le
un
pt
»From below«
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ility

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wit
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hole
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es, in part or in w
t to the co
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nform
mercia

com
tion in

r
te o
thi

s
iva

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rp

um
fo
en

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t.
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removed. t. Cop py
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pyri by
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by c lksw
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Prote AG.

expense!

equipment required
satelettronica
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
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erm
ab
ility
ot p
wit
, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
or c
thi
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r
rp
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♦ Adapter - 10-222A/3-
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
♦ Gearbox support - 3282- by c lksw
cted agen
Prote AG.


♦ Pin - 3282/29-
♦ Support - 3282/59-
♦ Engine and gearbox jack - V.A.G 1383 A- gen AG. Volkswagen AG
wa does
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Removing: d byV gu
ara
ise nte
r
– Raise vehicle. All 4 supportsutof
h lifting platform must be at same
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⇒ page 283 .
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10.11 Removing gearbox, Eos 2006 ►, with

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heat shield.
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removed.
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removed.

expense!

equipment required
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AG. Volkswagen AG d
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nuts M6).
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frame.


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nf
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or
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removed.
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AG. Volkswagen AG d
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very good for this.
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3282/42 A- .


A lower connecting bolt can be loosened but need not be re‐

moved.
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⇒ page 283 . n AG. Volkswagen AG do
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expense!

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♦ Adapter - 10-222A/3-


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Removing:
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could be damaged.
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nuts M6).
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connector.
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engine. Insert 18 mm - T10179- is especially good for this pur‐
pose.
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support eyes for support bracket - 10-222A- , remove these
now.


not raise.

AG. Volkswagen AG d
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satelettronica
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Now remove -subframe- ⇒ Rep. gr. 40 .

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cover plate -A-.
3282/42 A- .
⇒ page 283 .
10.14 Removing gearbox, Golf 2004 ►, with

3.2 l - V6 engine (R32 all-wheel drive)
satelettronica
Brief description
The gearbox is removed downwards separately. »Fromenabove«
AG. Volkswagen AG
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nform
ercia
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m
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at
om
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arated. Then the »last« connecting bolt between the engine and
n
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gearbox must be removed and the gearbox lowered.

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equipment required
AG. Volkswagen AG d
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olksw not
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du
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21 ; Charge air system with turbocharger .
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could be damaged.



nuts M6).
connector.
satelettronica
pose.

frame.
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heat shield.
pose.

AG. Volkswagen A
Refer to ⇒ Running gear,olkaxles,
swa steering; Rep. gr.do48
gen G
es n; Removing
o
and installing steering
db
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V to see what must be done. t guar
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In any case, firstthoreturn the steering wheel to the straight-ahead
eo
position. Engage
s au steering wheel lock. Notes on tightening the boltra
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A- , adapter - 10 - 222 A /8- and adapter - 10 - 222 A /18- . Do
not raise.
rrectness of i
– Use shackles - 10 - 222 A /12- for eyes on engine.

l purpos
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At most, 3 turns of each spindle are sufficient to remove bracket

-arrow-.
housing liners .
wage es n
satelettronica
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– Unbolt suspension links from suspension struts on both sides.
erm
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nf
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The tensioning straps - T10038- are also very good for securing
m
atio
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the drive shafts.

o
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The left drive shaft can be set aside in the wheel housing.
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-both suspension links- and -steering-. agen
AG. Volkswagen AG d
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Valuable information concerning the installation ed
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-subframe- can be found in ⇒ Rep. gr. 40 .hIt risis recommended to tee
t o
read this information »before« removing gearbox. Then it will be or
au ac
clear how to fix the position of the -subframe-
ss
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and brackets .
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- T10096- -2-.
rrectness of i
l purpos
must be supported.
nform
ercia
satelettronica
m
a
com
tion in
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te o
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cover plate -A-.
3282/42 A- .
⇒ page 283 .
10.18 Removing gearbox, Touran 2003 ►

Brief description
The gearbox is removed downwards separately, without engine.
»From above«

»From below«
Left drive shaft is removed. Right drive shaft is only removed from
gearbox, but remains in vehicle.

equipment required
satelettronica
AG. Volkswagen AG d
agen oes
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l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
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Cop py
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co
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Prote AG.
♦ Adapter - 10-222A/3-
♦ Adapter - 10-222A/16-

♦ Support - 3282/59-
AG. Volkswagen AG d
agen
satelettronica
oes
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nform
mercia
♦ Pin - 3282/48A-
a
com
tion in
♦ Pin - 3282/29-
r
te o
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Support engine and gearbox in the Touran. cted agen
Prote AG.
Contour of headlights has been changed several times in the

Touran. This means there are different contact surfaces for sup‐
port bracket - 10 - 222 A- on wing.

AG. Volkswagen AG d
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♦ To 11.06: small headlights -arrow 1-.
es, in part or in w
satelettronica
t to the co
♦ From 11.06 to 05.10: large headlights with curvature
-arrow 2-.
rrectness of i
♦ From 05.10: large headlights without curvature -arrow 3-
l purpos
Adapters have been adjusted accordingly. It is essential to take

this into account.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Small headlights -arrow 1-: adapter - 10 - 222 A /22- .

f
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– Large headlights with curvature -arrows 2-: adapter - 10 - 222

A /26- .

– Large headlights without curvature -arrow 3-: adapter - 10 -

222 A /30- .
Removing:
height.
– Step on the brake pedal while a second mechanic loosens the

left drive shaft bolt -arrow-.
Note
satelettronica
– Remove battery with battery tray ⇒ Rep. gr. 27 ; Battery;

AG. Volkswagen AG d
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Rep. gr.34 - Controls, housing Prote AG.


nuts M6).
satelettronica
AG. Volkswagen AG d
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Bit - T10061- can be used instead of an 18 mm socket.

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– If there are hose and cable connections or retainers in area of

h re
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spec
now.
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rrectness of i
l purpos
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mercia
a
com
tion in
r
te o
thi
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Cop py
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209
agen
Prote AG.
10. Removing and installing gearbox
– For vehicles with small headlights, use adapter - 10 - 222 A /

22- .
Figure shows Touran with diesel engine.
– Attach hook - 10-222A/10- to front right of engine.
AG. Volkswagen AG d
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– Now attach additional hook - 10-222A/2- to rear left of engine
erm
ab
satelettronica
-arrow-.
ility
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– Then connect hook - 10-222A/2- using adapter - 10-222A/16- .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– For vehicles with large headlights with round profile, use

m
at
om
adapter - 10 - 222 A /26- .

ion
c
in t
or
Figure shows Touran with petrol engine.

his
ate
do
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for
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Prote AG.

– For vehicles with large headlights without round profile, use

adapter - 10 - 222 A /30- .
Figure shows Touran with diesel engine.
Continuation all vehicles
– Take up weight of engine and gearbox assembly on spindles
but do not raise.
housing liners .
– Unbolt drive shafts from gearbox.
– Remove left drive shaft.
lkswage es n
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– Secure right drive shaft tothosuspension strut with tensioning tee
or
strap - T10038- . au ac
ss
satelettronica
ce
e
Do not damage surface protection of shafts.

nl
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Only in some 1.4 l petrol engines:
l purpos
– Unclip line to Lambda probe.

nf
ercia
– Remove hose for charge air ducting.

orm
m
atio
– Unscrew charge air pipe from engine at bottom and swivel it

om
forwards.
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– Remove front exhaust pipe. In this way, lower engine/gearbox
Prote AG.
connecting bolts -arrows- can be unscrewed and removed lat‐

er.
Continuation all vehicles


Remove subframe with steering rack. ⇒ Rep. gr. 40 ; Removing
and installing subframe with steering rack
For some diesel engines only:
cover plate -A-.
AG. Volkswagen AG d
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– Then lower engine/gearbox slightly using spindles of support
es, in part or in w
bracket - 10 - 222 A- so that bracket -A- can be removed.
t to the co
3282/42 A- .
rrectness of i
l purpos

nform
ercia

m
at
om
ion
c
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r

o
his
ate
do
priv
10.19 Removing gearbox, Passat 2006 ► with

um
for
en
ng
t.
2.0 l diesel engine
yi Co
Cop py
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Brief description py by
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The gearbox is removed downwards separately. »From above« Prote AG.
»From below«
Remove ⇒ pendulum support. The subframe remains in the ve‐
hicle.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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satelettronica
or eo
th
au ra
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ce
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un
pt
an
d
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ab
pe
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wit
, is n
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Support - 10 - 222 A-
m
a
com
tio
n in
r
te o
♦ Socket insert - T10061- thi

s
iva
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cum

fo
en
g
n
t.
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pyri by
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Prote AG.
♦ Adapter - 10 - 222 A /8-

AG. Volkswagen AG d
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Special tools and workshop equipment required by Vol
gu
ara
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ise nte
♦ Tools without illustration: thor eo
au ra
s c
♦ Engine support - 3300 A- s
ce
e
nl
pt
du
♦ Pin - 3282/29-
an
itte
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t to the co
Removing:
rrectness of i
height.
l purpos

nform
ercia

m
at
– Remove intake hose from turbocharger so that rear eye is ac‐
om
io
cessible for »hanging« engine.
n
c
in t
or
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at
do
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p
cum
for
en
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– Remove upper starter motor bolt.

n
t.
yi Co
Cop py
t. rig
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Vo
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Prote AG.


could be damaged. olkswage es n
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nl
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t to the co
rrectness of i
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satelettronica
nf
ercia
orm
m
atio
om
n in
or c
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or hose clamps to 25 mm - 3094- and remove. m

f
en
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t.
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op
t. rig
connector. gh ht
pyri by
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by
– Unbolt wiring retainer from front of »black« gearbox cover (2 Prote
cted AG.
agen
nuts M6).
engine.
♦ Insert tool 18 mm - T10179-
long time«.
housing liners .


– Remove radiator fan support.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
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satelettronica
s
ce
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nl
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du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
G266- .
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
– Remove exhaust system bracket from subframe -arrows-.

do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Separate exhaust system at double clamp -arrows-.

– Tie up front exhaust pipe or put down tunnel cross member.
– Remove left coupling rod from suspension link and lay to side.
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
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– Unscrew left transverse link from suspension strut.
erm
ab
ility
ot p
– Unbolt both drive shafts from gearbox and carefully lay to side.
wit
is n
h re
– Swing left drive shaft into wheel housing onto longitudinal
ole,
spec
member. This will keep the shaft out of the way during further
work.
t to the co
satelettronica
rrectne
very good for this.
ss o
cial p
f inform
mer
atio
m

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

straps - T10038- .

– Unbolt front left vehicle level sender - G78- from suspension

link.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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– Remove ⇒ pendulum support, bolt -1-, -2- and bolt -3-.
ce
le
un
pt
an
d
itte
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ab
ility
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t to the co
satelettronica
rrectness o
– Unbolt right securing bolt for heat shield -1- from subframe.
cial p
f inform
– Screw bracket - T10346- tight using a suitable bolt -2-.
mer
atio
m
Bolt -2- = M6 X 20
o
n
c
i
or
n thi
– Secure engine support - 3300 A- on bracket - T10346- .
te
sd
iva
o
r
Set engine support against engine crank case. Do not exert pres‐
p
cum
r
fo
sure yet! en
ng
t.
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Cop py
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Prote AG.

Use two spindles.


satelettronica
– Remove lower starter bolt and remove starter.
It is easier to remove the starter »from above«. Lower vehicle.
There is now a working step »from above«. Volkswa
AG. gen AG
agen does
– Remove bolt in starter hole. y Volksw not
gu
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ility
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hole
spec

es, in part or in w
t to the co
cover plate -A-.

– Lower engine and gearbox until there is sufficient »clearance«
between upper edge of gearbox and left longitudinal member.
rrectness of i

l purpos
3282/42 A- .
nform
ercia

m
at
om

on
c
in t
or

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ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
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by
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Prote AG.

– Carefully press engine and gearbox forwards.
Note
lkswage es n
Observe connecting bylines,
Vo hoses and radiator when moving
ot g
ua en‐
gine/gearbox assembly.
d ran
ir se tee
tho
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
⇒ page 283 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.0 l petrol engine
rrectness of i
Brief description
l purpos
satelettronica
nf
ercia

orm
m
atio
om
n in
»From below«
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te

sd
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en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
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satelettronica
ol not
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ara
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t to the co
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cial p
♦ Support - 10 - 222 A-
inform
mer

atio
om

n
c
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t
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i
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pr
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en
ng

t.
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op py
. C rig
ht ht
rig by
copy Vo
by lksw
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Prote AG.

Removing:
height.
– Remove air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery


connector.
– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter . AG. Volkswagen n AG do
wage es n
It is advisable to remove the »lower« bolt first. Volks ot g
by ua
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– Unbolt earth strap from bracket. thoris tee
or
au ac
ss
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectnes
satelettronica
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

t
sd
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pr
c
um
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en
ng

t.
yi Co
op py
. C rig
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rig
ered. Then observe cable whilst lowering gearbox. py by
co Vo
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During later installation, do not clip »small« securing clips on until Prote AG.
cable has been checked and adjusted.

3094- and remove.

lkswage es n
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d ran
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tho
u or
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ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
A bolt is located in the starter motor hole -arrow-. , is n
h re
hole
spec
es, in part or in w
t to the co
sulation .
– Remove lower part of front left wheel housing liner ⇒ General
rrectness of i
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing wheel housing liner .
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
nuts M6).
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o
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rp
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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.
G266- .


– Disconnect both drive shafts from gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Removing and installing drive
shaft .
– Secure drive shaft to suspension strut with tensioning strap -

T10038- .
– If there are hose and cable connections in area of engine sup‐ AG. Volkswagen AG d
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⇒ page 283 .

3.6 l - V6 engine (all-wheel drive)
Brief description
The battery, air filter and starter are removed. Coolant hoses are
clamped off and engine and gearbox are supported.
»From below«
First pendulum support and bevel box are removed. The sub‐
frame remains in the vehicle. The propshaft remains in the vehi‐
cle. Then the gearbox is removed downwards.


equipment required
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height.
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
and installing air filter , and remove retaining plate beneath
that.


could be damaged.
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Both securing clips must be later renewed whenrise cable is adjusted.
d b ara
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connector.
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housing liners .
– Remove left coupling rod from suspension link and lay to side.
– Unbolt front left vehicle level sender - G78- from suspension
link.
– Remove pendulum support ⇒ Rep. gr. 40 ; Assembly over‐
view - subframe, anti-roll bar, suspension links .

– Unbolt propshaft from gearbox.
satelettronica
– Therefore, clamp assembly tool - T10071- tight with a cloth.
This »protects« the ring.
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Heat shields for drive shafts .
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straps - T10038- .
– Remove bracket -A- between cylinder block and bevel box.

First remove bolt -1-.
When installing, hand-tighten all bolts until the heads make con‐
tact. Then tighten bolts -2-.
Specified torques: 40 Nm
satelettronica
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– Remove counter-sunk bolt using insert - T10107 A- d b.
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The flange shaft remains in the gearbox. utho
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port bracket - 10 - 222 A- so that bracket -A- can be removed.

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space is sufficient to later AG Volkswagen AG d past the longitudinal
w agen guide the gearbox oe
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hole

spec

es, in part or in w
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⇒ page 283 .
rrectness of i

l purpos
10.22 Removing gearbox, Scirocco 2009 ►

nform
ercia
with 2.0 l diesel engine

m
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Brief description
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removed.
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Prote AG.
Rep. gr.34 - Controls, housing

equipment required
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♦ Adapter - 10-222A/3-
♦ Adapter - 10 - 222 A /18-

Special tools and workshop equipment required n AG. Volkswagen AG do

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Removing:
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AG. Volkswagen AG d
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– Remove selector lever cable from gearbox. d by V gu
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Use pliers to remove the washer on the cableutsupport bracket. Do
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a
on the cable c
could be damaged.
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– Clamp off coolant hoses using hose clamps to 40 mm - 3093- cop Vo
by lksw
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connector.
M6 nuts).


frame.
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– Disconnect electrical connector -3-. AG. Volkswagen AG d
agen oes
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ol not
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subframe with steering rack . ss a c ce
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– Now remove all upper connecting bolts from engine and gear‐
un
pt
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box. Insert 18 mm - T10179- is especially good for this pur‐

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satelettronica
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Secure both drive shafts to suspension struts using tensioningolks
wag does
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straps - T10038- . ed
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removed.
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and brackets .
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- T10096- -2-.
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(At rearmost of the 3 support points of the battery tray)olkswage es n
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– Remove filler pieces from upper edges of both
ris wings
ed ran
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2 l - 103 kW engine
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c
in t
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AG. Volkswagen AG d
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agen
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– Position rack feet - 10 - 222 A /1- :

• On upper longitudinal members (-arrows-)
• Directly next to plenum chamber
– Pull off seal -1- for plenum chamber cover -2- near both rack
feet - 10 - 222 A /1- if they can not be set in place as shown.
– Observe line -3-.
Caution
The rack - 10 - 222 A /1- must not be placed on the bolt-on

sheet metal of the wings. The metal panel could be damaged.
– Connect bracket - T10346- to support bracket .



3282/42 A- .
satelettronica
⇒ page 283 .
AG. Volkswagen AG d
agen
10.23 Removing gearbox, Scirocco 2009 ► Volksw
oes
not
gu
by
with 2.0 l petrol engine d ara
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Brief description ss a c
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n
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removed.
expense!
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c
in t
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priv
cum
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en
ng
t.
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Cop py
t. rig
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equipment required
AG. Volkswagen AG d
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fo
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could be damaged.
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frame.
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subframe with steering rack .
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housing liners .

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straps - T10038- .
form
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removed.
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- T10096- -2-.
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c
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3282/42 A- .
– Remove remaining engine/gearbox
wage
n AG. Volkswaconnecting
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doe bolts.
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by engine while »observing selector
gu
alever
ran ca‐
ble«, and lower
horis gearbox. tee
t or
au ac
Transporting
ss gearbox and securing to assembly stand
⇒ page 283 .
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
10.24 Removing gearbox, Sharan 2011 ► with
wit
, is n
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2.0 l diesel engine
hole
spec
es, in part or in w
Brief description
t to the co
satelettronica
rrectness of i
The battery with battery tray, air filter and starter are removed.
The coolant hoses must be clamped off. Support engine and
l purpos
gearbox before left subframe mounting is unbolted.

»From below«
nform
ercia
Remove ⇒ pendulum support. The subframe remains in the ve‐

m
hicle.
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
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pyri by
Vo
co lksw
by
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Prote AG.


equipment required
satelettronica
AG. Volkswagen AG d
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olksw not
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ris nte
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nl
pt
du
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erm
ab
ility
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wit
, is n
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spec
es, in part or in w

t to the co
♦ Adapter - 10 - 222 A /8-

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
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

lkswage es n
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byV ua
d ran
ir se tee
tho
u or
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ss
ce
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pt
an
d
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rm
ab
pe
ility
ot
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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
l purpos
nform
ercia
satelettronica
m
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.
♦ Square tube - T40091 / 1- with connector - T40091/3- of engine

support basic set - T40091-
♦ Adapter - T40093/3- of supplementary engine support bracket
set - T40093-
up to 25 mm - 3094-
♦ Shackle - 10 - 222 A /12-

♦ Adapter - T40093/3-5 - of supplementary engine support

bracket set - T40093-
Removing:
height.
Note agen
AG. Volkswagen AG d
satelettronica
oes
olksw not
V gu
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After loosening centre bolt, do not lower risevehicle
d
to ground again. nte
ho eo
aut ra
s c
– Depress brake pedal to remove bolt for left drive shaft s
ce
le
-arrow-. (2nd mechanic).

un
pt
an
d
itte
y li
– Remove cover from engine.
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
– Then pull off grommet -arrow- so that it is not damaged when

supporting engine.
nform
ercia
Supports for support bracket - 10-222 A- are placed in area of

m
a
com
plenum chamber cover and radiator grille.

ion in
r
te o
– Therefore remove plenum chamber cover: ⇒ Rep. gr. 50 ;

thi
s
iva
Plenum chamber cover ; and remove radiator grille ⇒ Rep.

do
r
rp
gr. 66 ; Radiator grille .

um
fo
en
ng
t.
yi Co
op py
and installing air filter . t. C rig
gh ht
pyri by
o Vo
by c lksw
cted
agen
Prote AG.


connector.

satelettronica
AG. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
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le
un
pt

an
d
itte

y li
rm
ab
pe
ility
– Remove charge air line ⇒ Rep. gr. 21 ; Removing and instal‐

ot
wit
ling parts of charge air cooling .

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
253
Prote AG.
10. Removing and installing gearbox


long time«.
– Remove noise insulation and front left wheel housing liner ⇒
General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner; Front wheel housing liner .
satelettronica
– Remove left drive shaft ⇒ Rep. gr. 40 . 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
ening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unbolt right drive shaft from gearbox and secure to suspen‐

sion strut using tensioning straps - T10038- ⇒ Rep. gr. 40 .
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.

CC 2010 ➤ , Eos 2006
agen
➤. V,oGolf
AG lkswag2004
en AG ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
does
olksw 6-speed dual clutch not gearbox 02E - Edition 01.2018
yV b gu
ara
ed nte
ris
– Remove ⇒ pendulum support.
au
tho
First remove bolt -1-, followed e or
ac
by bolts -2- and -3- ⇒ Rep.
ss gr. 40 .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
s
s o
cial p
f i
– Support engine and gearbox.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
satelettronica
p
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
• Before putting on support bracket - 10-222 A- , note assembly
of following special tools:
• Adapters - 10-222 A /8- must be mounted as shown.
• Supports -A- must face outwards.
• -Arrow- = vehicle driving direction.
• Bolt adapter - T40093/3-5 - onto adapter - T40093/3- .

• Connect 2 bars - 2024 A / 1- of support bracket - 2024 A- to‐

gether using shackle - 10 - 222 A /12- .
• 2 holes -arrows- each point in one direction.
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
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erm
ab
ility
ot p
wit
, is n
h re
– Set up support bracket - 10-222 A- behind bonnet support: hole
spec
es, in part or in w
– First put on adapter -10-222A/8- -A- next to bolts -arrow- on
t to the co
left side.
– Then fit support bracket - 10-222A- behind bonnet support.
rrectness of i
Position the right adapter - 10-222A/8- next to the bolts as well
-arrow-.
l purpos
satelettronica
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.
– Attach bars - 2024 A / 1- in engine support eyes.
• 2 holes -arrows- each point towards front end.
– Connect lugs - 2024 A / 1- to spindle - 10 - 222 A /12- using
shackle - 10 - 222 A /10- .
(⇒ previous illustration)
– Set up adapter - T40093/3- with adapter - T40093/3-5 - (notch
-A-) on sheet metal fold of bumper carrier.
– Push one spindle onto square tube - T40091/1- .
– Assemble square tube - T40091/1- with adapter - T40093/3-
and support bracket - 10-222A- .
– Then attach spindle in front engine support eye.
– Take up weight of engine/gearbox assembly on spindle .

bracket - 10 - 222 A- and remove bracket.


Note
Before removing flange shaft, check oil seal for leaks. If oil seal
is leaking, it must be renewed before flange shaft is installed.
– Remove right flange shaft of gearbox using socket -T10107

A- .
satelettronica
– Close opening in drive shaft using a suitable plug.
– When flange shaft is reinstalled, compression spring prevents
bolt engaging in thread. If necessary press flange shaft against
gearbox with a lever and screw in bolt.
– Set up gearbox support - 3282- with adjustment plate
agen -
AG. Volkswagen AG d
oes
3282/42 A- . olksw not
yV gu b ara
ed
– Move engine and gearbox jack - V.A.Gtho1383
ris A- under gearbox nte
e or
and support gearbox. Do not raise.s au ac
s
ce
le

un
pt
an
d
itte
– Remove remaining engine/gearbox connecting bolts. y li

rm
ab
pe
ility
ot
wit
, is n
h re
hole

spec
⇒ page 283 .
es, in part or in w
t to the co

rrectness of i

1.8 l and 2.0 l petrol engine
l purpos
Brief description
nform
ercia

m
a
com
tio
Remove battery with battery tray, air filter, starter and radiator
n in
r
grille removed. The coolant hoses must be clamped off. Support

te o
thi
engine and gearbox before left subframe mounting is unbolted.

s
iva
do
r
rp
cum
»From below«
fo
en
ng
t.
yi Co
⇒ Pendulum support and both flange shafts removed from gear‐ Cop py
box. The subframe remains in the vehicle.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

6-speed dual clutch w
gearbox
agen 02E
AG. Volksw-aEdition
gen AG 01.2018
doe
ks s no
Vol t gu
by ara
ris
ed
nte
equipment required tho eo
au ra
c
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
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
satelettronica
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.
♦ Adapter - 10 - 222 A /8-

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
satelettronica
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
♦ Square tube - T40091 / 1- with connector - T40091/3- of engine

um
for
en
g
support basic set - T40091-

n
t.
yi Co
op py
♦ Adapter - T40093/3- of supplementary engine support bracket
t. C rig
gh ht
yri
set - T40093- p by
o Vo
by c lksw
cted agen
Prote AG.
up to 25 mm - 3094-
♦ Adapter - T40093/3-5 - of supplementary engine support
bracket set - T40093-
Removing:
height.
Note



connector.
satelettronica
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
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
ercia

m
at

om
ion

c
in t
or
his
te

a
do
riv

p
cum
for
en
g

n
t.
yi Co
op
cable has been checked and adjusted ⇒ page 70 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen o
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 V➤ olk,s Golf 2009 ➤ , Golf Plus s2005
w e n
ot g ➤ ...
by ua
6-speed risedual
d clutch gearbox 02E - Edition 01.2018
ran
t ee
tho or
au ac
– Clamp off coolant hoses using hose clamps to 40
ss mm - 3093-
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


– If fitted, remove front vehicle level sender from transverse link

on »left« and »right« ⇒ Rep. gr. 43 ; Level control .
– Remove left drive shaft ⇒ Rep. gr. 40 .

ening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Unscrew right
s autransverse
t
link from suspension strut -arrows- ra
c
⇒ Rep. gr. s40 .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Unbolt right drive shaft from gearbox and secure to suspen‐

ss
sion strut using tensioning straps - T10038- ⇒ Rep. gr. 40 .

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

. Volkswagen AG
gen AG doe
swa
CC 2010 ➤ , Eos 2006 ➤ , Golfy2004 Volk ➤ , Golf 2009 ➤ , Golf sPlus
not 2005 ➤ ...
gu
b a
6-speed
rised
dual clutch gearbox 02E - Editionra01.2018
nte
ho eo
aut ra
– Remove ⇒ pendulum support. First removes bolt -1-, followed
s c
ce
le
by bolts -2- and -3- ⇒ Rep. gr. 40 .
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
Before removing flange shaft, check oil seal for leaks. If oil seal
ole,
spec
is leaking, it must be renewed before flange shaft is installed.
t to the co
rrectnes
– Remove »left« and »right« flange shafts from gearbox using
s o
cial p
f
insert -T10107 A- .
inform
mer
atio
om
n
c
i
or
n
thi
te
sd
iva
o
pr
cum
r

fo
satelettronica
en
ng
t.
yi Co
– Close opening in drive shaft using a suitable plug. . Cop py
rig
ht ht
rig
– When flange shaft is reinstalled, compression spring prevents py by
co Vo
bolt engaging in thread. If necessary press flange shaft against
by lksw
cted agen
Prote
gearbox with a lever and screw in bolt.
AG.
– Remove exhaust system bracket from subframe -arrows- ⇒

Rep. gr. 26 ; Exhaust system .

Remove following components before fitting support bracket:
♦ Windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wash/wipe system
♦ Plenum chamber cover ⇒ Rep. gr. 50 ; Plenum chamber
cover
♦ Radiator grille ⇒ Rep. gr. 66 ; Radiator grille

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
CC 2010 ➤ , Eos 2006 tho➤
r , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005
eo ➤ ...
u ra
6-speed dual clutchssgearbox
a 02E - Edition 01.2018 c
ce
le
un
pt
– Push rotary joint - T40091/3- and adapter - 10 - 222 A /3- onto
an
d
itte
y li
square tube of support bracket - 10 - 222 A- .
erm
ab
ility
ot p
– Fit adapter - 10-222 A /8- as shown and bolt to support bracket
wit
- 10-222 A- . 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
• Rubber blocks -A- must face outwards.
en
ng
t.
yi Co
op
py
satelettronica
t. C rig
gh ht
yri by
• Set up support bracket - 10-222 A- behind bonnet support. cop Vo
by lksw
cted agen
Prote AG.
• Bolt adapter - T40093/3-5 - onto adapter - T40093/3- .

– Push mounting - T40093/3- as well as one spindle onto square

tube - T40091/1- .
– Place mounting - T40093/3- with adapter - T40093/3-5- onto
bumper carrier and push square tube - T40091/1- into articu‐
lated joint - T40091/3- .
– Align support bracket and tighten all bolts hand-tight.
– Take up weight of engine/gearbox assembly on spindle .
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
satelettronica
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
– Then lower engine/gearbox assembly to dimension -a- using
in t
or
his
spindle of support bracket - 10 - 222 A- .
ate
do
priv
Dimension -a- = about 20mm cum

for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


3282/42 A- .
⇒ page 283 .

1.4 l petrol engine
satelettronica
Brief description
The gearbox is removed downwards
wage
n AG. Vseparately.
olkswagen AG»From above«
doe
ks s no
Vol t
The battery, air filtereand
d b starter are removed. The coolant
y gu
ahoses
ran
must be clampedhooff.ris Left subframe mounting is removed and tee
engine and gearbox
s aut
supported. or
ac
s
»From below«
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.


equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
satelettronica
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
♦ Support - 10 - 222 A-
by lksw
cted agen
Prote AG.
♦ Adapter - 10 - 222 A /8-
♦ Hose clamps to 25 mm - 3094-
Removing:
height.


satelettronica
connector.
AG. Volkswagen AG d
agen oes
– Remove selector lever cable from gearbox -arrows-. Volksw not
gu
by ara
ed
Use pliers to remove the securing clip on the cablehosupport
ris brack‐ nte
eo
et. Do not use a sharp-edged lever, as the rubber autgrommet on the ra
c
cable could be damaged. 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

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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


3094- and remove.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
satelettronica
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
satelettronica
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
A bolt is located in the starter motor hole -arrow-. by c lksw
cted agen
Prote AG.

– Remove coolant circulation pump - V50- -arrow 1-; do not open

coolant lines ⇒ Rep. gr. 19 .
– Unclip line to Lambda probe.

charge air pipe.
– Unbolt bottom of charge air pipe from engine and swing for‐
wards ⇒ Rep. gr. 21 ; Removing and installing parts of charge
air cooling .
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– Unbolt both drive shafts from gearbox and secure to suspen‐

sion strut using securing straps - T10038- ⇒ Rep. gr. 40 ;
rrectness of i

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a
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tion in
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Next remove -subframe- together with -pendulum support-, both

-suspension links- and -steering-.
– Disconnect front exhaust pipe from catalytic converter so that gen AG

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lower engine/gearbox connecting bolts -arrows- can be re‐ yV
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moved ⇒ Rep. gr. 26 ; Removing and installing parts of rised b ara
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Remove following components before fitting support bracket:
an
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♦ Windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
satelettronica
pe
ility
Windscreen wash/wipe system
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♦ Plenum chamber cover ⇒ Rep. gr. 50 ; Plenum chamber
hole
spec
cover
es, in part or in w
t to the co
Adapters - 10-222 A /8- for support bracket - 10-222 A- are placed
in area of plenum chamber cover.
rrectness of i
– Fit adapter - 10-222 A /8- as shown and bolt to support bracket
l purpos
- 10-222 A- .
nform
mercia
a
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te o
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iva
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Prote AG.
• Rubber blocks -A- must face outwards.

• Set up support bracket - 10-222 A- behind bonnet support.
– Attach spindle to left support eye on engine.
– Take up weight of engine/gearbox assembly on spindles.


bracket - 10 - 222 A- and remove bracket.

3282/42 A- .
satelettronica
AG. Volkswagen AG d
– Press gearbox off engine while »observing selector lever ca‐lkswagen oes
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Transporting gearbox and securing to assembly stand tho eo
⇒ page 283 . s au ra
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10.27 Install gearbox
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Install in reverse order of removal. Nevertheless, important steps
h re
ole,
are listed here:
spec
– Renew needle bearing -arrow- in crankshaft ⇒ Rep. gr. 13 ;
t to the co
Crankshaft; Renewing needle bearing in crankshaft .
– Lightly grease journal and splines on gearbox using high-tem‐
rrectne
perature grease - G052133A2- .
– Check for proper seating of both dowel sleeves between en‐
ss
gine and gearbox.
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cial p
f in
– Check for proper seating of intermediate plate.
form
mer
atio
It must be possible to guide the engine and gear box together by
om
hand until the flanges make contact all around.

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If this is not so, then »something is wrong«!

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– Readjust gearbox support until engine and gearbox are

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»aligned with each other«.

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Pay attention to selector lever cable when raising gearbox. Guide
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cable as soon as possible into cable support bracket.
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Do not grease cable!
Prote AG.

– Securing clips -arrows- for selector lever cable must be re‐

newed.
– Check and adjust selector lever cable ⇒ page 70 .
– Check coolant level and top up if necessary ⇒ Rep. gr. 19 .
– Checking oil level and topping up ⇒ page 302
Specified torques ⇒ page 275
satelettronica
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11 Torque settings »gearbox to engine«

The »next chapters« list the torque settings for gearbox installa‐
tion.
There is also information about the »left-hand« assembly mount‐
ing.
Threaded connections that are not directly assigned to theggear‐
AG. Volkswagen AG d
box can be found in the associated assembly groups. a en oes
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The correct torque settings for the engine/gearbox combination
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11.1 Torque settings (⇒ ELSA)
spec
t to the co
Petrol en‐ Eos Golf Golf Plus Scirocco Passat Touran Golf 2009 ► Sharan
gine 2006 ► 2004 ► 2009 ► 2006 ► 2003 ► 2011 ►
satelettronica
and Pas‐
rrectne
sat CC
2009 ►
s
1.4 l - 103 ⇒ ⇒ ⇒ ⇒
s o
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- 110 kW page page page 277 page 277
f in
277 277
form
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1.4 l - ⇒ ⇒ ⇒
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125 kW page page page 277

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277 277
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agen
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- 155 kW page page page page page 276 page 276
276 276 276 276
2.0 l - ⇒
169 kW page
278
3.2 l - ⇒ ⇒ ⇒
184 kW page page page
280 281 281
3.6 and ⇒
3.6 l - V6 page
engine 282
Diesel en‐ Eos 2006 Scirocco Golf Golf Plus Passat Touran Golf Sharan
gine ► 2009 ► 2004 ► 2006 ► 2003 ► 2009 ► 2011 ►
and Pas‐
sat CC
2009 ►
1.9 l - ⇒ ⇒ ⇒
77 kW page 281 page 278 page 278
2.0 l - 81 ⇒ ⇒
kW and page 278 page 278
103 kW
11. Torque settings »gearbox to engine« 275

Diesel en‐ Eos 2006 Scirocco Golf Golf Plus Passat Touran Golf Sharan
gine ► 2009 ► 2004 ► 2006 ► 2003 ► 2009 ► 2011 ►
and Pas‐
sat CC
2009 ►
2.0 l - ⇒
88 kW page 278
2.0 l - ⇒ ⇒ ⇒ ⇒
100 kW page 278 page 278 page 278 page 278
2.0 l - 103 - ⇒ ⇒ ⇒ ⇒ ⇒ ⇒
105 kW page 278 page 278 page 278 page 278 page 278 page 278
2.0 l - ⇒
120 kW page 278
2.0 l - 125 ⇒ ⇒ ⇒ ⇒ ⇒
kW page 278 page 278 page 278 page 278 page 278
11.1.1 Torque settings and note on engine

mountings
satelettronica
for:
Scirocco 2009 ►, Golf 2009 ►, Golf Plus 2009 ►, Passat 2006 ►
and Passat CC 2009 ► Eos 2006 ► with 2.0 l - 147- 155 kW
AG. Volkswagen AG d
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M12 - 80 Nm
❑ If insert 18 mm -
T10179- is used: 65 Nm.
M10 - 40 Nm
- Arrows indicate dowel
sleeves.
satelettronica
AG. Volkswagen AG d
agen oes
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– Renew all bolts on left assembly mounting. s aut ra
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– First screw in all bolts by hand.
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– First bolt bracket -A- to gearbox -1- with 40 Nm + 90° further

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– The bracket can be levered into the correct position with a

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screwdriver as bolts -2- are tightened. Torque settings of

hole
-bolts 2-: 60 Nm + 90°.

spec
es, in part or in w
t to the co
Starter to gearbox ⇒ Rep. gr. 27 ; Removing and installing start‐

er .
Assembly mounting bolts must be renewed.
rrectness of i
Subframe to body ⇒ Rep. gr. 40 ; Assembly overview - subframe,

l purpos
anti-roll bar, suspension links .

nf
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mountings
o
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for:
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Golf 2004, Golf Plus 2005, Touran 2003 with 1.4 l - 103 and
o
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125 kW TSI and Sharan with 1,4l - 110 kW TSI

t.
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277
by lksw
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Prote 11. Torque settings »gearbox to engine«
AG.
M12 - 80 Nm
T10179- is used: 65 Nm.
M10 - 40 Nm
sleeves.
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ate
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– Renew all bolts on left assembly mounting. by c lksw
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Prote AG.
turn.
-bolts 2-: 60 Nm + 90°.
er .

mountings
for:
♦ Golf with 2.0 l - 147 and 169 kW »petrol engines«

♦ Golf with 1.9 l - 77 kW and 2.0 l - 100, 103 and 125 kW »diesel
engines«
♦ Golf Plus with 1.9 l - 77 kW and 2.0 l - 100, 103 and 125 kW
»diesel engines«
♦ Touran with 1.9 l - 77 kW and 2.0 l - 100, 103 and 125 kW
»diesel engines«
♦ Passat and Passat CC with 1.9 l - 77 kW and 2.0 l - 88, 100,
103 and 125 kW »diesel engines«
♦ Eos with 2.0 l - 147 kW »petrol engines«
♦ Eos with 2.0 l - 103 kW »diesel engines«
♦ Scirocco »diesel engine«: 2.0 l - 103 kW
♦ Sharan with 2.0 l - 100, 103 and 125 kW »diesel engines«
M12 - 80 Nm
T10179- is used: 65 Nm.
M10 - 40 Nm
satelettronica
sleeves.
AG. Volkswagen AG d
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– Renew all bolts on left assembly mounting.

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279
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11. Torque settings »gearbox to engine«
agen
Prote AG.

turn.
-bolts 2-: 60 Nm + 90°.
er .
Assembly mounting bolts must be renewed. n AG. Volkswagen AG do
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Subframe to body ⇒ Rep. gr. 40 ; Assembly overview - bsubframe,
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anti-roll bar, suspension links . ir se
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tee
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mountings
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Eos with 3.2 l - 184 kW »petrol engine«
h re
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es, in part or in w
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M12 - 80 Nm
satelettronica
T10179- is used: 65 Nm.
rrectness of i
M10 - 40 Nm
l purpos

sleeves.
nf
ercia
orm
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Heat shield/drive shaft 25 Nm


. Volkswagen AG
gen AG
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swa 2010 ➤ , Eos 2006do➤ , oGolf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
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ed by 6-speed ara dual clutch gearbox 02E - Edition 01.2018
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– First screw
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pt
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screwdriver as bolts -2- are tightened. Torque setting of
wit
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-bolts 2-: 60 Nm + 90°.
h re
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spec
es, in part or in w
er .
t to the co
rrectness of i
l purpos
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ercia
mountings
m
at
om
ion
for:
c
in t
or
his
te
Golf 2004 and Passat 2006 with 3.2 l - V6 engine (all-wheel drive)
a
do
priv
cum
satelettronica
for
en
ng
t.
M12 - 80 Nm
yi Co
Cop py
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T10179- is used: 65 Nm. cop Vo
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M10 - 40 Nm
AG.

sleeves.
11. Torque settings »gearbox to engine« 281

Propshaft
♦ Drive shaft heat shield to bevel box: 25 Nm
♦ Propshaft to bevel box ⇒ Final drive 02D, 0AV (01Z); Rep. gr.
39 ; Removing and installing propshaft
turn.
-bolts 2-: 60 Nm + 90°. AG. Volkswagen AG d
agen oes
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Assembly mounting bolts must be renewed. ss a ra
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un
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ility
satelettronica
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mountings
spec
for:
t to the co
3.2 and 3.6 l - V6 engine
rrectne
Gearbox to engine
Bolts M12 “80 Nm”
ss o
• If insert 18 mm - T10179- is used: 65 Nm.
cial p
f inform
Bolts M10 “40 Nm”
mer
atio
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Propshaft
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♦ Drive shaft heat shield to bevel box: 25 Nm
te
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♦ Propshaft to bevel box ⇒ Final drive 02D, 0AV (01Z); Rep. gr.
p
cum
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fo
39 ; Removing and installing propshaft

en
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Assembly mountings
C py
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– Renew all bolts on left assembly mounting. co Vo
by lksw
cted agen
Prote AG.

turn.
-bolts 2-: 60 Nm + 90°.
er .

12 Transporting gearbox and securing

to assembly stand
Always secure heavy parts for transport.
Keep in mind that there is oil in the gearbox. Do not turn gearbox
with breather downwards during transport or while on repair
stand. Oil will run out.
Transporting gearbox
– Use appropriate lifting tools, for example part of liftingVtackle -
. olkswagen AG
2024 A- and shackle - 10 - 222 A /12- (not illustrated).
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hole
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Gearbox may also be lifted with gearbox lifting tackle - 3336- .
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
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iva
do
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Example: securing all-wheel drive gearbox to assembly stand.

fo
en
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Example: securing front-wheel drive gearbox to assembly stand.
12. Transporting gearbox and securing to assembly stand 283

13 Removing and installing bevel box,

Golf 2004 ► and Passat 2006 ►
satelettronica
AG. Volkswagen AG d
agen oes
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Removing
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spec

es, in part or in w
t to the co
height.
– Remove front right wheel.
rrectness of i

Rep. gr. 66 ; Removing and installing wheel housing liner;
l purpos
Front wheel housing liner .

– Unbolt heat shield for right drive shaft from bevel box
nform
ercia
-arrows-.
m
at
om
– Unbolt right drive shaft from gearbox flange.

ion
c
in t
or
– Raise right drive shaft and secure with wire.

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ate
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CC AG2010 ➤ag,eEos
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agen
not 6-speed dual clutch gearbox 02E - Edition 01.2018
oes
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– Unbolt hobracket
r for exhaust system. eo
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ss c
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un
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t to the co
rrectness of i
– Remove retainer -2- for electrical cable to oil level and oil tem‐
l purpos
perature sender - G266- at subframe.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
satelettronica
r
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cum
fo
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t.
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Cop py
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– Remove bolts -1- and -2- from bevel box bracket.
Prote AG.
– Remove bracket -A- for bevel box.
– Disconnect exhaust system.
13. Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► 285
– Suspend exhaust system with a chain. To do this, insert hook

- 3004- in openings on underbody (remove plugs if necessary).
– Mark position of flexible coupling and bevel box flange relative
to each other.
– Unscrew flexible coupling of propshaft at bevel box.
satelettronica
AG. Volkswagen AG d
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– Push propshaft horizontally as far back as possible.ut
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Caution
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♦ Seal -arrow- in flange of propshaft must not be damaged
ility
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when gearbox is removed. If seal is damaged, propshaft
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must be renewed.
is n
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ole,
♦ When pendulum support/subframe bolts are loosened,
spec
the engine/gearbox assembly will swing slightly forwards.
t to the co
rrectne
– Unscrew bolts -2- and -3-.
ss
– Push engine and gearbox forwards slightly and then pull prop‐
o
cial p
shaft off bevel box.

inform
mer
– Put down propshaft on top of bevel box and secure to prevent

atio
m
falling down.
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or
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Cop py
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Prote AG.

– Remove subframe.
removed.
low gearbox.
– Remove right flange shaft bolt

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arrow
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olkswagen AG
does- T10107- .
Specified torque: ⇒ page
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– Remove 4 securing
tho
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– Pull bevel box
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Installing
an
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Install in reverse order of removal. During this procedure, observe
ab
satelettronica
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ility
the following:
ot
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– Push bevel box together with flange shaft onto gearbox while
h re
hole
turning flange shaft.
spec
es, in part or in w
– Bolt bevel box onto gearbox using 4 new bolts.
t to the co
Specified torque
rrectness of i
40 Nm
l purpos
– Screw in bolts -1- and -2- hand-tight.

– Observe assembly order:
nform
ercia
1- First tighten bolts -1- to 3 Nm.

m
a
com
tion in
2- Tighten bolts -2- to 35 Nm.

r
te o
thi
s
3- Finally tighten bolts -1- to 45 Nm.

iva
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rp
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– Install subframe ⇒ Rep. gr. 40 .

fo
en
ng
t.
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– Press engine/gearbox towards bulkhead panel, carefully guid‐ Cop py
t. rig
ing bevel box pin into propshaft flange. opyri
gh by
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c by lksw
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– Pay attention to oil seal.
13. Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► 287
– Bolt pendulum support onto gearbox - 2- and -3- with new

bolts.
– Install exhaust system without tension ⇒ Rep. gr. 26 .
– Install right drive shaft ⇒ Rep. gr. 40 .
– Check oil level in bevel box and top up ⇒ page 333 .
Specified torques
Component Nm
Heat shield for drive shaft to bevel box 25
AG. Volkswagen AG d
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Prote AG.

14 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with

diesel engine

equipment required
satelettronica
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♦ or Socket - T10107 A-
com
tion in
r
♦ Puller - T10037-
te o
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♦ Assembly tool - 3253/5-

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♦ Cap - T10460-
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Special tools and workshop equipment required by c lksw
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14. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 289
Removing
height.
Note
satelettronica
– Depress brake pedal to remove bolt for right drive shaft

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– Remove cover for engine.

rm
ab
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ot
– Remove diesel particulate filter -A- in upper area of engine

wit
, is n
-arrows- and secure on plenum chamber bulkhead to prevent

h re
hole
it from falling down ⇒ Rep. gr. 26 ; Removing and installing

spec
particulate filter .
es, in part or in w
t to the co
– Remove noise insulation below engine and gearbox. ⇒ Gen‐

eral body repairs, exterior; Rep. gr. 50 ; Noise insulation .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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pyri by
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Prote AG.

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004g➤ , GGolf
nA . Volk2009 ➤AG, dGolf Plus 2005 ➤ ...
swagen
wa e oe
6-speed
y Vo dual clutch gearbox 02E s- nEdition
lks ot g 01.2018
b ua
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– Remove drive shaft heat shield from bevel box
th (2 nuts
o
or
au
-arrows-) ⇒ Running gear, axles, steering;
ss Rep. gr. 40 ; Re‐ ac
pairing drive shafts .
ce
e
nl
pt
du
an
In vehicles with auxiliary heater, a bracket for coolant hoses is
itte
y li
erm
also removed with heat shield. When installing, first place bracket
ab
ility
onto threaded pins and only then install heat shield.
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew coolant hoses of auxiliary heater from engine

-arrow-, pull off from threaded pins and push to one side until
nf
ercia
o
gearbox carrier can be unscrewed ⇒ Auxiliary heater; Rep.
rm
m
atio
gr. 82 ; Removing and installing Thermo Top V auxiliary heat‐
om
er .
n in
or c
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Do not open the pipe/hose system.

t
sd
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satelettronica
r
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cu
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– Remove right drive shaft ⇒ Running gear, axles, steering;
Co
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Rep. gr. 40 ; Removing and installing drive shafts .
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cted agen
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– Remove lower bracket for diesel particulate filter ⇒ Rep. gr.
26 ; Removing and installing particulate filter .

– Push front propshaft tube to stop.

– Place a cloth on subframe and put propshaft on it.
– Remove pendulum support from gearbox, bolt -2- and bolt

-3-.
Do not take account of bolt -1-.
satelettronica
AG. Volkswagen AG d
agen oes
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– Push engine/gearboxdto by front end and support using pendulum
V gu
ara
support as shown.oris e nte
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-A- = Collar bolt M10
ss a
x 35 c
ce
le
un

pt
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under bevel box.

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hole
spec
es, in part or in w
t to the co
– Unscrew and remove oil drain plug -A- from bevel box and
rrectness of i
allow oil to drain out. Then screw in new bolt and tighten to 15
l purpos
Nm.
Some vehicles have an intermediate flange on flange shaft/bevel
nform
ercia
box.
m
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tion in
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te o
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Prote AG.

CC 2010 ➤ n, AEos
G. Vo2006
lkswag➤
en A, G
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
wage does
y Volks 6-speed nodual
tg clutch gearbox 02E - Edition 01.2018
b ua
ed ran
ris te
– Unscrew intermediate
utho flange -arrows- if a »new« bevel box is e or
installed, because
ss
a
there is no intermediate flange on »new« ac
bevel box.
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove countersunk bolt for right flange shaft with socket -
l purpos
T10107 A- by screwing 2 bolts into flange and counterholding

flange shaft with a lever.
nform
ercia
Always renew countersunk bolt.

m
at
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ion
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or
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ate
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Prote AG.
– Now bolt puller - T10037- to right flange shaft.
Note
To remove right flange shaft, use puller - T10037- to avoid dam‐

age to bearings of flange shaft.
– Lay a spacer (e.g. press piece - T10371/1- ) between bevel

box carrier and knurled nut - VW 434- .
– Use spindle -A- to align puller parallel to flange.
– Pull out right flange shaft.
– Seal bevel box with cap - T10460- .
– Remove support for turbocharger -arrow-. ⇒ Rep. gr. 21 ;

Assembly overview - turbocharger
– Remove bolts -A- and -B- for bevel box carrier to engine and
bevel box.
– Remove bevel box carrier.
– Remove upper securing bolts -arrows- for joining bevel box to

gearbox.
AG. Volkswagen AG d
agen oes
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un
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– Remove lower securing bolts -arrows- for joining bevel box to

h re
hole
gearbox. spec
es, in part or in w
– Carefully press off bevel box and remove.

t to the co
Installing
rrectness of i
Install in the reverse order of removal, observing the following.

l purpos
The bevel box is installed with the flange shaft removed.

– Before installing, lightly grease stub shaft splines on differen‐
nform
ercia
tial of gearbox with clutch plate spline grease - G 000 100- .

m
– Push bevel box completely onto gearbox, ensuring that

a
com
tio
splines of bevel box input shaft and differential are centred

n in
r
when brought together.

te o
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do
– If splines are correctly positioned and shafts are centred, then

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bevel box will slide to stop against gearbox.

fo
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Note
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Do not use securing bolts to pull bevel box onto gearbox, or bevel
AG.
box will cant and bolt holes can break off.

– Screw in upper securing bolts -arrows- for joining bevel box to

gearbox. Specified torque: ⇒ page 295 .
– Screw in lower securing bolts -arrows- for joining bevel box to

gearbox. Specified torque: ⇒ page 295 .
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– Bolt bevel box carrier to engine and bevel box, observing tight‐
ce
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nl
ening sequence of bolts -A- and -B- ⇒ page 295 .
pt
du
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itte
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– Install support for turbocharger -arrow- ⇒ Rep. gr. 21 ; As‐
erm
ab
sembly overview - turbocharger .
ility
ot p
wit
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– Drive in right flange shaft carefully, turning flange shaft as you
h re
do so, in order to avoid damaging bearings.
hole
spec
es, in part or in w
– Secure flange shaft with new countersunk bolt. Specified tor‐
t to the co
que ⇒ Item 13 (page 324)
rrectness of i
– Fill bevel box with axle oil ⇒ page 334 .
l purpos

gr. 50 ; Noise insulation .
nf
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orm
14.1 Specified torques

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Bevel box to gearbox 40 Nm + 90° further

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♦ Renew bolts
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Intermediate flange on 70 Nm
en
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right flange shaft
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Allocation of bolts for bevel box carrier to engine and bevel box
Item Bolt Quantity
A M10 x 21 2
B M10 x 45 2
– Screw in all bolts hand-tight.
– Tighten bolts -B- to 40 Nm.
– Tighten bolts -A- to 40 Nm.
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ss
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ab
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spec
t to the co
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cial p
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mer
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Prote AG.

15 Removing and installing bevel box,

Passat CC 2009 ►, CC 2010 ► with
3.6 l V6 engine
AG. Volkswagen AG d
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nl
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itte
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ab
ility
ot p
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spec
es, in part or in w
t to the co
rrectness of i
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Removing:
nform
ercia

m
at
om
i
height.
on
c
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or

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ate
do
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p
cum
for
Rep. gr. 66 ; Removing and installing wheel housing liner;

en
ng
t.
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Front wheel housing liner .
Co
Cop py
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– Unbolt right drive shaft from gearbox⇒ Rep. gr. 40 ; Removing
ht
pyri by
Vo
o
and installing drive shafts . by c lksw
cted agen
Prote AG.
– Use tensioning strap - T10038- to secure drive shafts on sus‐
pension strut.
– Remove pendulum support ⇒ Rep. gr. 40 ; Assembly over‐
view - subframe, anti-roll bar, suspension links .
15. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3.6 l V6 engine 297
– Remove exhaust system bracket from subframe -arrows- ⇒

Rep. gr. 26 ; Exhaust system .

– Push front propshaft tube to stop.
satelettronica
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agen does
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ab
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is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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pr
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Prote AG.

– Remove bracket -A- between engine and bevel box.

First remove bolt -1-.
– Remove counter-sunk bolt using insert - T10107 A- .

Flange shaft remains in bevel box.
satelettronica
– Unbolt bevel box from gearbox -arrows- and remove it.
To remove bevel box, push engine forwards slightly (second me‐
chanic).
Installing
the following:
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gen AG does
– Push bevel box together with flange shaft onto gearbox while
Vol
ksw
a
not
turning flange shaft. ed by gu
ara
ris nte
ho eo
– Bolt bevel box onto gearbox using 4 new bolts. aut ra
ss c
Specified torque ce
e
nl
pt
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40 Nm
itte
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ab
ility
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hole
spec
es, in part or in w
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– Screw in bolts -1- and -2- hand-tight.

– Observe assembly order:
rrectness of i
1- First tighten bolts -1- to 3 Nm.

l purpos
2- Tighten bolts -2- to 40 Nm.

nf
ercia
3- Finally tighten bolts -1- to 40 Nm.

orm
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om
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by c lksw
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Prote
299
AG.
15. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3.6 l V6 engine
– Install counter-sunk bolt using insert - T10107 A- .

Specified torque
30 Nm
– Install heat shield above right drive shaft -1- ⇒ Rep. gr. 40 ;
– Bolt right drive shaft to gearbox⇒ Rep. gr. 40 ; Removing and
installing drive shafts .
– Install pendulum support ⇒ Rep. gr. 40 ; Assembly overview
- subframe, anti-roll bar, suspension links .
– Bolt propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Removing
satelettronica
and installing propshaft .
– Bolt exhaust system bracket to subframe -arrows- ⇒ Rep. gr.
26 ; Exhaust system .
Continue installation in reverse order of. removal.
gen AG
Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
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un
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d
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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
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sd
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pr
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Cop py
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by lksw
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Prote AG.

16 Oil and oil filter

Please also follow instructions:
♦ About this workshop manual ⇒ page 1
♦ Breather pipe of adapter for oil filling - VAS 6262 A- may need
to be shortened.
Volkswa
Shortening breather pipe of adapter for oil
swa
filling
gen AG- VAS 6262
.
A-do:es
gen AG
olk not
yV gu
– In order to ensure that the breather db pipe of the adapter for oil ara
ise nte
filling - VAS 6262 A- does tnotho contact the bottom of some oil
r eo
bottles, the pipe must bess
ashortened
u
to the length -a-. ra
c
ce
le

un
pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
h re
The dimension -a- is measured from the shaft (green area in the
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
– Mark dimension -a- on the breather pipe and shorten pipe with
pipe cutter - VAS 6056/2- .
l purpos
nform
mercia
a
com
tion in
r
te o
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s
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16.1 Oil filter: renewing
by lksw
cted agen
Prote AG.
Note
♦ Normally, there is no need to renew oil filter.

♦ Oil filter change “Yes or no?” ⇒ page 3
Removing
– Removing air filter ⇒ Rep. gr. 24 ; Removing and installing
air filter .
– Remove battery with battery tray ⇒ Rep. gr. 27 ; Battery;
Note
♦ A residual amount of oil remains in oil filter. It runs out when

oil filter is unscrewed.
♦ Before unscrewing oil filter, cover area around oil filter with a
sufficient number of cloths.
16. Oil and oil filter 301

– First loosen filter housing -arrow- 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 oil filter.
Installing
the following:
– Thoroughly clean oily areas on gearbox.
– Insert oil filter with collar -arrow- downwards.
satelettronica
– Screw in filter housing and tighten to 30 Nm.
– Check oil level and top up ⇒ page 302 .
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agen oes
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y V gu
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16.2 Checking oil level and topping up au ra
ss c
ce
e
nl
pt
If DSG oil must be added, use only oil listed in ⇒ Electronic parts
du
an
itte
catalogue “ETKA” .
y li
erm
ab
ility
ot p
wit
, is n
♦ Vehicle diagnosis, testing and information system - VAS h re

hole
5051B-
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
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pyri by
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co lksw
by
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Prote AG.

satelettronica
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Conditions ss
ce
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nl
pt
du
♦ Vehicle level, all mountings of lifting platform evenly at same

an
itte
height
y li
erm
ab
♦ Noise insulation removed ility
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wit
, is n
♦ Vehicle diagnosis, testing and information system - VAS h re

hole
5051B- is connected.
spec
es, in part or in w
♦ At start of work, oil temperature must not be above 45°C.

t to the co
♦ Test temperature: 35 - 45°C

rrectness of i
Check
l purpos
– Connect vehicle diagnosis, testing and information system -

VAS 5051B- and identify the vehicle in Guided functions .
nf
ercia
– Select Dual clutch gearbox .

orm
m
atio
– Select Check oil level .

om
n in
or c
thi
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sd
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Note
o
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f
en
ng
If the oil temperature is above 45°C, allow the gearbox to cool

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Engine is running at idling speed with selector lever in “P”.
by lksw
cted agen
Prote AG.
– Remove oil drain plug.


It is important not to interchange these bolts. Unscrew only bolt
-A-, near ⇒ pendulum support
Gearboxes built after 20th September 2004, i.e. which are »later«,
are fitted with bolt -A- only.
– Renew oil seal -arrow- of bolt.

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gen AG does
swa
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o
Even if oil level isatoo
ut low, a small amount of oil will initially run out or a
h e
of oil level pipe sbecause pipe fills up during operation.
s c
ce
e
nl
pt
du
satelettronica
an
– Let surplus oil flow out.
itte
y li
erm
ab
– When excess oil has run out (when it begins only to drip), in‐
ility
ot p
stall plug with new seal.

wit
, is n
– Top up oil if no oil flows out. h re

hole
spec
es, in part or in w
Topping up t to the co
rrectness of i

l purpos

nf
ercia
or
Note
m
m
atio
om
n in
c
or
thi

te
sd
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o
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t.
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pyri by
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by c lksw
cted agen
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Shake bottles before opening.
– 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 302 n. AG. Volkswagen A
age G do
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y Vol ot g
ua
b
WARNING ris
ed ran
tee
ho
satelettronica
t or
au ac
An oil level which is too low sor
s too high will impair the function
of the gearbox.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Torque setting for drain plug: 45 Nm
ility
ot p
wit
, is n
h re
16.3 Draining and filling 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” .
Brief description
rrectness of i
First read the oil temperature. If it is above 50°C, allow the gear‐
l purpos
box to cool down.

With engine stopped, unscrew and remove overflow pipe and let
nf
ercia
the oil drain out. Then reinstall overflow pipe and »overfill« gear‐
orm
box with oil.

m
atio
om
n in
Then start engine and drain excess oil until oil level attains level
or c
of overflow pipe.
thi
te
sd
iva
o
r

rp
cu
o
m
f
en
ng
♦ Vehicle diagnosis, testing and information system - VAS

t.
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op
5051B- C py
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pyri by
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by c lksw
cted agen
Prote AG.

satelettronica
Conditions
♦ Engine switched off
♦ Vehicle level, all mountings AG. Volkswagen AG devenly at same
agenof lifting platform oes
ksw
height by
Vol not
gu
d ara
se nte
♦ Noise insulation
tho
ri removed if previously fitted e or
au ac
♦ Selector slever
s
at “P”
ce
e
nl
pt
du
♦ Vehicle diagnosis, testing and information system - VAS

an
itte
5051B- is connected.
y li
erm
ab
ility
♦ At start of work, oil temperature must not be above 45°C.

ot p
wit
, is n
Procedure
h re
hole
spec
– Comply with rules for cleanliness when working on gearbox.

es, in part or in w
t to the co
– Only gear oil available as spare part is allowed to be used for

dual clutch gearbox. Other oils will lead to malfunctions or fail‐
ure of gearbox.
rrectness of i
l purpos
WARNING
nf
Risk of injury from hot gearbox oil.

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– Connect vehicle diagnosis, testing and information system -

or
thi
VAS 5051B- and identify the vehicle in Guided functions .

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– Select Dual clutch gearbox .

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– Select Check oil level .
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AG. Volkswagen AG d
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oes clutch gearbox 02E - Edition 01.2018
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If the oil temperature is higher than 45°C, allow gearbox to cool
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down.
rm
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WARNING
hole
spec
es, in part or in w
Do not start engine if there is no oil in gearbox.
t to the co
– Engine switched off - do not start engine!
rrectness of i
– Remove oil drain plug close to pendulum support -arrow-.
l purpos
A plastic overflow tube (with 8 mm hexagon) is located in this hole.

Its length determines the oil level in the gearbox.
nform
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Allocation via ⇒ Electronic parts catalogue “ETKA”

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– Remove oil level pipe -arrow- and allow oil to run out.
Approximately 5 litres of oil will run out.
– Screw oil level pipe back in to stop and tighten to 3 Nm.
Note


– Shake bottles before opening.

– Fill 5.5 litres of oil.
– To change bottle, shut off tap or hold adapter for filling oil -
. Volkswagen AG
VAS 6262 A- higher than gearbox swa
gen AG does
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– Tighten oil drain plug -A- only until finger tight.
hole
spec
– Start engine.
es, in part or in w
t to the co
– Depress brake pedal and select each selector lever position
for about 3 seconds, then move lever back to »P«
rrectness of i
– Do NOT switch off engine.
l purpos
– Then check oil level and top up. ⇒ page 302
nform
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tion in
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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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mer
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Cop py
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1. Currently, no repairs can be made to gears and shafts 309

39 – Final drive G-. Vdifferential

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1 Overview - seals
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1 - Checking oil level in bevel
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box ⇒ page 333
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❑ All-wheel drive only
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2 - Seal for propshaft
ot
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⇒ page 318
h re
hole
3 - Seal for selector shaft
spec
es, in part or in w
⇒ page 55
t to the co
4 - »Left« seal ⇒ page 313
5 - Seal »right«
rrectness of i
❑ Front-wheel drive
l purpos
⇒ page 311
❑ All-wheel drive
satelettronica
nform
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⇒ page 325
m
6 - Seal in bevel box

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⇒ page 331 n in
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7 - Only all-wheel drive »right«

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❑ All-wheel drive
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⇒ page 314
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rig
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⇒ page 311 op Vo
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Prote AG.
Never loosen both securing bolts in left and right flange shafts at
the same time. If the differential bevel gears turn, it is difficult to
reinstall the bolts.
310 Rep. gr.39 - Final drive - differential

1.1 Renewing seals for right flange shaft or

stub shaft - front-wheel drive
♦ Thrust piece - 3377-
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♦ Torque wrench - V.A.G 1331-aut or
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♦ Sealing grease - G 052 128 A1-
nform
ercia
♦ Universal grease - G 052 735-

m
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Removing
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– Remove right wheel.

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or

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– Remove right drive shaft ⇒ Running gear, axles, steering; cop Vo
by lksw
Rep. gr. 40 ; Repairing drive shafts; Removing and installing cted agen
Prote AG.
drive shafts .
Vehicles with intermediate shaft
– After removing right drive shaft -A-, unbolt intermediate shaft
-B- from mounting bracket -C- -arrows- and pull out stub shaft
of gearbox.
Continued for all vehicles
– Place drip tray under gearbox.
1. Overview - seals 311

– Remove securing bolts -arrow- for stub shaft or flange shaft.

– Pull out stub shaft or flange shaft together with compression
spring.
– Pry seal out using assembly lever.
Installing
– Lightly oil outer circumference of new oil seal.
grease - G 052 128- .
lkswage es n
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– Drive in new seal to stop, being careful not to cant d bseal.
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– Insert stub shaft or flange shaft. auth or
ac
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– Screw in new countersunk bolt for securing stub shaft or flange
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nl
pt
shaft and tighten to 30 Nm.
du
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Vehicles with intermediate shaft
erm
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– Renew O-ring of stub shaft.
wit
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satelettronica
h re
– Grease splines of stub shaft with grease for clutch plate
hole
spec
splines - G 000 100- .
es, in part or in w
t to the co
rrectness of i
– Guide intermediate shaft -B- through mounting bracket -C-
onto stub shaft of gearbox.
l purpos
– Bolt intermediate shaft to bearing bracket to specified torque

-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
nform
ercia
pairing drive shaft; Removing and installing drive shafts .

m
at
Continued for all vehicles
om
ion
c
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– Install right drive shaft ⇒ Running gear, axles, steering; Rep.

o
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e
gr. 40 ; Repairing drive shaft; Removing and installing drive

at
do
riv
shafts .
p
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en
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– Install right wheel ⇒ Running gear, axles, steering; Rep. gr.

n
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op
44 ; Torque settings for mounting wheels . C py
t. rig
gh ht
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p by
co Vo
by lksw
cted agen
Prote
AG.

2 Renewing oil seal for left flange shaft - front and all-wheel drive

equipment required
satelettronica
AG. Volkswagen AG d
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♦ Multipurpose tool - VW 771-

l purpos
♦ Extractor hook - VW 771/37-

nf
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♦ Thrust piece - 3305-

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Removing
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• Gearbox is installed.
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op py
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– Remove centre and left parts of noise insulation below engine
o Vo
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and gearbox, if fitted. Prote AG.
– Remove left drive shaft.

2. Renewing oil seal for left flange shaft - front and all-wheel drive 313
AG. Volkswagen AG d
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf ed 2009 ➤ , Golf Plus 2005 ➤ ...
b ara
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– Remove flange shaft securing bolts by screwing 2 bolts into
ce
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nl
pt
du
flange and counterholding flange shaft with a lever.
an
itte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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– Pull out flange shaft oil seal with multi-purpose tool
nf
ercia
-VW 771- and puller hooks -VW 771/37-.
orm
m
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Installing
om
n in
c
or
thi
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grease - G 052 128- .

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sd
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satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Insert flange shaft.
– Screw in new countersunk bolt for securing stub shaft or flange
shaft and tighten to 30 Nm.
– Bolt swivel joint to suspension link at old impression marks
using new bolts. ⇒ Rep. gr. 40 ; I - Assembly overview, sub‐
frame, anti-roll bar, wishbone
– Install left drive shaft. ⇒ Rep. gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts
– Install front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing wheel housing liner .
– Install left wheel ⇒ Running gear, axles, steering; Rep. gr.
44 ; Torque settings for mounting wheels .
2.1 Renewing oil seal for right flange shaft - all-wheel drive

AG. Volkswagen AG d
agen oes
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CC 2010 ised➤b , Eos 2006 ➤ , Golf 2004 ➤ , Golf ar2009
an ➤ , Golf Plus 2005 ➤ ...
r tee
tho 6-speed dual clutch gearboxor a 02E - Edition 01.2018
au c
ss
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nl
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equipment required
an
itte
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erm
ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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satelettronica
Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
♦ Puller - T10037-
♦ Thrust piece - T10049-
♦ Hexagon key - V.A.G 1669- or socket and extended bit -
T10107-
Removing
• Gearbox is installed.
WARNING
Follow the instructions below exactly to avoid damaging poly‐

gon bearings of flange shaft.
– Remove drive shaft ⇒ Rep. gr. 40 ; Repairing drive shafts;

– Remove bolt for right flange shaft using hexagon key - V.A.G
1669- or socket and extended bit - T10107- .
– Bolt puller - T10037- to right flange shaft.

– Align puller parallel to flange using knurled knob - T10037/1-
and lower support -A-.
– Pull out flange shaft.
– Pry seal out using assembly lever.
Installing
grease - G 052 128- .

– »Carefully« drive in flange shaft while turning it.
– Secure flange shaft using countersunk bolt and tighten to
30 Nm.
– Install drive shaft ⇒ Rep. gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts .
satelettronica
– Attach drive shaft heat shield to bevel box.
– Check oil level in bevel box ⇒ page 333 .
– Install noise insulation, if part of original equipment.
Specified torques
Heat shield for drive shaft to bevel box 25 Nm
2.2 Dismantling and assembling flange

shaft
. Volkswagen AG
gen AG does
The flange shaft will now be dismantled for cleaning.
Vol
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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
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Vo
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by c lksw
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Prote AG.

1 - Bolt with hexagon socket

head
❑ Do not remove bolt from
both sides at once.
❑ 30 Nm
❑ Always renew
2 - Flange shaft
3 - Protective ring
⇒ page 317
4 - Compression spring
5 - Thrust washer
6 - Tapered ring
7 - Retaining ring lkswage es n
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nl
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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
l purpos
nform
mercia
at
om
ion
c
in t
r
Removing and installing protective ring for flange shaft

o
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ate
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– Press on protective ring by hand to stop.

p
cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
by
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Prote AG.
3 Renewing oil seal for propshaft drive flange at bevel box

equipment required
AG. Volkswagen AG d
agen oes
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un
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rm
ab
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
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Vo
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by c lksw
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Prote AG.
♦ Support clamp - VW 313-

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

satelettronica
AG. Volkswagen AG d
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♦ Tapered roller bearing puller - V.A.G 1582-
wit
is n
h re
♦ Grip tool - V.A.G 1582/6A-
ole,
spec

t to the co
♦ -1- Two-arm puller KUKKO 20/10
♦ Three-arm puller KUKKO 45-2
rrectne
♦ Multipurpose tool - VW 771-

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Renewing oil seal for propshaft drive flange at bevel box 319
lkswage es n
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CC 2010 th ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009e o➤ ,
o te
Golf Plus 2005 ➤ ...
u r
6-speed
ss
a
dual clutch gearbox 02E - Edition 01.2018 ac
ce
le
un
pt
♦ Puller hooks VW 771/37
an
d
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rm
ab
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia

m
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com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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op py
satelettronica
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Sealing grease - G 052 128 A1-

♦ 2 bolts M10x30
♦ 4 nuts ⇒ M12 x 10
Procedure
Note
The bevel box oil seal for the output flange can only be renewed
with the bevel box removed.
– Remove bevel box:

Golf 2004 ►, with 3.2 l - V6 engine, Passat 2006 ►, with 3.6 l -
V6 engine ⇒ page 284
Passat CC 2009 ►, CC 2010 ► Passat 2011 ► with diesel en‐
gine ⇒ page 289

– Set bevel box in gearbox support - T10108- on hole -arrow-

marked with the number -4-.
A - Lay nuts ⇒ M12 x 10 (Qty. 4) between bevel box and gearbox
support.
– Then align bevel box with remaining 3 holes and secure.
– Put used oil collection and extraction unit - V.A.G 1782- un‐
derneath.
– Drain oil from bevel box.
– Lock bevel box output flange with stop plate -T10108/1- ,
satelettronica
screwing in M10x30 bolts -arrows-.
– Unscrew hexagon nut for output flange.
A - 36 mm socket for 3/4" drive
– Swing bevel box so that output flange points upwards.
– Pull output flange off shaft bevel gear of bevel box.

A - Three arm puller, e.g. KUKKO 45-2
n AG. Volkswagen AG
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Note oris nte
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Tapered roller bearing inner ring remains on output flange when
ce
le
output flange is pulled off. Inner ring is then pulled off output flange
un
pt
an
d
⇒ page 321 .
itte
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erm
ab
ility
ot p
– Place thrust plate - 40-105- on output flange.

wit
is n
h re
ole,
spec
– Pull inner tapered roller bearing race off output flange using
t to the co
tapered roller bearing puller.

rrectne
Note
s
Grip - V.A.G 1582/6- may be used in place of grip - V.A.G

s o
1582/6A- .
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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Cop py
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321
copy Vo
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cted 3. Renewing oil seal for propshaft drive flange at bevel box
agen
Prote AG.
– Pull out seal -A- for output flange.

AG. Volkswagen
– Clean residual locking fluid from thread
lksw
agof
en shaft bevel gear.
AG do
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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
• Old shim -2- for preloading bearing of shaft bevel gear -1- must
be installed.
– Lay tapered roller bearing inner race -3- in outer race in bevel
rrectness of i
box.
l purpos
– Lightly oil outer circumference of new seal -4- for output flange.
nform
ercia
satelettronica
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.
– Drive in new oil seal to stop using thrust piece - T10049- .

grease - G 052 128 A1- .
– Pull on output flange using two arm puller -A-.

A - Two arm puller, e.g. KUKKO 20/10
– Apply puller hooks to underside of pinion housing for this pur‐
pose.
– Coat thread of new hexagon nut with locking fluid - D 000 600- .

– Tighten new nut for output flange, specified torque

⇒ Item 1 (page 324)
A - 36 mm socket for 3/4" drive
– Install bevel box ⇒ page 284 .
– Fill gear oil into bevel box ⇒ page 333 .
lkswage es n
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ss
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pt
du
an
itte
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erm
satelettronica
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.
3. Renewing oil seal for propshaft drive flange at bevel box 323
AG. Volkswagen AG d
agen oes
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a
CC 2010 ➤ , Eos 2006 ➤ , Golfris2004 ➤ , Golf 2009 ➤ , Golf Plus 2005ra➤
ed
nte...
o eo
6-speed dual clutch gearboxau02E
th - Edition 01.2018 ra
ss c
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e
nl
pt
du
4 Assembly overview - Flange shafts and seals on bevel box
an
itte
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erm
ab
ility
ot p
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1 - Hexagon nut
, is n
h re
❑ For output flange
hole
spec
❑ Always renew, ⇒ Elec‐
es, in part or in w
t to the co
tronic parts catalogue
❑ 480 Nm
rrectness of i
2 - Bevel box output flange
l purpos
3 - Cover for output flange

❑ Replace only if dam‐
aged
nf
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orm
m
4 - Seal
atio
om
❑ ⇒ “3 Renewing oil seal
n in
or c
for propshaft drive
thi
te
sd
a
flange at bevel box”,

iv
o
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rp
cu
page 318
o
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f
en
ng
t.
5 - Seal
yi Co
satelettronica
Cop py
❑ ⇒ “4.5 Renewing seal on ht. rig
rig ht
bevel box between
py by
co Vo
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gearbox and bevel box”, Prote
cted AG.
agen
page 331
6 - Bevel box
⇒ page 284
7 - Oil drain plug
❑ For bevel box
❑ Bolt M6; 15 Nm
❑ Bolt M8; 60 Nm
8 - Seal
❑
9 - Filling and inspection plug
❑ For bevel box
❑ Always renew, ⇒ Electronic parts catalogue
❑ 15 Nm
10 - Bolt
❑ Attachment of bevel box to gearbox
❑ Qty. 4
❑ 30 Nm
11 - Breather pipe
12 - Breather cap
13 - Countersunk bolt
❑ Always renew
❑ 30 Nm
14 - Right flange shaft
❑ ⇒ “4.2 Removing and installing right flange shaft”, page 326
15 - Seal
❑ Always renew after removing right flange shaft

16 - Bearings
❑ Needle bearing (polygon bearing) is difficult to turn with flange 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.
❑ ⇒ “4.4 Renewing needle bearing (polygon bearing) for right output shaft drive flange”, page 329
17 - Bearings
❑ Needle bearing (polygon bearing) is difficult to turn with flange 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.
❑ ⇒ “4.4 Renewing needle bearing (polygon bearing) for right output shaft drive flange”, page 329
18 - Retaining ring
4.1 Renewing seal on gearbox between

bevel box and gearbox
satelettronica
♦ Extractor hooks -T20143-
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4. Assembly overview - Flange shafts and seals on bevel box 325

CC 2010 ➤ , Eos 2006 w➤ age, nGolf 2004 ➤ , AGolf
AG. Volkswagen G d 2009 ➤ , Golf Plus 2005 ➤ ...
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6-speed dual clutch
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Vgearbox 02E - Edition 01.2018
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Procedure
– Remove bevel box ⇒ page 284 .
nform
ercia
Place used oil collection and extraction unit - V.A.G 1782- below
m
at
om
i
gearbox.
on
c
in t
or
– Lever out seal on gearbox using puller hook - T20143/1- or -
his
ate
T20143/2- .
do
riv
satelettronica
p
cum
or
– Fill space between sealing lip and dust lip -arrow- with sealing
f
en
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t.
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grease - G 052 128 A1- .
Co
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– Lightly oil outer circumference of oil seal.
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– Carefully drive in oil seal to stop using thrust piece - T10243- .

– Install bevel box ⇒ page 284 .
4.2 Removing and installing right flange shaft


equipment required
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♦ Used oil collector and extractor - V.A.G 1782- C py
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♦ Puller - T10037-
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Removing
– Remove right drive shaft ⇒ Running gear - front and four-
wheel drive; Rep. gr. 40 .
– Unbolt heat shield for right drive shaft from bevel box
-arrows-.

low gearbox.
– Remove countersunk bolt for right flange shaft with socket -
T10107- by screwing 2 bolts into flange and counterholding
flange shaft with a lever.
– Pull out flange shaft with puller - T10037- .

Installing
the following:
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Renew flange shaft countersunk
t
s au bolt. ra
c
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
– Remove seal -A- from groove -arrow- and renew.
ot p
wit
is n
– Carefully drive in flange shaft while turning it. h re

ole,
spec
– Secure flange shaft with new countersunk bolt, torque speci‐
fication ⇒ page 324

t to the co
– Install right drive shaft ⇒ Running gear - front and four-wheel

drive; Rep. gr. 40 .
rrectne

s
Specified torques
s o
cial p
f in
Component Nm
form
mer
atio
Heat shield for drive shaft to bevel box 25

om
n
c
i
or
n thi
e
4.3 Renewing seal for right flange shaft on

t
sd
iva
o
pr
outside of bevel box

um
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Special tools and workshop equipment required Cop py
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♦ Thrust piece - T10049- p by
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Procedure
The seal can be renewed with gearbox installed.
– Remove right flange shaft ⇒ page 326 .
– Lever out flange shaft oil seal with assembly lever.
– Drive in new oil seal toAGstop
. Volkusing
swagenthrust piece - T10049- .
agen AG do
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wit
is n
h re
ole,
spec
t to the co
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
satelettronica
rrectne
– Install right flange shaft ⇒ page 326 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
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t.
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4.4 Renewing needle bearing (polygon bearing) for right output shaft drive
Cop py
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flange
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equipment required
satelettronica
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♦ Thrust plates - VW 401-
s c
ce
le
un
pt
♦ Thrust plate - VW 402-

an
d
itte
y li
erm
♦ Press tool - VW 407-

ab
ility
ot p
♦ Press tool - VW 412-

wit
is n
h re
ole,
♦ Assembly tool - VAS 3253-

spec
♦ Tensioning device - T10047-

t to the co
Procedure
– Remove right flange shaft ⇒ page 326 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
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330
Prote AG.
Rep. gr.39 - Final drive - differential
– Mount clamp - T10047- so that marks “B” on both parts of tool

are facing one another.
• The shoulders -arrows- must then be below the bearing.
– Screw both parts together up to stop.
– Remove retaining ring -A- for bearings.
satelettronica
lks wage es n
– Turn shaft while pressing
byV
o it off -arrow-. This will prevent
ot g
ua dam‐
age to bearing o
ir srace
ed on shaft. ran
tee
th or
u
– Secure bearing
ss
a with a new retaining ring. ac
ce
le
– Install right flange shaft ⇒ page 326 .

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
4.5 Renewing seal on bevel box between

rrectness of i
gearbox and bevel box

l purpos

nform
ercia
♦ Extractor hooks -T20143-

m
a
com
tion in
r
te o
thi
s
iva
do
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rp
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en
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t.
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Procedure
– Remove bevel box ⇒ page 284 .
– Lever out seal on bevel box using puller hook - T20143/1- or
- T20143/2- .
satelettronica
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agen oes
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– Fill space between sealing olip
ris and dust lip -arrow- with sealing
e nte
eo
grease - G 052 128 A1-a.uth
ra
ss c
– Lightly oil outer circumference of oil seal.
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
– Drive in oil seal to stop using thrust piece - T10298- .

l purpos
nf
ercia
orm
m
atio
om
n in
or c
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5 Checking and topping up gear oil in

bevel box
♦ Filling device - VAS 6291 A-
♦ Adapter - VAS 6291/2-
satelettronica
♦ For some oil bottles adapter - VAS 6262/6- must be used as
well. agen
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♦ Not illustrated: Torque wrench - V.A.G 1331-

Bevel box is bolted to side of gearbox and has its own oil supply.
rrectness of i
Gear oil specification for bevel boxes ⇒ Electronic parts cata‐

l purpos
logue “ETKA” .
5.1 Checking gear oil in bevel box

nf
ercia
orm
m
Requirement
atio
om
n in
c
• Bevel box must be in installation position.

or
thi
te
sd
a

iv
o
r
rp
cu
Rep. gr. 50 ; Noise insulation .

o
m
f
en
ng
t.
– Place drip tray for workshop hoist - VAS 6208- underneath.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
333
Prote AG.
5. Checking and topping up gear oil in bevel box
Note
Cover area beneath oil filler plug -arrow- with a cloth.
– Remove oil filler plug -arrow- from bevel box.

Oil filler plug -arrow- must be renewed.
Oil level is correct when bevel box is filled to lower edge of filler
hole.
If oil should get on bevel box, carefully remove it.
– Top up gear oil if necessary ⇒ page 334 .
– Install new oil filler plug -arrow- and tighten to 15 Nm.
5.2 Topping up gear oil in bevel box

Requirement
satelettronica
• Vehicle is level.
– To top up oil, use filler device - VAS 6291- .
– Route hose of filler device - VAS 6291- behind right drive shaft
through right wheel housing to outside.
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spec
es, in part or in w
Note
t to the co
Cover area under oil filler plug -arrow- with a cloth.

rrectness of i
– Remove oil filler plug -arrow- from bevel box.

l purpos
nf
ercia
orm
m
atio
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or c
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– Screw adapter - VAS 6291/2- -A- in to stop.

– An Allen key can be used for this.
-Arrow- = Allen key, 5 mm, commercially available.
AG. Volkswagen AG d
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pt
an
d
itte
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– Engage elbow -B- in adapter -A-.
erm
ab
ility
ot p
• Do not allow hose to sag.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Ensure that valve -arrow- is closed.

atio
om
– Screw oil container -1- onto filling device - VAS 6291- .

n
c
i
or
n thi
e
– Open valve -arrow-, and hold up oil container as shown in il‐

t
sd
iva
lustration.
pr
cum
r
fo
en
ng
The bevel box will now be filled.

t.
yi Co
Cop py
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5. Checking and topping up gear oil in bevel box 335

Note
♦ If bevel box has been properly filled, oil will have run out at
adapter -A-.
♦ Continue with filling procedure if no oil has run out yet.
– If oil has emerged from adapter -A-, position oil container so

that surplus oil can run back into oil container.
– When no more oil flows back, remove filling device by pushing

detent in -direction of arrow-.
– Unscrew adapter - VAS 6291/2- .
– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
satelettronica
– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oilagagain
en AG.to
Volower
lkswageedge
n AG d
oes
of filler hole. olksw not
y V g ua
b
ed ran
– Install new oil filler plug -arrow-
ho
risand tighten to 15 Nm. tee
t or
au ac
If oil should get on bevel box,ss carefully remove it.
ce
le
un
– Install noise insulation ⇒ General body repairs, exterior; Rep. pt

an
d
itte
gr. 50 ; Noise insulation . y li

rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.

Service

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Service

Golf Plus 2009 ➤ , Passat 2006 ➤ ,

Passat CC 2009 ➤ , Scirocco 2009 ➤ ,

Sharan 2011 ➤ , Touran 2003 ➤

6-speed dual clutch gearbox 02E

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg K0458972220

3.1 Reading gearbox code letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.3 Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.4 Scirocco 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.7 Passat 2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.8 Eos 2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.10 Sharan 2011 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

10 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

16.3 Draining and filling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

A summary of the special tools and workshop equipment used in

Uncertainty often occurs with smaller bolts having low tightening

1. General repair instructions 1

1 - Filter ⇒ page 301

6 - Gearbox input speed send‐

♦ Before installing seals, lightly oil outer diameter and half-fill

2 Rep. gr.00 - Technical data

1.5 ⇒ DSG® oil

Do not change the filter if:

1.7 Oil drain and inspection plug -A-

1. General repair instructions 3

1.8 Nuts and bolts

1.9 Electrical components

4 Rep. gr.00 - Technical data

2.2 Useful information about the “behaviour

ware is able to execute, monitor and control electronic functions

prevent gearbox damage. The gear will not be engaged until

Selector lever position display - no “R”

segments indicates gearbox emergency running mode. The ve‐

hicle cannot reverse.

6 Rep. gr.00 - Technical data

Touch function does not work - no gear change

ingfully with the VW tester.

Faults have been saved:

Guided fault finding . Properly used, Guided fault find-

If there are faults »not caused by the gearbox«:

gearbox memory and additionally another control unit reports

GKF - Gearbox code

On some gearboxes, gearbox code is also located on the top of

3.1 Reading gearbox code letters

8 Rep. gr.00 - Technical data

Once on top of the gearbox close to the selector lever cable

– Then lower engine and gearbox slightly using spindles of sup‐

port bracket - 10 - 222 A- until bracket can be removed.

In most cases, 2 turns of the spindle will be sufficient to remove

– Always adjust selector lever cable after installing bracket

4 Code - engine allocation

4.1 Golf Plus 2009 ►

1.4 l - 103 1.9 l -

and 77kW TDI

4.2 Golf Plus 2005 ►

If Genuine parts are required for a repair, always refer to the

KPQ, HQN, KMZ, GPU, GYM, GYQ,

10 Rep. gr.00 - Technical data