VOLKSWAGEN GOLF VARIANT 2010 (12) PDF Document

Uncertainty often occurs with smaller bolts having low tightening forces. Torque wrench 2…10 Nm -V.A.G 1783- can be used with these bolts.

The gearbox has a hole in the housing.

Make sure no small parts drop into this hole during installation work.

Cover the hole with a cloth before installation work.

Make sure that no dirt can enter an “open” gearbox.

If gearbox covers have been unbolted or gearbox has no fluid, do not run engine. Do not tow vehicle.

First thoroughly clean connecting points and surrounding areas and then loosen bolts.

During installation, ensure that the dowel sleeves between the engine and gearbox are correctly located.

Place removed parts on a clean surface. Cover parts to prevent soiling. Use plastic sheeting and paper. 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, cover opened parts carefully.

The dual clutch gearbox 0AM capacity is 1.7 l gear oil -G 052 171-.

The mechatronic unit for dual clutch gearbox -J743- capacity is 1 l central hydraulic oil and power steering oil -G 004 000-.

Further information in the part number designates the container size.

Only work with vehicle diagnostic testers from Volkswagen.

Vehicle diagnosis and service information system -VAS 5052 A-

Vehicle diagnosis, testing and information system -VAS 5051B-

Vehicle diagnostic tester -VAS 5053-

Various functions are available in the operating modes guided functions and guided fault finding. The 3 most important functions are:

• Adapting installation information
• Reading measured values for mandatory reporting
• Initiating basic adjustment

The mechatronic unit detects other control units in the vehicle by means of signals on the data bus. Pressing the Adapt installation information lock button instructs the mechatronic unit to forget all communication partners.

All “active partners” are detected once again the next time the ignition system is switched on.

You cannot “generate” any faults using this function. Please always perform the Adapt installation information function after the following activities:

• After a selector lever has been installed.
• After another control unit has been installed, e.g. engine, ABS or gateway.
• After work on the steering wheel paddle.

You must read these measured values before contacting your Technical Service Center or your importer.

Save the measured values in the diagnosis log so that all necessary gearbox data will be available for fault analysis.

This teaches important settings into the mechatronic unit. Even important adjustments are taught in again, or reset to programmed points. These include, for example, the synchronisation points and “reference points” for the engaging lever and gear actuator.

Press the button DSG Mechatronic -J743- performing basic measurement only:

• if you are prompted to do so in “guided fault finding”
• after you have processed a fault entry
• after you have installed another gearbox
• after you have installed a clutch
• or after you have installed a mechatronic unit

The clutch is installed “upwards” with the gearbox removed. The mechatronic unit remains on the gearbox.

If one new clutch is installed, the positions of the engagement bearings for “K 1” and “K 2” must be found and set. Then the clutch is pressed onto the input shaft.

When installing a clutch, “most” mechanics push the clutch onto the input shaft up to the stop. This is not the optimum position for the clutch!

For this reason, pull the clutch slightly “upwards” against the retaining ring after it has been installed.

After the gearbox has been installed, you must initiate a basic adjustment using the Vehicle diagnosis, testing and information system VAS 5051.

Note: The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Therefore, please do not drop the clutch. Do not let the clutch drop into the gearbox either when installing the clutch. Even if the mechatronic unit has been removed, “pulling out” the assembly lever -T10407- under the engaging levers can have a negative effect on the adjusting device.

Transporting gearbox and securing to assembly stand.

Remove dual clutch.

Adjust the position of the engagement bearings “K 1 and K 2”.

Install dual clutch.

For removing the dual clutch, special tools and workshop equipment required are:

• Hook -3438-
• Support device -T10323-
• Assembly tool -T10356-
• Puller -T10373-
• Thrust piece -T10376-

Remove gearbox.

Pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal.

Turn gearbox with clutch upwards.

Remove retaining ring of hub -arrow-.

Remove hub with hook -3438- and a screwdriver.

Remove retaining ring of clutch -arrow-.

Note: It is possible that the retaining ring is seated very tightly. The cause may be that the clutch is pressing so hard against the retaining ring that the ring is stuck.

If you cannot get the ring out of the groove, press the clutch down slightly. Never strike the clutch or shaft with a hammer! Set up the tools that are shown in this illustration.

Support bracket -T10323- fits on all 0AM gearboxes.

Make sure that you place support bracket -T10323- in parallel to the gearbox flange.

Secure engine support with bolts -A-, as required with nuts.

Always renew retaining ring.

Clutch should only be pressed down slightly. Often, it is sufficient to rotate spindle against thrust piece -T10376- without pressing. This will “release” retaining ring.

Pull off clutch.

Remove clutch together with puller -T10373- .

Remove small engagement bearing.

Remove large engaging lever.

Remove bolts and remove small engaging lever.

Remove retainer for engaging lever.

Before installing clutch, please refer to page 12 to see whether clutch needs adjusting during assembly or not.

Adjusting.

Install dual clutch.

Special tools and workshop equipment required for adjustment are:

• Gauge block -T10374-
• Ruler -T40100-
• Digital depth gauge e.g. -VAS 6594-
• Adhesive -AMV 195 KD1 01-
• Micrometer caliper

Position of engagement bearings must be set after clutch and its actuators have been renewed.

Retainer also belongs to actuator.

There is no need to adjust anything if all the named parts have only been removed and reinstalled.

Conditions for adjustment:

• Only use tools in perfect condition.
• Contact surface of “gearbox on engine” must be free from “irregularities”. This guarantees straight edge makes good contact.
• Mechatronic unit is installed.

Perform the following steps:

Position of engagement bearings is comparable with clutch play of a manual gearbox. In this 0AM dual clutch gearbox, there are tolerances in engagement system of gearbox and in gearbox itself. There are also tolerances within the dual clutch. These tolerances must be considered separately when adjusting.

In the following procedure, you are first shown how to measure all necessary dimensions “on gearbox”, in order to determine what is the appropriate shim. Tolerances on gearbox and tolerances in clutch determine thickness of shim.

First find a dimension “B”. This dimensions is required for both clutches “K 1” and “K 2”.

Then find a dimension “A” for each clutch. The following 2 illustrations show where to measure these dimensions.

Note: Perform the following steps “in sequence” and precisely.

Adjusting:

Install parts of clutch as far as large engaging lever.

Do not install small engagement bearing, do not insert any shim.

Install retaining ring of outer input shaft -arrow-.

Place a ruler -T40100- on its side on flange of clutch housing. It should lie sideways on shaft end.

Note: Ruler -T40100- should remain in this position during subsequent measurements. Do not turn over, do not remove.

Place digital depth gauge onto outer input shaft.

“Zero” depth gauge.

Measure distance from retaining ring.

Note down result and call it “B”. Example: “B” = 2.91 millimetres

Measure dimension “B” again on opposite side.

Note: Do not measure on ring joint. This could force ring away at that point and falsify measuring result.

Remove retaining ring again. This ring is not allowed to be installed again!

Calculate average of both measuring results. Example: Dimension “B” = B1+B22 = 2,91+3,02 = 2.96. This dimension “B” is needed in the following calculations. In the following sample calculations, “B” should be 2.96 mm. The dimension given for “B” is and example. The value for “B” may be different in another gearbox.

There are 2 clutches, therefore there are 2 setting procedures to follow.

Each measurement requires different preparatory measures, as well as a few calculations. Please comply with the following working procedures.

Start by calculating shim for clutch “K 1”. Do not insert any shim!

Place gauge block -T10374- on “large” engagement bearing.

Press once onto gauge block -T10374- whilst turning. In this way, it is possible to observe how the engagement bearing turns. This means gauge block -T10374- also “sits” correctly on bearing.

Place digital depth gauge “at top” onto outer input shaft. Ruler -T40100- is already “on its side” on gearbox flange.

Measure distance from “shaft end” to gauge block -T10374- .

To make sure this measurement is as accurate as possible, position digital depth gauge twice at opposite sides. This allows the value to be found even more accurately, because the inaccuracy caused by “tilting” on the engagement bearing is minimised.

Calculate average of both measurements onto gauge block -T10374- .

Note down this value and call it “A1”. Example: Dimension “A1” = 2,61+2,812 = 2.71. Example: “A1” = 2.71 millimetres

Next calculation: “A1” minus “B” plus height of gauge block -T10374- = Depth of engagement bearing of clutch 1. Height of gauge block -T10374- is always the same. It is: 51.81 mm. Sample calculation: 2.71 mm minus 2.96 mm plus 51.81 mm = 51.56 mm. You have now calculated value for how deep engagement bearing is actually seated inside gearbox. Depth of bearing in each gearbox should be 50.08 millimetres. Subtract nominal dimension “50.08 millimetres” from this actual value. This gives result for actual gap of clutch 1.

Continue the calculation: Calculated value (in example: 51.56 mm) minus nominal dimension = gap of clutch. Sample calculation: 51.56 mm minus “50.08 millimetres” = gap of clutch 1 = 1.48 mm. Now tolerances in dual clutch must be introduced into this calculation. Procedure for this is very simple:

Please read off value of clutch tolerance of “new” clutch. A value between minus 0.40 and plus 0.40 millimetres is provided with a new clutch.

Make a note of this value. Example 1: “- 0.40” is indicated on your clutch. The previous calculation for “K 1”: “your calculated” gap minus value of clutch 1 = 1.48 mm minus 0.40 = 1.08 mm. Example 2: “+ 0.20” is indicated on your clutch. Then, the last calculation of “K 1” is as follows: 1.48 mm plus 0.20 = 1.68 mm.

Refer to table to find correct shim and install.

From the supplied shims, select the one that is required.

WARNING: Later on, only insert this 1 shim. Not 2 shims.

With this, you have found “correct” shim for “K 1”. Please install this shim during subsequent clutch installation.

Continue setting for clutch “K 2”.

Calculate shim for clutch “K 2”.

Only insert small bearing. Do not insert any shim!

Small engagement bearing only fits in one position due to 4 grooves.

By “turning”, check whether small engagement bearing is installed correctly and that grooves are seated correctly.

Place gauge block -T10374- on small bearing “with large opening upwards”.

Place digital depth gauge “at top” onto outer input shaft.

“Zero” depth gauge.

Measure distance from “shaft end” into gauge block -T10374- .

To make sure this measurement is as accurate as possible, position digital depth gauge twice at opposite sides. This allows the value to be found even more accurately, because the inaccuracy caused by “tilting” on the engagement bearing is minimised.

Calculate average of both measurements onto gauge block -T10374- .

Note down this value and call it “A2”. Example: Dimension “A2” = 2,50+2,542 = 2.52. Example: “A2” = 2.52 millimetres

Next calculation: “A2” minus “B” plus height of gauge block -T10374- = Depth of engagement bearing of clutch 2. Height of gauge block -T10374- is always the same. On inside, it is: 36.20 mm. Sample calculation: 2.52 mm minus 2.96 mm plus 36.20 mm = 35.76 mm. You have now calculated value for how deep engagement bearing is actually seated inside gearbox. Depth of bearing in each gearbox should be 34.35 millimetres. Subtract nominal dimension “34.35 millimetres” from this actual value. This gives result for actual gap of clutch 2.

Continue the calculation: Calculated value (in example: 35.76 mm) minus nominal dimension = gap of clutch. Sample calculation: 35.76 mm minus “34.35 millimetres” = gap of clutch 2 = 1.41mm. Now tolerances in dual clutch must be introduced into this calculation. Procedure for this is very simple:

Please read off value of clutch tolerance of “new” clutch. A value between minus 0.40 and plus 0.40 millimetres is provided with a new clutch.

Make a note of this value. Example 1: “- 0.40” is indicated on your clutch. The previous calculation for “K 2”: “your calculated” gap minus value of clutch 2 = 1.41 mm minus 0.40 = 1.01 mm. Example 2: “+ 0.20” is indicated on your clutch. Then, the last calculation of “K 2” is as follows: 1.41 mm plus 0.20 = 1.61 mm.

Refer to table to find correct shim.

From the supplied shims, select the one that is required.

WARNING: Later on, only insert this 1 shim. Not 2 shims.

With this, you also have found “correct” shim for “K 2”. Please install this shim during subsequent clutch installation. This shim should be under small engagement bearing.

Insert clutch.

Use puller -T10373- to insert clutch into gearbox.

Turn spindle “back” first.

Note: The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Therefore, please do not drop the clutch. Do not let the clutch drop into the gearbox either when installing the clutch.

Press clutch on onto stop.

Support bracket -T10323- fits on all 0AM gearboxes.

Make sure that you place support bracket -T10323- in parallel to the gearbox flange.

Secure engine support with bolts -A-, as required with nuts.

Push clutch down via spindle.

Note: Place a hand on clutch whilst pressing on. You will be able to feel a slight rattling. Rattling means the clutch is being pressed onto its press seat. In the same way, you can also “feel” the stop when the clutch has reached its seat.

Installation position of retaining ring: Joint of retaining ring is “narrower at top”.

If you can insert retaining ring -arrow-, clutch is correctly pressed on to stop.

Insert new retaining ring -arrow-.

To enable clutch to find its installation position already, turn clutch against puller -T10373- by hand.

Now turn clutch by hand, without using a tool.

In this way, clutch slides against retaining ring. Do not use any other tool.

Pressing on causes “clutch to locate at bottom” on input shaft. Clutch should only be pulled up far enough for it to contact retaining ring.

Then insert hub.

Hub has a “large” tooth and therefore only fits in one position.

“Large” tooth has a mark on -engine end- -arrow-.

Insert retaining ring for hub -arrow-. Installation position: Joint of ring must point towards “hub” on clutch.

Turn clutch by hand and observe “small” engaging lever whilst turning.

Engaging levers must remain “still” in their position whilst this is being done. They are not allowed to move up and down.

If an engaging lever moves up and down, then shim is not properly seated.

Remove clutch again in this case.

Look at shims -arrows- precisely.

Shims must be correctly seated. They must not be damaged.

Remove plugs and put both breather caps -arrows- back on.

After the gearbox has been installed, you must initiate a basic adjustment using the Vehicle diagnosis, testing and information system VAS 5051.

The following table shows calculated shim thickness to shim to be installed (in millimetres):

Calculated shim thickness	Shim to be installed (in millimetres)
from	to
0.31	0.90	0.8
0.91	1.10	1.0
1.11	1.30	1.2
1.31	1.50	1.4
1.51	1.70	1.6
1.71	1.90	1.8
1.91	2.10	2.0
2.11	2.30	2.2
2.31	2.50	2.4
2.51	2.70	2.6
2.71	3.30	2.8

From the supplied shims, select the one that is required.

WARNING: Later on, only insert this 1 shim. Not 2 shims.

With this, you have found “correct” shim for “K 1”. Please install this shim during subsequent clutch installation.

Continue setting for clutch “K 2”.

Calculate shim for clutch “K 2”.

Only insert small bearing. Do not insert any shim!

Small engagement bearing only fits in one position due to 4 grooves.

If clutch has been replaced, shim should also be under bearing.

By “turning” bearing, check whether it is installed correctly and that grooves are seated correctly.

Secure shim using 3 drops of glue -AMV 195 KD1 01-. This prevents shim from slipping out of its seat when clutch is inserted.

Large shim is for clutch “K 1”, small one for clutch “K 2”.

Turn back spindle of puller -T10373- .

Insert clutch.

Turn assembly lever -T10407- anticlockwise. In this way, engaging levers are pressed away from plungers -direction of arrow-. Do not take out assembly lever -T10407-. It must remain inserted between engaging lever and gearbox housing for the entire process.

If necessary, press assembly lever -T10407- against gearbox using a screwdriver.

If lever slips off, this indicates you applied a bit of leverage to handle whilst turning.

Apply a bit of force to tip of lever when turning. This stops lever from slipping out when turning.

Remove mechatronic unit. Mechatronic unit remains filled with oil.

Make sure no oil runs out of breather. Mechatronic unit is to be sent for reconditioning with its oil in.

If mechatronic unit “jams” and cannot be removed:

Sometimes, the mechatronic unit cannot be removed. In this case, the gear actuator is “caught” at the “top left” of the gearbox housing.

In this case, mechatronic unit is not allowed to be removed with significant force.

First reposition mechatronic unit on gearbox housing and secure it with one bolt.

Move mechatronic unit into “removal position” by hand.

Installing mechatronic unit.

Sometimes, the mechatronic unit cannot be removed. In this case, the gear actuator is “caught” at the “top left” of the gearbox housing -arrow-.

Only if you cannot set the mechatronic unit to removal position with the vehicle diagnostic tester, you must move the unit by hand to this position.

The “sticking” gear actuator -arrow- can be pressed by hand into its “removal position”. To do this, push a selector fork behind the parking lock cover. How to do this is described in the following work procedure:

• First reposition mechatronic unit on gearbox housing and secure it with one bolt.
• Move selector lever to position “P” position.

Watch out for seal on mechatronic unit. Seal must be pushed in all around.

Look at sender. Clip must not be damaged.

Put on mechatronic unit.

When gripping and putting on, make sure selector forks are not inadvertently pressed out of their position.

Also observe engaging levers and plungers on mechatronic unit.

Screw in 7 new bolts and tighten until finger-tight.

Remove guide pins -T10406- again.

Make sure that plungers meet up correctly in cups of engaging levers.

Pull out plungers by hand until they are seated in cups. Plungers can be moved into position with a hook bent from a piece of welding wire (local manufacture).

Now check seat of plungers again. Plungers that are not seated correctly will damage mechatronic unit.

Tighten mechatronic unit diagonally to 10 Nm.

Grease oil seal in cover with sealing grease -G 052 128 A1- .

Fit cover and lever again. Attach lever again in same position.

If you are unsure, refer to this illustration for guidance.

Press selector lever cable back onto ball head and install new securing clip.

A securing clip which has been removed is not allowed to be installed again. The clip will have lost its internal tension and so it might fall off.

Therefore, when installing, always use a “new” securing clip.

Adjust selector lever cable.

Remove clutch again in this case.

Look at shims -arrows- precisely.

Shims must be correctly seated. They must not be damaged.

Remove plugs and put both breather caps -arrows- back on.

After the gearbox has been installed, you must initiate a basic adjustment using the Vehicle diagnosis, testing and information system VAS 5051.

The gearbox is filled for life. Therefore, there is no need to check the oil level of this gearbox.

This explains why there is no oil level check.

In case of leaks on gearbox, find out what is the cause and rectify the faults.

Raise vehicle.

Place drip tray under gearbox.

Then drain all gear oil and fill with new oil.

Then install the drain plug again.

If the gearbox is installed, you must remove the battery and battery tray to add oil.

Remove battery and battery tray -arrows-.

Move selector lever to position “P” position.

Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.

Remove Bowden cable from ball head.

Use your hand to press lever to stop in direction of cable support bracket.

Note installation position of lever and remove it from selector shaft.

If you are unsure, refer to this illustration for guidance.

Unbolt cover. Only leaking covers must be renewed. If the cover was not leaking, it does not need to be renewed.

Pour 1.7 l of oil in through opening -arrow-. Take care not to “spill” any. Gearbox must have precisely 1.7 litres of oil.

Caution: Do not fill any more or any less oil. Malfunctions would result!

Clean sealing surface on gearbox and on cover.

Grease oil seal in cover with sealing grease -G 052 128 A1- .

Always renew bolt of lever.

Fit cover and lever again. Attach lever again in same position.

If you are unsure, refer to this illustration for guidance.

Press selector lever cable back onto ball head and install new securing clip.

A securing clip which has been removed is not allowed to be installed again. The clip will have lost its internal tension and so it might fall off.

Therefore, when installing, always use a “new” securing clip.

Adjust selector lever cable.

Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

For vehicles up to 02.2009:

• Do not remove handle without reason. For emergency release, only the cover needs to be unclipped.
• Before removal of handle, pull lock button out past its pressure point. Secure locking button with a cable tie or appropriate wire against being pressed in. This will prevent lock button from being accidentally pressed into the handle.
• Removing and installing selector lever handle.

For the selector mechanism with selector lever:

• With selector lever lock solenoid -N110-
• Emergency release.
• Brief instructions for removing and installing:
• Remove centre console.
• Remove Bowden cable from gearbox.
• If necessary, disconnect or remove parts of exhaust system.
• Remove heat shield beneath selector mechanism.
• Adjust selector lever cable after installing.

For Bolt with spring: 3 Nm

For Pin: Removing.

For Locking plate: Do not grease.

For Nut: 9 Nm, Qty. 4.

For Selector housing: With seal.

For Selector lever cable:

• Bowden cable is not greased.
• Removing and installing.
• Checking.
• Adjusting.

For Securing clip: Always renew after removing.

For Hexagon flange nut: 8 Nm, Qty. 4.

Torque setting, selector lever to selector shaft.

For removing and installing selector lever cable – vehicles up to 02.2009:

Note: Following installation, Bowden cable must be checked for ease of movement and be adjusted.

Removing:

Move selector lever to position “S” position.

Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.

Remove Bowden cable from ball head.

Raise vehicle.

To remove Bowden cable and/or selector mechanism, heat shield under selector mechanism and, if necessary, parts of exhaust system must now be removed.

Remove -selector housing- beneath selector lever.

Remove locking plate of cable support bracket. Always renew locking plate.

Selector housing- is pushed forwards slightly on cable.

To remove cable, securing tab must be pushed forwards -arrow 1-. At same time, push -pin- up with a screwdriver -arrow 2-.

Please insert -screwdriver- from underneath whilst pushing securing tab forwards.

Clarification:

• -Arrow 1- Push tab forwards
• -Arrow 2- Push pin up

Remove selector lever cable.

Remove selector housing from cable.

Installing:

Route selector lever cable without tension. Also insert into cable support bracket on gearbox. Do not secure with securing clips yet. Do not clip in ball head.

Ensure that selector lever cable is properly routed during installation. If the sheet metal is bent downwards, it may cause noises. The cable will vibrate against the sheet metal.

Observe sheet metal. Press it back up in the tunnel during installation.

Loosen adjustment screw -arrow-.

Put selector housing onto cable.

Insert selector lever cable into selector mechanism.

Insert cable into bearing and insert pin from above, downwards through eye.

When you have checked freedom of movement of cable, insert locking plate.

Attach cable with new locking plate on cable support bracket of selector mechanism.

Remove selector mechanism.

Install in reverse order of removal.

Before you put on ball head: check cable.

Install all parts of exhaust system which were removed.

Install heat shield.

Adjust selector lever cable after installing.

Selector lever cable must be removed from gearbox so that its freedom of movement can be checked. Put removed end down so it does not rub against anything.

Then the selector lever must be moved and after that, the Bowden cable must be reattached to the gearbox.

Then the selector lever cable must be adjusted.

Do not grease connections of cable!

Checking:

Move selector lever to position “P” position.

Remove cable from lever on gearbox.

Move selector lever repeatedly from “P” to “S” and back to “P”.

Selector lever must move easily.

Reinstall cable with “loosened” adjustment screw.

If you remove the securing clip, you must always install a “new” securing clip.

Adjust 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 installed.
• 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. Adjuster screw -arrow- must be “loosened”.

Shift lever on gearbox to position “P”.

The gearbox lever must be pressed “completely to right side of vehicle” in the direction of selector lever cable support bracket.

This figure shows the view of gearbox from “behind”. -P- in direction of cable support bracket.

Install Bowden cable with loosened adjusting screw -arrow- and new securing clip.

WARNING: Be sure that the parking lock is engaged.

To do this, turn both front wheels simultaneously “under the car” in the same direction until the parking lock can be heard to engage.

The parking lock is engaged when both front wheels cannot be turned in the same direction at the same time.

Gently push handle of selector lever forwards and backwards but under no circumstances must you shift out of “P”. In this way the inner cable of the Bowden cable finds it optimal position.

Tighten adjusting screw -arrow- to 13 Nm. This completes the adjustment.

Do not remove handle.

Unclip selector cover and hold to side.

Depress brake pedal or set handbrake.

For Vehicles up to 02.2009:

Press yellow plastic part -arrow- from right to left.

Or press on the pin of the solenoid.

For Vehicles from 03.2009 onwards:

Press onto yellow plastic part -arrow-.

However, should this happen, unclip handle trim upwards.

Press small lever for pull rod -arrow- back into groove before installing handle.

It is possible with all handles that lock button is pressed into handle. Do not install a handle with the locking button pressed in.

Before removal, pull lock button out past its pressure point.

Secure locking button with a cable tie or wire against being pressed in.

Unclip cover.

Push sleeve upwards to release handle.

Lock the handle again after installing. To do this, press the sleeve under the handle back down.

You only have to remove transport guard from “new” handles. The locking button is already in installation position.

Pull connector from cover.

Pull off handle upwards.

Lock the handle again after installing. Press the sleeve under the handle back down.

In vehicles with lock button at front on handle -arrow- Lock button -arrow- is not allowed to be pressed in when handle is being fitted and removed.

Faults which can be detected electrically can be determined with guided fault finding. In the case of mechanical faults, skill is required to localise and repair a faulty system or defective “part”.

It must not be possible to start the engine in the selector lever positions “R”, “D” or “S”.

When selector lever is shifted to position “N” at speeds above 5 km/h, solenoid for selector lever lock must not engage and block selector lever. Selector lever can be shifted into a driving range.

When travelling at speeds below 5 km/h (almost stationary) and shifting into selector lever position “N”, solenoid for selector lever lock should only engage after about 1 second. Selector lever cannot be shifted out of “N” position until brake pedal is depressed.

Selector lever in “P” position and ignition switched on:

• Brake pedal not depressed: Selector lever is locked and cannot be shifted out of “P” position with the lock button pressed. Solenoid for selector lever lock blocks selector lever.
• Brake pedal is depressed: Solenoid for selector lever lock releases selector lever. It is possible 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.

Selector lever in “N” position and ignition switched on:

• Brake pedal not depressed: Selector lever is locked and cannot be shifted out of “N” position with the lock button pressed. Solenoid for selector lever lock blocks selector lever.
• Brake pedal is depressed: Solenoid for selector lever lock releases selector lever. It is possible to shift into a driving gear.

Selector lever in position “Tiptronic”:

Shift selector lever into Tiptronic gate.

Symbols must change from “P R N D S” to “7 6 5 4 3 2 1”.

Ignition and light switched on:

The respective symbol in the shift mechanism cover lights up.

Selector lever position display:

Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode.

WARNING: Do not work on pressure accumulator. The accumulator is under pressure and is not allowed to be opened.

Note: Take care with the breather when handling the mechatronic unit. When doing any work on the mechatronic unit, please remove cap -arrow- from breather and seal with a suitable plug. Protective cover -0AM 325 120- is well suited.

For Bolt 1:

• 10 Nm
• M8 x 35
• Always renew

For Bolt 2:

• 10 Nm
• M8 x 90
• Always renew

This description only applies to installed gearboxes. If gearbox has been removed, first remove clutch then mechatronic unit.

Move mechatronic unit for dual clutch gearbox -J743- into “removal position” by hand.

Special tools and workshop equipment required are:

• Assembly lever -T10407-
• Drip tray for workshop hoist -VAS 6208-
• Vehicle diagnostic tester

Perform the following steps:

In order to remove the mechatronic unit, sufficient space must be available in front of the gearbox. Depending on the vehicle, parts must be removed which do not have anything to do directly with the gearbox. For example, the air filter housing and, if present, charge air lines or coolant lines.

Any retainers fitted on the cover of the mechatronic unit must also be removed.

The vehicle diagnostic tester brings the mechatronic unit into the correct position for removal. All gear actuators are moved “into neutral”.

In this position, insert assembly lever -T10407- between release lever and gearbox housing. This makes it possible to remove load from plungers of mechatronic unit so that they may be removed by hand from cups of engaging levers.

Mechatronic unit can be removed and inserted. When installing, make sure clutch plungers are correctly seated in cups of engaging levers.

Therefore, please follow description below step by step.

Note: The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Even if the mechatronic unit has been removed, the “sudden removal” of the assembly lever -T10407- from under the engaging levers can have a negative effect on the adjusting mechanism.

In order to remove the mechatronic unit, sufficient space must be available in front of the gearbox. In some vehicles, parts must be removed which do not have anything to do directly with the gearbox. Remove any charge air lines or coolant lines that may be present.

Any retainers fitted on the cover of the mechatronic unit must also be removed.

A “new” mechatronic unit is correctly filled with oil.

Do not drain oil. A “removed” mechatronic unit is sent back with its oil in.

Mechatronic unit remains filled with oil.

Removing:

Raise vehicle. All 4 supports of lifting platform must be at same height.

Move selector lever to position “P” position.

Remove noise insulation.

Connect vehicle diagnostic tester and then select “7-speed dual clutch gearbox”, Moving gear actuator into -neutral- position under Guided functions.

Switch off ignition.

Raise vehicle.

Remove complete air filter housing.

Vehicles with petrol engines.

Vehicles with diesel engines.

Remove battery and battery tray.

In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in. Torque setting: 8 Nm.

If this cover is fitted, remove it.

Remove starter.

Release mechatronic unit connector by pulling in -direction of arrow- and pull off connector.

Place drip tray under gearbox.

Drain gear oil, then reinstall drain plug.

Pull cap off breather and close using a suitable plug to achieve an oil-tight seal.

Note: Protective cover -0AM 325 120- is well suited.

Remove all retainers and brackets from front of gearbox.

Using a screwdriver, carefully unclip gearbox input speed sender 3 -G641- from housing in -direction of arrow-.

Unscrew bolts of mechatronic unit for dual clutch gearbox -J743- “in diagonal sequence”. “There are 4 long and 3 short bolts.” Do not remove more than 7 bolts!

Please look carefully to check which bolts you are unscrewing. Do not unscrew any cover bolts.

The gearbox is shown here again from the side to make this situation clearer. The mechatronic unit must be removed. The cover does not have to be removed. Therefore, do not remove more than 7 bolts!

The next step is “difficult”: Now press both engaging levers of dual clutch “away” from plungers of mechatronic unit. Otherwise, levers will jam mechatronic unit at plungers and prevent mechatronic unit from being removed.

Please read through this description all the way to the end first. This will help you to perform the following steps “correctly”. Both levers must now be carefully pressed away from the plungers.

First take a look at -reddish-brown- engaging lever in this picture.

Insert assembly lever -T10407- to its right.

Far enough until groove lines up with housing rib -arrow-.

Assembly lever -T10407- should make contact with gearbox housing with its entire “rear face”.

Caution: Housing rib and groove of lever must be flush with one another. Do not insert tool as far as stop.

Apply a bit of force to tip of lever when turning. This stops lever from slipping out when turning.

Turn assembly lever -T10407- anticlockwise. In this way, engaging levers are pressed away from plungers -direction of arrow-.

Do not take out assembly lever -T10407-. It must remain inserted between engaging lever and gearbox housing for the entire process.

If necessary, press assembly lever -T10407- against gearbox using a screwdriver.

Apply a bit of force to tip of lever when turning. This stops lever from slipping out when turning.

Remove mechatronic unit. Mechatronic unit remains filled with oil.

Make sure no oil runs out of breather. Mechatronic unit is to be sent for reconditioning with its oil in.

If mechatronic unit “jams” and cannot be removed:

Sometimes, the mechatronic unit cannot be removed. In this case, the gear actuator is “caught” at the “top left” of the gearbox housing -arrow-.

Only if you cannot set the mechatronic unit to removal position with the vehicle diagnostic tester, you must move the unit by hand to this position.

Watch out for seal on mechatronic unit. Seal must be pushed in all around.

Look at sender. Clip must not be damaged.

Put on mechatronic unit.

When gripping and putting on, make sure selector forks are not inadvertently pressed out of their position.

Also observe engaging levers and plungers on mechatronic unit.

Screw in 7 new bolts and tighten until finger-tight.

Remove guide pins -T10406- again.

Make sure that plungers meet up correctly in cups of engaging levers.

Pull out plungers by hand until they are seated in cups. Plungers can be moved into position with a hook bent from a piece of welding wire (local manufacture).

Now check seat of plungers again. Plungers that are not seated correctly will damage mechatronic unit.

Tighten mechatronic unit diagonally to 10 Nm.

Grease oil seal in cover with sealing grease -G 052 128 A1- .

Fit cover and lever again.

Press selector lever cable back onto ball head and install new securing clip.

Securing clips for selector lever cable must always be renewed.

Add gear oil after completing work on mechatronic unit. Fill oil into gearbox.

Adjust selector lever cable.

Place plug on removed mechatronic unit. This way, the mechatronic unit can be sent sealed in oil-tight condition.

Turn assembly lever -T10407- clockwise and remove it.

Install gearbox input speed sender 3 -G641- .

Look at sender. Clip must not be damaged.

Sender lug must be fully and firmly in contact with gearbox housing. If sender is “loose” or clip is broken, renew mechatronic unit.

Remove plug and put breather cap -arrow- in place.

Join connector of mechatronic unit.

Attach all retainers and brackets to front of gearbox.

The bracket can be moved within its seat with a screwdriver when bolts -2- are tightened. Torque setting of -bolts 2-: 60 Nm + 90°.

Starter to gearbox.

Pendulum support to subframe and gearbox.

Gearbox to engine:

For 1.4 l/90 kW TFSI engine, 1.4 l/118 kW TSI engine, 1.6 l/75 kW MPI engine:

M12 – 80 Nm. If insert 18 mm -T10179- is used: 65 Nm.

M10 – 40 Nm.

Arrows point towards dowel sleeves.

For Engine: 1.9 l/77 kW TDI PD:

M12 – 80 Nm. If 18 mm insert -T10179- is used: 65 Nm.

M10 – 40 Nm.

Arrows point towards dowel sleeves.

For Engine: 1.6 l/77 kW TDI CR:

M12 – 80 Nm. If 18 mm insert -T10179- is used: 65 Nm.

M10 – 40 Nm.

Arrows point towards dowel sleeves.

If it has not already been done, renew needle bearing in crankshaft -arrow-.

Check for proper seating of both dowel sleeves between engine and gearbox.

Check for proper seating of intermediate plate.

Guide selector lever cable as soon as possible into its cable support bracket.

Check Bowden cable as soon as gearbox is raised. Be sure to insert it in cable support bracket “early”. Bowden cable must not be greased.

It must be possible to guide the engine and gearbox together by hand until the engine flange and gearbox flange make contact all around. If not, “something has gone wrong”!

Readjust gearbox support until engine and gearbox are “aligned with each other”.

Turn crankshaft slightly if necessary.

After fitting starter motor, check that both breather caps are in place -arrows-!

Securing clip for selector lever Bowden cable -arrow- must be renewed.

A securing clip which has been removed is not allowed to be installed again. The clip will have lost its internal tension and so it might fall off.

Therefore, when installing, always use a “new” securing clip.

Ensure that selector lever cable is properly routed during installation -arrow-. If the sheet metal has been bent downwards when the gearbox was removed, it may cause noises. The cable will vibrate against the sheet metal.

Observe sheet metal. Press it back up in the tunnel during installation.

Always adjust selector lever cable.

Carrying out basic adjustment.

Torque settings for gearbox installation.

Left assembly mounting:

Renew all bolts on left assembly mounting.

First screw in all bolts by hand.

First bolt bracket to gearbox -1- with 40 Nm + 90° further turn.

For Engines: 1.4 l/90 kW TFSI, 1.4 l/118 kW TSI, 1.6 l/75 kW:

M12 – 80 Nm. If insert 18 mm -T10179- is used: 65 Nm.

M10 – 40 Nm.

For Engine: 1.9 l/77 kW TDI PD:

M12 – 80 Nm. If 18 mm insert -T10179- is used: 65 Nm.

M10 – 40 Nm.

For Engine: 1.6 l/77 kW TDI CR:

M12 – 80 Nm. If 18 mm insert -T10179- is used: 65 Nm.

M10 – 40 Nm.

The bracket can be moved within its seat with a screwdriver when bolts -2- are tightened. Torque setting of -bolts 2-: 60 Nm + 90°.

The torque setting for the first bolt bracket to gearbox -1- is 40 Nm + 90° further turn.

Special tools and workshop equipment required are:

• Support bracket -10 – 222 A-
• Adjustment plate -3282/59-
• Adapter -10 – 222 A /8-
• Insert tool, 18 mm -T10179-
• Gearbox support -3282-
• Socket -T10061-
• Engine and gearbox jack -V.A.G 1383 A-

The gearbox is removed downwards separately, without engine. The battery, air filter and starter are removed “from above”.

Noise insulation beneath engine/gearbox, lower cover in front left wheel housing and pendulum support are removed “from below”.

Perform the following steps:

Raise vehicle. All 4 supports of lifting platform must be at same height.

Move selector lever to position “P” position.

Only in vehicles with stub shafts:

Note: After loosening centre bolt, do not lower vehicle to ground again.

Step on the brake pedal while a 2nd mechanic loosens the two drive shaft bolts -arrow-.

Remove both front wheels.

Continuation for all vehicles:

Remove complete air filter housing.

Remove battery and battery tray.

Remove starter.

Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.

Remove Bowden cable from ball head. 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.

Release mechatronic unit connector by pulling and pull off connector.

Now remove all upper connecting bolts between engine and gearbox.

These tools are appropriate for this.

Remove noise insulation.

Remove front part of wheel housing.

Remove all retainers and brackets from front of gearbox.

Remove pendulum support.

Only in vehicles with stub shafts:

Remove both drive shafts.

Only in vehicles with flange shafts:

If fitted, remove the heat shield over the right-hand drive shaft.

Unbolt only left suspension link from swivel joint -arrows-.

Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work. The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of tensioning straps -T10038- are therefore very good for this.

Secure both drive shafts to suspension struts using tensioning straps -T10038- .

Remove right flange shaft of gearbox. Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669- . Torque setting: 30 Nm.

Continuation for all vehicles:

Unbolt exhaust system bracket from subframe.

Remove front exhaust pipe so that lower bolts can be removed -arrows-.

Remove engine cover from cylinder head.

Bolt bracket -T10346- to rear of the 3 mounting holes for battery tray. To do this, use a collar bolt M 6 or a securing bolt for battery tray.

If there are hose and cable connections in area of engine support eye for support bracket -10-222 A- , remove these now.

Set up support bracket -10-222 A- in front of bonnet support. Use Adapter -10 – 222 A /8- and Adapter -10 – 222 A /3- . Place adapters -10 – 222 A /8- on upper longitudinal carriers, directly before the raised portion (-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.

Remove all bolts -1- and -2- for bracket.

Then lower engine and gearbox slightly using spindles of support bracket -10 – 222 A- so that bracket can be removed. At most, 5 turns are sufficient to remove bracket. In many cases, the spindle does not need to be lowered further for the later removal of the gearbox.

To remove gearbox 0AM, set up gearbox support -3282- with adjustment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- .

Align arms of gearbox support according to holes in adjustment plate -3282/59- .

Screw in support elements as illustrated on adjustment plate -3282/59- .

Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow on adjustment plate -3282/59- points in direction of travel.

Align gearbox support -3282- parallel to gearbox.

Screw pin -3282/29- into “rear” hole for pendulum support.

Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit.

Secure gearbox with tensioning strap -T10038- .

Raise gearbox and engine support -V.A.G 1383 A- from below to support gearbox. The gearbox is separated from the engine in this position.

Remove remaining engine/gearbox connecting bolts.

Press gearbox off engine, “observing selector lever cable” and lower gearbox.

Note: Distance between engine flange and gearbox flange should be about 50 mm before gearbox is lowered. Be careful of all lines and coolant hoses when lowering gearbox.

Renew needle bearing in crankshaft -arrow-.

Transporting gearbox and securing to assembly stand.

Installing gearbox.

If gearbox is to be sent:

In some cases, there are retainers on the front of the gearbox.

Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

Install right flange shaft of gearbox with flange shafts.

Please read these important work steps before installing gearbox.

In some cases, there are brackets on the front of the removed gearbox. Attach these brackets to the “new” gearbox.

If it has not already been done, renew needle bearing in crankshaft -arrow-.

Check for proper seating of both dowel sleeves between engine and gearbox.

Check for proper seating of intermediate plate.

Guide selector lever cable as soon as possible into its cable support bracket.

Check Bowden cable as soon as gearbox is raised. Be sure to insert it in cable support bracket “early”. Bowden cable must not be greased.

It must be possible to guide the engine and gearbox together by hand until the engine flange and gearbox flange make contact all around. If not, “something has gone wrong”!

Readjust gearbox support until engine and gearbox are “aligned with each other”.

Turn crankshaft slightly if necessary.

After fitting starter motor, check that both breather caps are in place -arrows-!

Securing clip for selector lever Bowden cable -arrow- must be renewed.

A securing clip which has been removed is not allowed to be installed again. The clip will have lost its internal tension and so it might fall off.

Therefore, when installing, always use a “new” securing clip.

Ensure that selector lever cable is properly routed during installation -arrow-. If the sheet metal has been bent downwards when the gearbox was removed, it may cause noises. The cable will vibrate against the sheet metal.

Observe sheet metal. Press it back up in the tunnel during installation.

Always adjust selector lever cable.

Carrying out basic adjustment.

Torque settings for gearbox installation.

Special tools and workshop equipment required are:

• Support bracket -10 – 222 A-
• Adjustment plate -3282/59-
• Adapter -10 – 222 A /8-
• Insert tool, 18 mm -T10179-
• Gearbox support -3282-
• Socket -T10061-
• Bracket -T10346-

Adapter -10 – 222 A /3-

Engine and gearbox jack -V.A.G 1383 A-

The gearbox is removed downwards separately, without engine. The battery, air filter and starter are removed “from above”.

Noise insulation beneath engine/gearbox, lower cover in front left wheel housing and pendulum support are removed “from below”.

Perform the following steps:

Raise vehicle. All 4 supports of lifting platform must be at same height.

Move selector lever to position “P” position.

Remove complete air filter housing.

Remove battery and battery tray.

Remove starter.

Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.

Remove Bowden cable from ball head.

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.

Release mechatronic unit connector by pulling and pull off connector.

Now remove all upper connecting bolts between engine and gearbox.

Bolt bracket -T10346- to rear of the 3 mounting holes for battery tray. To do this, use a collar bolt M 6 or a securing bolt for battery tray.

If there are hose and cable connections in area of engine support eye for support bracket -10 – 222 A- , remove these now.

Set up support bracket -10-222 A- in front of bonnet support. Use Adapter -10 – 222 A /8- and Adapter -10 – 222 A /3- . Place adapters -10 – 222 A /8- on upper longitudinal carriers, directly before the raised portion (-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.

Remove all bolts -1- and -2- for bracket.

Then lower engine and gearbox slightly using spindles of support bracket -10 – 222 A- so that bracket can be removed. At most, 5 turns are sufficient to remove bracket. In many cases, the spindle does not need to be lowered further for the later removal of the gearbox.

To remove gearbox 0AM, set up gearbox support -3282- with adjustment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- .

Align arms of gearbox support according to holes in adjustment plate -3282/59- .

Screw in support elements as illustrated on adjustment plate -3282/59- .

Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow on adjustment plate -3282/59- points in direction of travel.

Align gearbox support -3282- parallel to gearbox.

Screw pin -3282/29- into “rear” hole for pendulum support.

Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit.

Secure gearbox with tensioning strap -T10038- .

Raise gearbox and engine support -V.A.G 1383 A- from below to support gearbox. The gearbox is separated from the engine in this position.

Remove remaining engine/gearbox connecting bolts.

Press gearbox off engine, “observing selector lever cable” and lower gearbox.

Note: Distance between engine flange and gearbox flange should be about 50 mm before gearbox is lowered. Be careful of all lines and coolant hoses when lowering gearbox.

Renew needle bearing in crankshaft -arrow-.

Transporting gearbox and securing to assembly stand.

Installing gearbox.

If gearbox is to be sent:

In some cases, there are retainers on the front of the gearbox.

Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

Install right flange shaft of gearbox with flange shafts.

Special tools and workshop equipment required are:

• Support bracket -10 – 222 A-
• Adjustment plate -3282/59-
• Adapter -10 – 222 A /8-
• Socket -T10061-
• Gearbox support -3282-
• Insert tool, 18 mm -T10179-

Special tools and workshop equipment required for adapter is: Adapter -10 – 222 A /16-

Hook -10 – 222 A /2-

Shackle -10 – 222 A /12-

Engine and gearbox jack -V.A.G 1383 A-

The gearbox is removed downwards separately, without engine. The battery, air filter and starter are removed “from above”.

Noise insulation beneath engine/gearbox, lower cover in front left wheel housing and pendulum support are removed “from below”.

Perform the following steps:

Raise vehicle. All 4 supports of lifting platform must be at same height.

Move selector lever to position “P” position.

Only in vehicles with stub shafts:

Note: After loosening centre bolt, do not lower vehicle to ground again.

Step on the brake pedal while a 2nd mechanic loosens the two drive shaft bolts -arrow-.

Remove both front wheels.

Continuation for all vehicles:

Remove complete air filter housing.

Remove battery and battery tray.

Remove starter.

Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.

Remove Bowden cable from ball head. 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.

Release mechatronic unit connector by pulling and pull off connector.

Now remove all upper connecting bolts between engine and gearbox.

These tools are appropriate for this.

Remove noise insulation.

Remove front part of wheel housing.

Remove all retainers and brackets from front of gearbox.

Remove pendulum support.

Only in vehicles with stub shafts:

Remove both drive shafts.

Only in vehicles with flange shafts:

If fitted, remove the heat shield over the right-hand drive shaft.

Unbolt only left suspension link from swivel joint -arrows-.

Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work. The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of tensioning straps -T10038- are therefore very good for this.

Secure both drive shafts to suspension struts using tensioning straps -T10038- .

Remove right flange shaft of gearbox. Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669- . Torque setting: 30 Nm.

Continuation for all vehicles:

Remove all retainers and brackets from front of gearbox.

To remove gearbox 0AM, set up gearbox support -3282- with adjustment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- .

Align arms of gearbox support according to holes in adjustment plate -3282/59- .

Screw in support elements as illustrated on adjustment plate -3282/59- .

Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow on adjustment plate -3282/59- points in direction of travel.

Align gearbox support -3282- parallel to gearbox.

Screw pin -3282/29- into “rear” hole for pendulum support.

Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit.

Secure gearbox with tensioning strap -T10038- .

Raise gearbox and engine support -V.A.G 1383 A- from below to support gearbox. The gearbox is separated from the engine in this position.

Remove remaining engine/gearbox connecting bolts.

Press gearbox off engine, “observing selector lever cable” and lower gearbox.

Note: Distance between engine flange and gearbox flange should be about 50 mm before gearbox is lowered. Be careful of all lines and coolant hoses when lowering gearbox.

Renew needle bearing in crankshaft -arrow-.

Transporting gearbox and securing to assembly stand.

Installing gearbox.

If gearbox is to be sent:

In some cases, there are retainers on the front of the gearbox.

Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

Install right flange shaft of gearbox with flange shafts.

In some cases, there are retainers on the front of the gearbox.

Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

Install right flange shaft of gearbox with flange shafts.

Special tools and workshop equipment required are:

• Support bracket -10 – 222 A-
• Adjustment plate -3282/59-
• Socket -T10035-
• Socket -T10061-
• Gearbox support -3282-
• Insert tool, 18 mm -T10179-

Adapter -10 – 222 A /3-

Adapter -10 – 222 A /18-

Engine and gearbox jack -V.A.G 1383 A-

The gearbox is removed downwards separately, without engine. The battery, air filter and starter are removed “from above”.

Noise insulation beneath engine/gearbox, lower cover in front left wheel housing and pendulum support are removed “from below”.

Perform the following steps:

Raise vehicle. All 4 supports of lifting platform must be at same height.

Move selector lever to position “P” position.

Remove engine cover from cylinder head.

Remove complete air filter housing.

Remove battery and battery tray.

Remove starter.

Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.

Remove Bowden cable from ball head. 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.

Release mechatronic unit connector by pulling and pull off connector.

Now remove all upper connecting bolts between engine and gearbox.

Remove noise insulation.

Remove front part of wheel housing.

If fitted, remove the heat shield over the right-hand drive shaft.

Unscrew left suspension link from swivel joint.

Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work. The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of tensioning straps -T10038- are therefore very good for this.

Secure both drive shafts to suspension struts using tensioning straps -T10038- .

Remove right flange shaft of gearbox. Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669- . Torque setting: 30 Nm.

Remove all retainers and brackets from front of gearbox.

Remove pendulum support.

If there are hose and cable connections in area of engine support eye for support bracket -10-222 A- , remove these now.

Remove filler pieces from upper edges of both wings.

Support engine and gearbox with support bracket -10-222 A but do not raise.

Secure shackle -10 – 222 A /16- to gearbox housing.

Remove all bolts -1- and -2- for bracket.

Then lower engine and gearbox slightly using spindles of support bracket -10 – 222 A- or adapter -10 – 222 A /16- so that bracket can be removed. At most, 5 turns are sufficient to remove bracket. In many cases, the spindle does not need to be lowered further for the later removal of the gearbox.

To remove gearbox 0AM, set up gearbox support -3282- with adjustment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- .

Align arms of gearbox support according to holes in adjustment plate -3282/59- .

Screw in support elements as illustrated on adjustment plate -3282/59- .

Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow on adjustment plate -3282/59- points in direction of travel.

Align gearbox support -3282- parallel to gearbox.

Screw pin -3282/29- into “rear” hole for pendulum support.

Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit.

Secure gearbox with tensioning strap -T10038- .

Raise gearbox and engine support -V.A.G 1383 A- from below to support gearbox. The gearbox is separated from the engine in this position.

Remove remaining engine/gearbox connecting bolts.

Press gearbox off engine, “observing selector lever cable” and lower gearbox.

Renew needle bearing in crankshaft -arrow-.

Transporting gearbox and securing to assembly stand.

Installing gearbox.

If gearbox is to be sent:

In some cases, there are retainers on the front of the gearbox.

Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

Install right flange shaft of gearbox with flange shafts.

Gearbox with different output shafts.

A – Stub shafts “to 11.2008”

B – Flange shafts “from 12.2008”

Vehicles with stub shafts on gearbox:

To remove gearboxes with stub shafts, it is necessary to remove stub shafts. Only shafts with straight joints can be put back onto the output shafts safely. Therefore, these drive shafts must be removed.

Vehicles with flange shafts on gearbox:

For gearboxes with flange shafts, the drive shafts must be unbolted from the gearbox. This way, the gearbox can be removed. In individual cases, it is necessary to remove right-hand flange shaft from gearbox. This gives you enough clearance for removing gearbox.

Secure both drive shafts to suspension struts using tensioning straps -T10038- .

Please read these important work steps before installing gearbox.

In some cases, there are brackets on the front of the removed gearbox. Attach these brackets to the “new” gearbox.

If it has not already been done, renew needle bearing in crankshaft -arrow-.

Transporting gearbox and securing to assembly stand.

Installing gearbox.

If gearbox is to be sent:

In some cases, there are retainers on the front of the gearbox.

Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

Install right flange shaft of gearbox with flange shafts.

In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in. Torque setting: 8 Nm.

Gearbox with stub shafts -A

Gearbox with flange shafts -B-

In gearboxes with flange shafts, flange shaft must be reinstalled on “new” gearbox in some cases.

Note: There is no need to renew oil seal for flange shaft when doing this.

Remove right-hand flange shaft of gearbox in order to install gearbox.

Gearbox with flange shafts, torque setting.

Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669- .

If the cover is fitted, remove it.

Fit charge air or coolant hoses as necessary.

Install battery and battery tray.

Install complete air filter housing.

Vehicles with petrol engines.

Vehicles with diesel engines.

If necessary, top up coolant.

Install noise insulation.

Carrying out basic adjustment.

Mechatronic unit remains filled with oil.

Place plug on “removed” mechatronic unit if necessary. This way, the mechatronic unit can be sent sealed in oil-tight condition.

Ensure that selector lever cable is properly routed during installation -arrow-. If the sheet metal has been bent downwards when the gearbox was removed, it may cause noises. The cable will vibrate against the sheet metal.

Observe sheet metal. Press it back up in the tunnel during installation.

Always adjust selector lever cable.

Carrying out basic adjustment.

Torque settings for gearbox installation.

Pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal.

Secure gearbox on gearbox support -VW 353-

Lift gearbox into assembly stand. The gearbox is lifted “into assembly stand” together with gearbox support -VW 353- .

N – Idling/gearbox neutral position “in the middle”

R – Reverse gear:

If reverse gear is engaged, extended plunger of mechatronic unit catches behind gearbox housing. Therefore, move mechatronic unit into removal position by hand.

1 – Gear

2 – Gear

3 – Gear

4 – Gear

5 – Gear

6 – Gear

7 – Gear