VOLKSWAGEN JETTA 2011 (08) PDF Document

The special tools and workshop equipment required for the removal and installation of the dual clutch on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM are:

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

Before installing the clutch, refer to the page to see whether the clutch needs adjusting during assembly or not. Adjusting is detailed on the page. The special tools and workshop equipment required are:

The position of engagement bearings must be set after the clutch and its actuators have been renewed. The retainer also belongs to the actuator. There is no need to adjust anything if all the named parts have only been removed and reinstalled. The conditions for adjustment are:

• 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:

The position of engagement bearings is comparable with clutch play of a manual gearbox. In this 0AM dual clutch gearbox, there are tolerances in the engagement system of the gearbox and in the 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 the thickness of the shim.

First find a dimension “B”. This dimension 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.

For “K 1”:

• 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 an 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. 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.

For “K 2”:

• 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.

Calculated shim thickness table for K1:

Calculated shim thickness table for K2 (same as K1):

The special tools and workshop equipment required for installing the dual clutch on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM are:

• Support device -T10323-
• Assembly tool -T10356-
• Puller -T10373-
• Thrust piece -T10376-
• Adhesive -AMV 195 KD1 01-

Perform the following steps:

Caution: Do not oil or grease anything!

Before the clutch is installed, the position of engagement bearings “K 1 and K 2” must be set.

• Insert plastic retainer of engaging lever and check for correct seating.
• Install small engaging lever with clip. The sleeve with its retaining plate fits only in one position. “New” clutches always have one clip. Some “older gearboxes” do not have a clip.
• Check engaging lever is properly seated.
• Screw on engaging lever with 2 new bolts. Torque setting: 8 Nm + 90°.
• Note: Mounting for engaging lever and entire mechanism of engagement bearing must be dry and free from oil or grease. If necessary, clean these components with a cloth.
• Insert 2nd, “larger” engaging lever. This “larger” lever is for clutch “K 1”.
• Check both engaging levers are seated correctly.
• Caution: Before continuing with assembly, check whether clutch needs to be adjusted. Do not continue with the assembly before the clutch has been adjusted! Adjust positions of engagement bearings.
• Insert small engagement bearing with measured shim. The shim should be under the small engagement bearing. Therefore, insert shim first. The small engagement bearing only fits in one position due to 4 grooves. If the clutch has been replaced, the shim should also be under the bearing.
• By “turning” the 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 the shim from slipping out of its seat when the clutch is inserted. The large shim is for clutch “K 1”, the small one for clutch “K 2”.
• Turn back spindle of puller -T10373-.
• Insert clutch.
• Use puller -T10373- to insert the clutch into the gearbox.
• Turn the 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 the clutch on onto the 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 the clutch down via the spindle.
• Note: Place a hand on the 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.
• The installation position of the retaining ring: The joint of the retaining ring is “narrower at top”. If you can insert the retaining ring -arrow-, the clutch is correctly pressed on to the stop.
• Insert new retaining ring -arrow-.
• To enable the clutch to find its installation position already, turn the clutch against puller -T10373- by hand. Now turn the clutch by hand, without using a tool. In this way, the clutch slides against the retaining ring. Do not use any other tool. Pressing on causes “clutch to locate at bottom” on the input shaft. The clutch should only be pulled up far enough for it to contact the retaining ring.
• Then insert the hub. The hub has a “large” tooth and therefore only fits in one position. The “large” tooth has a mark on the -engine end- -arrow-.
• Insert the retaining ring for the hub -arrow-. Installation position: The joint of the ring must point towards the “hub” on the clutch.
• Turn the clutch by hand and observe the “small” engaging lever whilst turning. The 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 the shim is not properly seated.
• Remove the clutch again in this case. Look at the 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 procedure for removing the dual clutch from a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM is as follows:

• Pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal.
• Turn the gearbox with the clutch upwards.
• Remove the retaining ring of the hub -arrow-.
• Remove the hub with hook -3438- and a screwdriver.
• Remove the retaining ring of the 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 the retaining ring. Clutch should only be pressed down slightly. Often, it is sufficient to rotate the spindle against the thrust piece -T10376- without pressing. This will “release” the retaining ring.
• Pull off the clutch.
• Remove the clutch together with puller -T10373-.
• Remove the small engagement bearing.
• Remove the large engaging lever.
• Remove bolts and remove the small engaging lever.
• Remove the retainer for the engaging lever.

The gearbox on the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM 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.

Additional instructions regarding the gearbox when covers are unbolted or fluid is missing:

• If gearbox covers have been unbolted or the gearbox has no fluid, do not run the engine. Do not tow the 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 “0AM” gearbox on the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM has two oil circuits. One oil fill is for gears, shafts and differential. A 2nd oil fill is for the mechatronic unit for dual clutch gearbox -J743-.

Both oils are Genuine parts. Do not mix “additives” in oil. Oil which has been drained out cannot be added again.

Caution: Use caution when handling oil. Dispose of used oil properly. One drop of oil will contaminate 600 litres of water.

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

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

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

For adapting installation information: 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.

For reading measured values for mandatory reporting: 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.

For initiating basic adjustment: 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.

Perform 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 capacities for the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM are:

Further information in the part number designates the container size.

The gearbox on the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM 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 the gearbox, find out what is the cause and rectify the faults.

Procedure for renewing gear oil (if gearbox is removed):

• Raise vehicle.
• Place drip tray under gearbox.
• Then drain all gear oil and fill with new oil.
• Then install the drain plug again (Torque setting: 30 Nm).

Procedure for renewing gear oil (if gearbox is installed):

• You must remove the battery and battery tray to add oil.
• Remove battery and battery tray.
• 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 the 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 the 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.

Screw on the engaging lever with 2 new bolts. The torque setting is 8 Nm + 90°.

The torque setting for the selector lever to selector shaft on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM is detailed on the page.

The torque settings for the selector mechanism housing bolts on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM (vehicles up to 02.2009) are:

• Bolt with spring (3): 3 Nm
• Nut (6): 9 Nm (Qty. 4)
• Hexagon flange nut (10): 8 Nm (Qty. 4)

When removing and installing the selector mechanism in vehicles from 03.2009 onwards for the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM, the torque setting for the 4 bolts securing the mechanism is 8 Nm.

When removing and installing the selector mechanism in vehicles up to 02.2009 for the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM, the torque setting for the selector lever handle is detailed on the page. The torque setting for the hexagon flange nut (10) is 8 Nm.

Before working on the vehicle with the engine running while servicing the selector mechanism on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM, move the selector lever into position “P” and apply the handbrake.

To check if the parking lock is engaged during selector mechanism adjustment on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM:

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 the handle of the 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 its optimal position.
• Tighten the adjusting screw -arrow- to 13 Nm. This completes the adjustment.

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

When handling the mechatronic unit for dual clutch gearbox -J743- on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM, take care with the breather. When doing any work on the mechatronic unit, please remove the cap -arrow- from the breather and seal with a suitable plug. The protective cover -0AM 325 120- is well suited.

The torque settings for the bolts when removing the mechatronic unit for dual clutch gearbox -J743- on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM with the gearbox installed are:

• Bolt (1) M8 x 35: 10 Nm (Always renew)
• Bolt (2) M8 x 90: 10 Nm (Always renew)

If the mechatronic unit “jams” and cannot be removed from the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM:

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, the mechatronic unit is not allowed to be removed with significant force. Perform the following:

• First reposition the mechatronic unit on the gearbox housing and secure it with one bolt.
• Move the mechatronic unit into “removal position” by hand.

If the mechatronic unit for dual clutch gearbox -J743- sometimes cannot be removed on the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM because the gear actuator is “caught” at the “top left” of the gearbox housing -arrow-, move the unit by hand to this position if you cannot set it to removal position with the vehicle diagnostic tester. 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.

Work procedure:

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

After installing the mechatronic unit for dual clutch gearbox -J743- on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM:

The mechatronic unit is tightened diagonally to 10 Nm.

If a cover is fitted over the engaging levers on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM, the torque setting is 8 Nm.

The procedure for installing the dual clutch on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM after calculating the shims is as follows:

The special tools and workshop equipment required are:

• Support device -T10323-
• Assembly tool -T10356-
• Puller -T10373-
• Thrust piece -T10376-
• Adhesive -AMV 195 KD1 01-

Perform the following steps:

Caution: Do not oil or grease anything!

Before the clutch is installed, the position of engagement bearings “K 1 and K 2” must be set.

• Insert the plastic retainer of the engaging lever and check for correct seating.
• Install the small engaging lever with clip. The sleeve with its retaining plate fits only in one position. “New” clutches always have one clip. Some “older gearboxes” do not have a clip.
• Check the engaging lever is properly seated.
• Screw on the engaging lever with 2 new bolts. Torque setting: 8 Nm + 90°. Note: Mounting for engaging lever and entire mechanism of engagement bearing must be dry and free from oil or grease. If necessary, clean these components with a cloth.
• Insert the 2nd, “larger” engaging lever. This “larger” lever is for clutch “K 1”.
• Check both engaging levers are seated correctly. Caution: Before continuing with assembly, check whether clutch needs to be adjusted. Do not continue with the assembly before the clutch has been adjusted! Adjust positions of engagement bearings.
• Insert the small engagement bearing with the measured shim. The shim should be under the small engagement bearing. Therefore, insert the shim first. The small engagement bearing only fits in one position due to 4 grooves. If the clutch has been replaced, the shim should also be under the bearing.
• By “turning” the bearing, check whether it is installed correctly and that grooves are seated correctly.
• Secure the shim using 3 drops of glue -AMV 195 KD1 01-. This prevents the shim from slipping out of its seat when the clutch is inserted. The large shim is for clutch “K 1”, the small one for clutch “K 2”.
• Turn back the spindle of puller -T10373-.
• Insert the clutch.
• Use puller -T10373- to insert the clutch into the gearbox.
• Turn the 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 the clutch on onto the 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 the clutch down via the spindle. Note: Place a hand on the 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.
• The installation position of the retaining ring: The joint of the retaining ring is “narrower at top”. If you can insert the retaining ring -arrow-, the clutch is correctly pressed on to the stop.
• Insert the new retaining ring -arrow-.
• To enable the clutch to find its installation position already, turn the clutch against puller -T10373- by hand. Now turn the clutch by hand, without using a tool. In this way, the clutch slides against the retaining ring. Do not use any other tool. Pressing on causes “clutch to locate at bottom” on the input shaft. The clutch should only be pulled up far enough for it to contact the retaining ring.
• Then insert the hub. The hub has a “large” tooth and therefore only fits in one position. The “large” tooth has a mark on the -engine end- -arrow-.
• Insert the retaining ring for the hub -arrow-. Installation position: The joint of the ring must point towards the “hub” on the clutch.
• Turn the clutch by hand and observe the “small” engaging lever whilst turning. The 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 the shim is not properly seated.

When installing the dual clutch on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM, the torque setting for screwing on the small engaging lever with 2 new bolts is 8 Nm + 90°.

To check the selector lever cable for freedom of movement on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM (vehicles up to 02.2009):

Brief description: The selector lever cable must be removed from the gearbox so that its freedom of movement can be checked. Put the 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.

Checking procedure:

• Move the selector lever to position “P” position.
• Remove the cable from the lever on the gearbox.
• Move the selector lever repeatedly from “P” to “S” and back to “P”. The selector lever must move easily.
• Reinstall the cable with the “loosened” adjustment screw. If you remove the securing clip, you must always install a “new” securing clip.
• Adjust the cable.

The selector lever cable on the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM 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.

The adjustment procedure is:

• Move the selector lever in the vehicle to “P” position. The adjuster screw -arrow- must be “loosened”.
• Shift the lever on the gearbox to position “P”. The gearbox lever must be pressed “completely to right side of vehicle” in the direction of the selector lever cable support bracket.
• Install the Bowden cable with the loosened adjusting screw -arrow- and a new securing clip.
• Tighten the adjusting screw -arrow- to 13 Nm. This completes the adjustment.

When ignition and light are switched on for the selector mechanism on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM, the respective symbol in the shift mechanism cover lights up. Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode. Symbols must change from “P R N D S” to “7 6 5 4 3 2 1”.

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

• Brake pedal not depressed: The selector lever is locked and cannot be shifted out of “P” position with the lock button pressed. The solenoid for the selector lever lock blocks the selector lever.
• Brake pedal is depressed: The solenoid for the selector lever lock releases the selector lever. It is possible to shift into a driving gear. Slowly shift the selector lever from “P” through to “S”, checking whether the selector lever position in the dash panel insert corresponds to the selector lever position.

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

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

Selector lever in position “Tiptronic”:

• Shift the selector lever into Tiptronic gate.

Do not remove the handle for the emergency release of the selector lever on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM.

For vehicles up to 02.2009:

• Unclip the selector cover and hold it to the side.
• Depress the brake pedal or set the handbrake.
• Press the yellow plastic part -arrow- from right to left. Or press on the pin of the solenoid.

For vehicles from 03.2009 onwards:

• Press onto the yellow plastic part -arrow-.

It is possible with all handles that the lock button is pressed into the handle when removing and installing the selector lever handle on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM. Do not install a handle with the locking button pressed in.

Procedure for removal:

• Before removal, pull the lock button out past its pressure point.
• Secure the locking button with a cable tie or wire against being pressed in.
• Unclip the cover.
• Push the sleeve upwards to release the handle.

Procedure for installation:

• Lock the handle again after installing. To do this, press the sleeve under the handle back down.
• For “new” handles, you only have to remove the transport guard. The locking button is already in the installation position.
• Pull the connector from the cover.
• Pull the handle off upwards.
• Lock the handle again after installing. Press the sleeve under the handle back down.

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

To remove the selector housing and associated parts when working on the selector mechanism of a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM (vehicles up to 02.2009):

• Remove the securing clip in the direction of the arrow. Securing clips for the selector lever cable must always be renewed.
• Remove the Bowden cable from the ball head.
• Raise the vehicle.
• To remove the Bowden cable and/or the selector mechanism, the heat shield under the selector mechanism and, if necessary, parts of the exhaust system must now be removed.
• Remove the selector housing beneath the selector lever.
• Remove the locking plate of the cable support bracket. Always renew the locking plate.

The selector mechanism and selector lever cable on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM (vehicles from 03.2009 onwards) are not allowed to be separated from one another. Both are removed together. In the engine compartment, it may be necessary to provide installation space. Often, it is necessary to remove the air filter. In the interior, it may be necessary to remove the centre console.

Perform the following steps:

• Move the selector lever to position “P” position.
• Remove the selector lever handle.
• Remove the centre console.
• Remove 4 bolts. Torque setting: 8 Nm.
• Raise the vehicle.
• Remove the heat shield beneath the selector mechanism. This makes subsequent removal of the selector mechanism easier. To do so, remove parts of the exhaust system if necessary.
• Remove the securing clip in the direction of the arrow. Securing clips for the selector lever cable must always be renewed.
• Remove the Bowden cable from the ball head.
• Remove the selector mechanism.
• Install in reverse order of removal.
• Before you put on the ball head: check the cable.
• Install all parts of the exhaust system which were removed.
• Install the heat shield.
• Adjust the selector lever cable after installing.

Information about gearboxes with different output shafts for the VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM when removing the gearbox:

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 the 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 the right-hand flange shaft from the gearbox. This gives you enough clearance for removing the gearbox. Secure both drive shafts to suspension struts using tensioning straps -T10038-.

For the left assembly mounting when installing the gearbox on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM:

Left assembly mounting:

• Renew all bolts on the left assembly mounting.
• First screw in all bolts by hand.
• First bolt bracket to gearbox -1- with 40 Nm + 90° further turn.

Torque settings for gearbox installation are listed for various engines when installing the gearbox on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM:

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

Arrows point towards dowel sleeves.

Engine: 1.9 l/77 kW TDI PD:

Arrows point towards dowel sleeves.

Engine: 1.6 l/77 kW TDI CR:

Arrows point towards dowel sleeves.

Before installing the gearbox on a VOLKSWAGEN JETTA 2011 7-speed dual clutch gearbox 0AM, please read these important work steps. In some cases, there are brackets on the front of the removed gearbox. Attach these brackets to the “new” gearbox.

If the 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 the right flange shaft of the gearbox with flange shafts.

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

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

Guide the selector lever cable as soon as possible into its cable support bracket. Check the Bowden cable as soon as the gearbox is raised. Be sure to insert it in the cable support bracket “early”. The 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 the gearbox support until the engine and gearbox are “aligned with each other”. Turn the crankshaft slightly if necessary.

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

The securing clip for the 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 the 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 the sheet metal. Press it back up in the tunnel during installation.

Always adjust the selector lever cable.

Carrying out basic adjustment.

Torque settings for gearbox installation are listed on the page.