Manual-Transmision-0DL.pdf

Service
Workshop Manual
Arteon 2018 ➤ , Passat 2015 ➤ ,
Passat Variant 2015 ➤ , Tiguan 2016 ➤ ,
Tiguan RUS 2017 ➤
7-speed dual clutch gearbox 0DL
Edition 07.2018
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00 - Technical data
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30 - Clutch
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34 - Controls, housing
35 - Gears, shafts
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39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B804A300A

Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 07.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Overview of fitting locations - electrical components ..............................
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30 - Clutch . . . . . . . . . . . . . . . . . . . .e.d b.y . . . . . . . . . . . . .
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1 Clutch . . . . . . . . . . . . . . . . u.th.o.r . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . e.e .or. . . . . . . . . . . 11
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1.1 Assembly overview - dual sclutch ................. .. . . . . . . . . . . . . . . . .c . . . . . . . . . 11
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1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
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1.2 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 up to gearbox date 05/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.1 Distinguishing between different types of bevel boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.2 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2.3 Detaching bevel box from gearbox - gearbox removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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3.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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3.9 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Contents i
5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

6 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.1 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.2 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
39 - Final drive - differential

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1 Gear oiled by. . . . . . . . . . . . . . . . . . . . . . . . . . g.u.ar.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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1.1 Checking
tho gear oil level . . . . . . . . . . . . . . . . . . te. e.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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1.2 Draining
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and filling gear oil . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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2.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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2.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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2.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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3 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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3.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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3.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

3.3 Renewing needle bearing (polygon bearing) for stub shaft . . . . . . . . . . . . . . . . . . . . . . . . 208
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ii Contents
00 – Technical data
1 Safety information
(VRL011986; Edition 07.2018)
⇒ “1.1 General safety provisions”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Notes on tow-starting/towing”, page 2
⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
1.1 General safety provisions

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

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♦ Before working on vehicle
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To prevent personal injury and damage to or destruction of elec‐

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trical and electronic components, observe the following:

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♦ Connect and disconnect measuring and testing devices only

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with the ignition switched off.

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To prevent damage to the electronic components when dis‐

connecting the battery:
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♦ Take the necessary measures when disconnecting the

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

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Disconnecting and reconnecting battery .

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1. Safety information 1
1.2 Safety measures when working on ve‐

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

with start/stop system.
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert) the engine
can start automatically if required.
♦ When working on the vehicle, always make sure that the
start-stop system is deactivated (switch off the ignition;
switch the ignition on again if necessary).
1.3 Notes on tow-starting/towing
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♦ If the vehicle must be towed, theauselector
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the “N” position, and the vehicles must be towed at a speed
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no greater than 50 km/h and for a distance not exceeding
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It is not possible to tow-start the engine, e.g. if the battery is too t to the co
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1.4 Safety precautions when using testers

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road test
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Observe the following if test and measuring equipment is required

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WARNING
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Risk of accident due to distraction and inadequate securing of

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test and measuring equipment.
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Danger as a result of activation of front passenger airbag in
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• Operating test instruments and measuring equipment
while driving can cause distraction.
• Greater injury hazard as a result of unsecured test and
measuring equipment.
♦ Always strap in place test and measuring equipment on
rear seat and have a 2nd person sitting on the rear seat
to operate them.
2 Rep. gr.00 - Technical data

Please note the following to avoid personal injury and damage to,
or destruction of, electrical and electronic components:
♦ Connect and disconnect measuring and testing devices only
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connecting the battery:
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♦ Take the necessary measures when disconnecting the
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battery.
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
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1. Safety information 3
2 Identification
2.1 Gearbox identification

The gearbox code can be found on top of the gearbox, near the
starter.
1 - Gearbox code
2 - Day of production
3 - Month of production
4 - Year of production
5 - Serial number
6 - Minute of production
7 - Hour of production
8 - Factory
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The gearbox code is also indicated on the vehicle data stickers.
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3 Repair notes
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⇒ “3.1 General information”, page 5
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⇒ “3.2 Rules for cleanliness”, page 5
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⇒ “3.3 General repair instructions”, page 6
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⇒ “3.4 Gaskets and seals”, page 7
⇒ “3.5 Nuts and bolts”, page 7
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3.1 General information
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♦ The torque of the engine is transmitted via the flywheel to the
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dual clutch gearbox. The flywheel and the dual clutch are
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joined together by a toothed connection. Together they take
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on the function of the dual-mass flywheel.
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♦ The gearbox is structured like a manual gearbox. Through op‐
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posed hydraulic actuation of the dual clutch, it is operated like
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The feedback for the gearbox concerning the selector lever po‐
sition is not transferred by mechanical means via the selector
lever cable and the multifunction switch (gear sensor) any more,
as is the case for the automatic gearbox. The information con‐
cerning selector lever positions or shifting operations are trans‐
ferred to the gearbox control unit via a separate control unit in the
selector mechanism and the CAN data bus. That is, gears are
shifted without any mechanical cables being involved. Only for
selector lever position “P” the parking lock is engaged mechani‐
cally via the selector lever cable.
Gear change point variations for gradients
An additional gear change map automatically selects gear
changes for gradients dependent upon accelerator pedal position
and driving speed.
• Gear change map for extreme uphill stretches is matched to
engine output.
• Gear change map for extreme downhill gradients is matched
to the braking efficiency of the engine.
• If a gear is selected directly via the Tiptronic system, it is also
possible to use the braking effect of the engine in a specific
gear, e.g. when driving down a slope with a trailer attached.
3.2 Rules for cleanliness

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

parts carefully.
♦ Protect disconnected electrical connectors from dirt and water,
and only reconnect them in dry condition.
3.3 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures. en AG. V
olkswagen AG
ag does
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A number of general notes on the individualyV repair procedures, gu
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which can otherwise be found in the ris relevant sections of the man‐
e nte
ual, are summarised here. They au
thapply
o
for this particular workshop eo
ra
manual. ss c
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un
Guided Fault Finding, vehicle self-diagnosis and test instruments
pt
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♦ Before performing repairs to the gearbox, determine the cause
rm
ab
pe
of the fault as accurately as possible ⇒ Vehicle diagnostic
ility
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tester, Guided Fault Finding , Vehicle Self-Diagnosis
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or Test Instruments .
hole
spec
Special tool
es, in part or in w
t to the co
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools" .
rrectness of i
Gearbox
l purpos
Always make sure that no dirt can enter an »open« gearbox. In

particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
nform
ercia
♦ If gearbox covers have been unbolted or gearbox has no fluid,

m
a
com
do not run engine or tow vehicle. tion in

r
te o
♦ First thoroughly clean connecting points and surrounding

thi
s
iva
areas and then loosen bolts.

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♦ When installing the gearbox, ensure that dowel sleeves be‐

en
ng
t.
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tween the engine and gearbox are correctly located.
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Locking devices
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♦ Do not overstretch retaining rings. cted agen
Prote AG.
♦ Always renew retaining rings which have been damaged or

overstretched.
♦ Retaining rings must locate properly in grooves.
Dual clutch gearbox oil
The oil quality is of critical importance for the function of the gear‐
box.
Shake oil bottle before opening.
Do not mix additives in oil. Do not fill any other oil.
Oil which has been drained out cannot be filled again.

Oil drain and inspection plug

A plastic overflow pipe (with 8 mm hexagon socket head) is lo‐
cated behind this plug -arrow-. Its length determines the oil level
in the gearbox.
3.4 Gaskets and seals

♦ Renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing seals, lightly oil outer diameter and half-fill
space between sealing lips -arrow- with sealing grease -
G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Only use dual clutch gearbox oil. Other lubricants will cause
problems in function.
♦ Coat O-rings with dual clutch gearbox oil to prevent pinching
of rings during assembly.
♦ After renewing gaskets, O-rings and seals, check oil level in
gearbox and top upagifennecessary
AG. Volkswag⇒enpage
AG do 163 .
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3.5 Nuts and bolts
se ran
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♦ Loosen
ss and tighten securing bolts and securing nut for covers
ce
le
and housings diagonally.

un
pt
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♦ Specified torques given are for unoiled nuts, bolts and screws.
y li
erm
ab
ility
♦ Clean threads of bolts which are to be installed with locking

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fluid using a wire brush. Then insert bolts with locking fluid -
is n
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AMV 185 101 A1- .

ole,
spec
urposes, in part or in wh
♦ Use a thread chaser to clear residual locking fluid from all

t to the co
threaded holes into which self-locking bolts are to be screwed.

Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
rrectne
♦ Check pitch of thread, to ensure correct thread chaser is used

to clean threads and to ensure the threads are not damaged.
ss o
♦ Always renew self-locking bolts and nuts.

cial p
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mer
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3. Repair notes 7
4 Technical data n AG . Volkswagen AG

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4.1 Allocation gearbox - engine
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4.1.1 Passat 2015 ►, Passat Estate 2015 ►
erm
ab
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Take account of the gearbox code if spare parts are required for
is n
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a repair.
ole,
spec
Dual clutch gearbox 0DL, all-wheel drive
t to the co
Identification code QAX, RCG, SDR, QBB, SDM
TJG, TJM
rrectne
Engine 2.0 l - 176 kW TDI 2.0 l - 162 kW TSI
4.1.2 Tiguan 2016 ►
ss o
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form
mer
a repair.
atio
om
n
c
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or
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Identifica‐ QAY, QBB, QAY,TAH, QBA,

t
sd
va
tion code RPN, RPL, SDK,TFQ, RPM,

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SDK, RPP, RPN,TNZ, SDL,

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TFR SDN, TFR,TUS TFS,

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TAH, TNY TJL
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Engine 2.0 l - 2.0 l - 2.0 l - 2.0 l -
AG.
2.0 l -
105, 110 130, 132, 169 kW 176 kW
kW TDI 140 162 kW TSI TDI
kW TDI TSI
Dual clutch gearbox 0DL, front-wheel drive

Identification code QAZ, RPK, SDS,
TFU
Engine 2.0 l - 110 kW TDI
4.1.3 Arteon 2018 ►

a repair.
Identification code RWU, TFT, TJM
Engine 2.0 l - 176 kW TDI
4.2 Capacities
Capacity Dual clutch gearbox 0DL
Initial filling 7.0 l ± 0.1 l
Changing approx. 5.5 litres
♦ Change interval: ⇒ Maintenance manual and/
or ⇒ service tables “ELSA”
Lubricant Dual clutch gearbox oil

The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .

Further information in the part number designates the container

size.
Capacity Front bevel box

Capacity of bevel box 0A6 0.9 l
⇒ page 34
Capacity of bevel box 0CP 0.75 l
⇒ page 34
Changing Filled for life, no change
Lubricant Gear oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
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4. Technical data 9
5 Electrical components
5.1 Overview of fitting locations - electrical components
AG . Volkswagen AG
1 - Mechatronic unit for dual ksw
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clutch gearbox - J743- yV
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rise
❑ Removing and installing nte
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⇒ page 26 s aut ra
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s
2 - Gearbox input speed send‐
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er - G182- and oil temperature
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sender in multi-plate clutch -
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G509-
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❑ Both senders are com‐
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bined in one component
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and can be renewed to‐
spec
gether only.
t to the co
❑ Removing and installing
⇒ page 32
rrectne
❑ Before removal of the
sender, the mechatronic
unit for dual clutch gear‐
ss
box - J743- must be re‐
o
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moved ⇒ page 26 .
inform
mer
❑ Discontinued as of gear‐
box date 06/15 atio
om
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3 - Selector lever - E313-

thi
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❑ With selector lever sen‐

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sors control unit - J587- ,

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selector lever lock sole‐

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❑ The components are in‐
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tegrated into the printed
circuit of the selector
mechanism and cannot
be renewed separately
❑ Checking ⇒ vehicle di‐
agnostic tester
selector mechanism ⇒ page 71

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

Replacement parts
1 - Retaining ring for dual

clutch end cover
❑ Renew after removal
2 - Retaining ring for dual
clutch
3 - Retaining ring for drive plate
4 - Dual clutch
Caution
The
♦ drive plate has to re‐
main engaged betweenAG. Volkswagen A
the teeth of theolkouter
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If♦theutdrive
ho plate de‐ or
taches,
ss
a the plates in the ac
dual clutch can shift. It
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may then not be possible

du
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to adjust the clutch cor‐

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rectly when it is installed.

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5 - Shims
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spec
❑ 10 spacer rings which

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have different »thick‐

t to the co
nesses«. They are sized

in 0.05 mm increments.
rrectness of i
❑ Thickness of spacer ring

must be determined
l purpos
when installing dual

clutch.
nform
ercia
6 - Dual clutch end cover

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1. Clutch 11
Caution
♦ This figure is intended only to provide an overview of the

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

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Special tools and workshop equipment required ho eo
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♦ Clean assembly sleeve - T10459- before using. Do not use a
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scratched sleeve.
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es, in part or in w
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rrectness of i
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Brief description
nf
ercia
orm
The cover is held in its seat by a retaining ring. After the retaining
m
atio
m
ring has been removed, the cover can be levered out of its seat.
o
n in
c
Cover and retaining ring must always be renewed. Never install

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

iv
o
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rp
cu
to leak!
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Removing
Co
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The gearbox must be removed for work on cover.
rig ht
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– Drain gear oil ⇒ page 165 .
cted agen
Prote AG.
– Remove gearbox ⇒ page 89 .

– Secure gearbox to assembly stand ⇒ page 158 .
Often, doubts arise as to whether the filter must be renewed or
not.
Note
It is not always necessary to change the oil filter ⇒ page 160 .
12 Rep. gr.30 - Clutch

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ra
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ss 7-speed c dual clutch gearbox 0DL - Edition 07.2018
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nl
pt
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– Remove filter if necessary ⇒ page 160 .
an
itte
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t to the co
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ion
c
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ate
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– Lever out retaining ring -2- of clutch end cover using screw‐
. Cop py
driver -1- -arrow- and remove.
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Cover can be levered out with a screwdriver.
by lksw
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Prote AG.
Note
The removed cover and retaining may not be installed again.
Install only a »new« cover.
Installing
Caution
Cover and retaining ring must always be renewed.

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

stickers are present, remove them carefully.
AG. Volkswagen AG d
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– The running surface on the end of the shaft
aut of the clutch ra
c
-arrow- must be free of oil and dry. ss
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– If necessary, thoroughly clean running surface.
an
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WARNING
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The centre seal of the new cover must be »preformed« before
hole
spec
installing:
es, in part or in w
t to the co
rrectness of i
l purpos
– Clean assembly sleeve - T10459- “before using”. Do not use

a scratched sleeve.
nform
ercia
– Set sleeve on a flat surface.

m
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ion
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or
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ate
do
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– Guide cover horizontally and evenly over entire sleeve
-as shown in this figure-. This will bring the sealing lip into in‐
stallation position.
– Remove sleeve upwards out of cover and set sleeve on end
of clutch shaft.
– Moisten outer seal of cover with oil.
Caution
Moisten only the outer seal of the cover with oil. Oiling the inner
seal will always cause leaks.

– Guide cover horizontally over sleeve and press evenly onto its
seat.
Caution
wage es n
Work carefully. Any sort of blow to the ycover
Vol
ks is certain to cause ot g
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leaks. ris
ed b ran
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ility
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It is possible to lever cover carefully into its seat with a
h re
-screwdriver- until »new« retaining ring can be installed.
hole
spec
– Install new retaining ring.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
– Do not remove bush until retaining ring is installed.
his
ate
do
riv
– Installing gearbox ⇒ page 147

p
cum
for
en
g
– Top up gear oil ⇒ page 165 .

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WARNING
p by
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Do not start engine if there is no oil in gearbox.
1.3 Removing dual clutch

Special tools and workshop equipment required
♦ 2 x hooks - 3438-
1. Clutch 15
♦ Puller - T10055-
♦ Puller - T10525-
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Brief description
du
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• The axial play of the clutch is readjusted during installation
ab
ility
procedure.
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• To remove or install clutch, gearbox must be securely attached
h re
hole
to an assembly stand in vertical position ⇒ page 158 . Only

spec
this way is it possible later to adjust axial play of the clutch
es, in part or in w
without error. t to the co

Removing
rrectness of i
– Remove clutch end cover ⇒ page 12 .

l purpos
Important! Installation location of drive plate

– Check that marking on drive plate -arrow- aligns with the mark‐
nform
ercia
ing on the outer plate carrier.

m
at
If there is no marking:
om
ion
c
in t
r
– Mark installation position of drive plate relative to periphery of

o
his
te
outer plate carrier with permanent marker, as shown in illus‐

a
do
riv
tration.
p
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en
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• During installation, drive plate must always be repositioned at

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marked position. C py
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Note Prote AG.
The retaining ring is renewed together with the clutch. If the clutch
which is removed is reinstalled, the securing ring is to be used
again as well.

AG. Volkswagen AG d
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Arteon 2018 ➤ ,auPassat
th 2015 ➤ , Passat Variant 2015 ➤ , Tiguan r a 2016 ➤ , ...
s c
s 7-speed dual clutch gearbox 0DL - Edition 07.2018
ce
e
nl
pt
du
an
– Lever out retaining ring -2- of drive plate using screwdriver
itte
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erm
-1- -arrow-.
ab
ility
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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– Apply puller - T10525- together with puller - T10055- on
C py
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splines and carefully pull drive plate off its seat -arrows-. rig ht
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Prote AG.
– Remove retaining ring -arrow- and save it for now.
Note
Do not dispose of the retaining ring yet because it will be needed

to measure axial clearance.
1. Clutch 17
– Remove shim -arrow-.
Caution
Carefully remove the dual clutch. Take care that no parts fall
out. Therefore, do not turn the clutch over!
AG. Volkswagen AG d
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– Engage 2 hooks - 3438- ons a opposite sides of clutch -arrow-.
u t ra
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ab
ility
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t to the co
rrectne
– Remove dual clutch using hooks - 3438- .
ss o
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mer
atio
om
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c
i
or
n thi
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1.4 Installing dual clutch

♦ Universal dial gauge holder - VW 387-

♦ Dial gauge - VAS 6079-

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♦ Retaining pins - T10524-
rrectness o
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mer
atio
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c
i
or
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Cop py
♦ Drift sleeve - 40-21-
t. rig
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Prote AG.
Caution
♦ The drive plate has to remain engaged between the teeth

of the outer plate carrier.
♦ If the drive plate detaches, the plates in the dual clutch can
shift. It may then not be possible to adjust the clutch cor‐
rectly when it is installed.
♦ Do not lift (not even slightly) or remove plate carrier! The
plates could turn.
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
1. Clutch 19
Installing
– Take great care when removing the dual clutch from its pack‐
age.
– Turn piston rings by hand. They must move freely and must
not bind.
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
align.
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
Important! Position of drive plate

– Before installing, check if there is a marking -arrow- on dual
clutch.
– If there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the gouter
en AG.plate
Volkswcarrier.
agen AG
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ab
pe
ility
– Insert retaining pin - T10524- .

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The retaining pin - T10524- should be held by a second mechanic

hole
spec
while the dual clutch is being inserted.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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en
ng
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Cop py
t. rig
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Prote AG.

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

– If necessary, insert clutch by turning slightly.
AG. Volkswagen AG d
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The dual clutch is properly ed bfitted if there is almost no play in the
y V gu
ara
retaining pin - T10524-hor.is nte
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Note
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♦ The retaining pin remains inserted until the clutch end cover
pe
ility
is installed.
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♦ The dual clutch must now not be rotated any more, as this can
hole
shift the position of the retaining pin - T10524- .
spec
es, in part or in w
t to the co
rrectness of i
– Lever out retaining ring -2- of drive plate using screwdriver
-1- -arrow-.
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Note
nform
mercia
This retaining ring will be used again. Do not dispose of it.

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1. Clutch 21
– Apply puller - T10525- together with puller - T10055- on

splines and carefully pull drive plate off its seat -arrows-.
Note
The retaining pin - T10524- must be held by a second mechanic

while pulling off.
– Carefully remove drive plate from dual clutch -arrows- and

place it on one side.
Caution
Do not lift (not even slightly) or remove plate carrier! The plates
could turn.
Determining shim for dual clutch:

• The retaining pin - T10524- remains installed!
– Temporarily install “old” retaining ring -arrow-.

Before this ring is finally disposed of, 3 measurements must be
made.
First measurement (axial play of shaft)
– Screw universal dial gauge - VW 387- to gearbox flange.
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– Set -tip of dial gauge- on input shaft.
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– Set ut
-dial gauge- to 0 with preload.
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– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.
Note
This value will be needed later for the check measurement so G. Volkswagen
save value “A” until the last measurement has been performed.
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– Set -dial gauge- to 0 with preload again.
– Lift dual clutch with force to stop and note measurement.
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– Call this value “B”.
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– Use this formula:

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Value “B” minus value “A” minus 0.11 = thickness of shim to
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be fitted.
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WARNING
AG.
Always use the next-largest shim, never the next-smallest.
Example:
Calculated dimension for shim New shim
1.28 mm 1.3 mm
1.26 mm 1.3 mm
– Remove old retaining ring -arrow-.
Note
Do not dispose of ring yet; it will be needed once more.
1. Clutch 23
– Fit calculated shim.

Third measurement (check measurement)
To make sure that the shim is correct, a test measurement must
still be carried out. Proceed as follows:
– Install old retaining ring -arrow- once more.
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Set the tip of the dial gauge on the shim -1-.

– Set -dial gauge- to 0 with preload again. olkswage es n
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– Lift dual clutch with force to stop and
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– Call this value “C”. ss
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This specification must lie between 0.05 and 0.12 mm.

hole
spec
If the specification is not attained, then achieve the specification

es, in part or in w
by fitting a thicker or thinner shim.

t to the co
– Install new retaining ring -arrow-.

rrectness of i
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– Fit drive plate into dual clutch.

• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier -arrows-. If the markings were
subsequently make, align these. en AG. V
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– A second mechanic must hold retaining
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– Starting at the opening, press retaining ring in clockwise di‐
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• The retaining ring must be fully engaged.
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spec
es, in part or in w
– Use screwdriver to check that retaining ring is correctly seated
t to the co
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
and housing.
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– Install clutch end cover ⇒ page 12 .
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1. Clutch 25
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Removing and installing mechatronic unit for dual clutch lkswage es n
gearbox J743 (gearbox installed)”, page 26 d byV
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ua
ran
ir se tee
⇒ “1.2 Removing and installing gearbox input speed sender G182
utho
or
and oil temperature sender in multi-plate clutch G509 up to
ss gear‐
a ac
box date 05/15”, page 32
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1.1 Removing and installing mechatronic
itte
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unit for dual clutch gearbox - J743-
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♦ Up to gearbox date 05/15 release tool - T10465-
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♦ Torque wrench - V.A.G 1331- t. Cop py
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Always make sure that no dirt can enter an »open« gearbox.

In particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- can lead to gearbox failure.
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 160 .
Remove mechatronic unit.
– Move selector lever to position “P”.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
26 Rep. gr.34 - Controls, housing

Note
It is possible that parts having nothing to do with the mechatronic

unit must be removed. This depends on the vehicle's equipment.
This will create enough space to remove the mechatronic unit.
Vehicles with petrol engine

Volkswa
– Remove connecting hose between agen charge air cooler
AG. gen AG
doesand
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charge air pipe ⇒ Rep.bygr.
Vol 21 ; Charge air system; Assembly
not
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overview - charge rair
ise system .
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Continued for all svehicles
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t to the co
– Remove electrical wiring and retainer from front of sump
-arrows- (2 x M6 nuts).
rrectness of i
– Raise wiring in area of sump and secure it.
l purpos
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
nform
ercia
– Drain oil ⇒ page 165 .

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– Remove securing clip -3-.
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– Unscrew bolts -1- diagonally and remove.
by lksw
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– Remove cover -2- with seal.
Note
Always renew bolts, securing clips and the cover with seal.
1. Mechatronic unit 27
Before touching mechatronic unit, touch an earthed object again.
AG. Volkswagen AG d
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To gearbox date 05/15
wit
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– Release connector -1- of gearbox input speed sender - G182-
ole,
spec
and oil temperature sender in multi-plate clutch - G509- using
release tool - T10465- .
t to the co
Continuation for all:
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– Remove bolts -arrows- diagonally.
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All 9 bolts have same length and are not allowed to be reused.
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– Remove mechatronic unit -1- carefully.
Caution
• Lift or put down mechatronic unit only on housing and on

solenoid valves.
Lay mechatronic unit to side properly.

– Put down mechatronic unit so that sensors -arrows- are point‐
ing upwards.
Install mechatronic unit. n AG. Volkswagen AG do
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Install in reverse order of removal. During this procedure,
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WARNING
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Before installing the mechatronic unit, clean the sealing sur‐
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face on the gearbox housing thoroughly without using cleaning
ility
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– Before installation, check that »sender« -1- is installed
⇒ page 32 . rrectne
ss o
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Before touching mechatronic unit, touch an earthed object again.
Caution
• Lift or put down mechatronic unit only on housing and on

solenoid valves.
AG. Volkswagen AG d
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– Carefully insert mechatronic unit -1- into gearbox.
rrectness of i
– Screw in new bolts -arrows- diagonally until finger-tight.
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– Tighten bolts in specified sequence to 8 Nm + 45°.


– Push on connector -1- and engage.
– After this, check that fastener -2- is notAGdamaged.
agen
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Caution ho
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• Work with great scare. The fastener of the connector -2-
ce
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can break. If this has happened, the connector will no
pt
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longer hold and the damaged part, e.g. mechatronic unit
itte
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for dual clutch gearbox - J743- must be renewed.
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– Renew seal -arrow-.
nform
A new mechatronic unit already has a new oil seal.
mercia
– Moisten seal with oil.
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– Set new cover with seal -2- in place and tighten with new bolts
-1- diagonally in several stages to 10 Nm + 45°.
– Install new securing clip -3-.
– Attach wire retainer to cover and tighten nuts to 10 Nm.
– Push on connector for mechatronic unit for dual clutch gearbox
- J743- and engage lock by turning.
– Do not start engine!

– Fill with oil ⇒ page 165 . agen
AG. Volkswagen AG d
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– Install noise insulation ⇒ General body repairs, exterior;d b Rep.
y gu
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gr. 66 ; Noise insulation; Assembly overview – noise rise insula‐ nte
ho eo
tion . s aut ra
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– Conduct basic adjustment of mechatronic unit for dual clutch
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gearbox - J743- .
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nf
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1.2 Removing and installing gearbox input
orm
speed sender - G182- and oil tempera‐
m
atio
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n in
ture sender in multi-plate clutch - G509-
or c
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up to gearbox date 05/15

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♦ As of gearbox date 06/15, the gearbox input speed sender -
cop Vo
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G182- and the oil temperature sender in multi-plate clutch -
cted agen
Prote AG.
G509- have been discontinued.
♦ If a sender is fitted, a sender must be reinstalled after it has
been removed.
♦ The following procedure applies only to gearboxes in which a
sender is fitted.
Brief description
Both senders are combined in one component and can be re‐
newed together only. They are in the gearbox near the multi-
clutch. Before removal, the mechatronic unit for dual clutch
gearbox - J743- must be removed.
Removing
– Remove mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
Do not pull on line!
– Unscrew and remove bolt -2- and pull out sender -1-.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Reinstall »old« sender only if:
• The sender has no defect
• The cable was not pulled on when it was removed
– Moisten sender with dual clutch gearbox oil and install.

– Tighten bolt -2- to 10 Nm.

– Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
lkswage es n
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⇒ “2.1 Distinguishing between different types of bevel boxes”,
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page 34
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⇒ “2.2 Removing and installing bevel box”, page 35
erm
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⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
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page 57
h re
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2.1 Distinguishing between different types
t to the co
of bevel boxes
The bevel box installed in the vehicle could be “0A6” or “0CP”.
rrectne
Bevel boxes can be identified by means of the following:
s
Distinguishing feature with bevel box installed:
s o
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f i
Determine version of bevel box by recess -arrow- in right area of
nform
subframe.
mer
atio
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Remove following components if necessary:

o
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– Noise insulation ⇒ General body repairs, exterior; Rep. gr.
te
sd
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66 ; Noise insulation .
i
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– Centre underbody cladding ⇒ General body repairs, exterior;
en
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t.
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Rep. gr. 66 ; Underbody cladding; Removing and installing
Co
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Area denoted by -arrow- is marked with “0A6” or “0CP”.
Additional distinguishing feature with bevel box removed:

Output flange on bevel box “0A6” is secured with a nut -A- ⇒ As‐
sembly overview - bevel box, “0A6” ⇒ page 187 .
Disregard -B- and -arrows-.

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

-A- ⇒ Assembly overview - bevel box, “0CP” ⇒ page 189 .
Located behind retaining ring -A- is a washer -B-.
2.2 Removing and installing bevel box

⇒ “2.2.1 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat Estate 2015 ►, Tiguan 2016 ►, Arteon 2018 ► vehicles with
2.0 l - 176 kW TDI and bi-turbocharger”, page 35
⇒ “2.2.2 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat Estate 2015 ►, vehicles with petrol engine”, page 40
⇒ “2.2.3 Removing and installing bevel box, Tiguan 2016 ►”, page
48
2.2.1 Removing and ksw installing bevel box, not Passat 2015 ►, Passat Estate 2015 ►,
AG n AG d . Volkswage
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2. Bevel box 35
. Volkswagen AG
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Special tools and workshop
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♦ Multi-purpose tool - VW 771-

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

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

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

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

after the cooler has been removed. This makes it easier to remove
the bevel box later.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box. AG. Volkswagen A n G do
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t to the co
– Remove upper securing bolts -arrows- securing bevel box to

gearbox.
rrectness o
cial p
f inform
mer
atio
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n
c
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2. Bevel box 37
. Volkswagen AG
gen AG does
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤y V, Tiguan 2016 ➤ , ...
olk not
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7-speed dual clutch gearbox 0DL - Edition 07.2018 ris ed
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– Loosen lower securing bolts securing bevel box to gearbox
ss c
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and unscrew only as far as dimension -a-.
nl
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Dimension -a- = 15 mm.
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This prevents the bevel box from falling down immediately when
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loosened using multi-purpose tool - VW 771- .
, is n
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es, in part or in w
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– Fit puller - T 10472- to bevel box. l purpos
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ion
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Prote AG.
– Prepare multi-purpose tool - VW 771- with a washer -a- and 2

sleeves from the supplementary set for engine and gearbox
support - VW 540/1 B- as shown in the illustration.
– Bolt multi-purpose tool - VW 771- onto puller - T10472- and

loosen bevel box from gearbox.
– Remove multi-purpose tool - VW 771- and puller - T10472-
from bevel box.

– Unscrew lower securing bolts -arrows- and remove bevel box.

Installing
When installing, note the following:
– Grease splines of differential with grease for clutch plate

splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
– Insert bevel box and press against gearbox as far as it will go.
AG. Volkswagen AG d
agen oes
Note Volksw not
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d by ara
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Turn stub shaft if spline position is unfavourableut (bevel box cannot
ho eo
ra
be pressed to stop against gearbox). ss a c
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nl
pt
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– If splines are correctly positioned and shafts are centred, then
an
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bevel box will slide to stop against gearbox.
erm
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Caution
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spec
To ensure that the retaining ring of the stub shaft engages
es, in part or in w
t to the co
properly in the differential bevel gear, strike the face of the
spline stub with a plastic hammer. Do not pull bevel box force‐
fully against gearbox by turning securing bolts. Damage to
gearbox or bevel box could result.
rrectness of i
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– Screw on bevel box with new bolts -arrows- until finger-tight,

nf
ercia
then tighten. Specified torque: ⇒ page 88 . orm

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2. Bevel box 39
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– Unbolt gearbox carrier for bevel box.
ut
ho Observe installation lo‐ or
cation and tightening sequencess aof bolts ⇒ page 88 . ac
ce
e
nl
– Install exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
pt
du
an
haust gas recirculation system; Removing and installing ex‐
itte
y li
erm
haust gas recirculation cooler .
ab
ility
– Install right drive shaft ⇒ Running gear, axles, steering; Rep. ot p
wit
, is n
gr. 40 ; Drive shaft; Removing and installing drive shaft .
h re
hole
spec
– Check gear oil in bevel box ⇒ page 171 .
es, in part or in w
t to the co
– Following installation, check oil level in gearbox
⇒ page 163 .
rrectness of i
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation .
l purpos
Specified torques: ⇒ page 88
nf
ercia
o
2.2.2 Removing and installing bevel box, Passat 2015 ►, Passat Estate 2015 ►,
rm
m
atio
m
vehicles with petrol engine

o
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or c
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equipment required
f
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♦ Supplementary set for engine and gearbox support - VW 540/1

B-
♦ Puller - T 10472-
♦ Counter-hold tool - T10172A-
♦ Engine support - T10533-
AG. Volkswagen AG d
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t to the co

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ss

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f inform
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Note
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om
n
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So that the propshaft can be turned later in order to loosen it:

thi
te
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iva
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– Move selector lever to »N« position.

um
r
fo
en
ng
t.
yi
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
Co
op py
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation
t. C rig
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pyri by
Vo
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cted agen
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2. Bevel box 41
– Disconnect connector -1- from oil level and oil temperature

sender - G266- .
olkswagen AG
en AG. V
– Remove right drive shaft ⇒ Running gear, axles,osteering;
ksw
ag does
not
V l
Rep. gr. 40 ; Drive shaft; Removing and installing
ed
by drive shaft . gu
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es, in part or in w
– Remove drive shaft heat shield -1-, if present, from bevel box
t to the co
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
rrectness of i
Caution
l purpos
Risk of damage to decoupling element.
nform
ercia
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly

overview - emission control .
m
at
om
ion
c
in t
or
his
te
– Remove front exhaust system from engine, raise it and tie it in

a
do
riv
place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly

p
cum
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overview - silencer .
f
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t.
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If fitted, remove heat shield for propshaft. C py
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co
– Unscrew bolts -A- and -B- from bevel box, and remove heat
by lksw
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shield -1-.
AG.
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output shaft of bevel box -arrows-.

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agen AGgearbox 0DL - Edition 07.2018
doe
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– Unbolt front propshaft from bevel box ris -arrows-.
e d
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c
ss
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an
d
itte
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erm
ab
ility
ot p
wit
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h re
ole,
spec
t to the co
rrectne
– If necessary, counterhold at rear final drive when loosening or
tightening propshaft.
ss o
cial p
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Note
form
mer
atio
m
To loosen »next« bolt, turn propshaft further by turning rear

o
n
c
i
wheels at same time.
or
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te
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t.
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Cop py
t. rig
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by c lksw
– Unscrew pendulum support bolts -1- from gearbox. cted agen
Prote AG.
– Place a cloth on subframe to avoid damaging paint of prop‐

shaft when it is placed on subframe.
– Push font propshaft back to stop. Make sure not to damage

seal -arrow- in centring bush.
2. Bevel box 43
– Guide propshaft upwards into tunnel, and

nA use
G. Volkswa
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of wood to support it on subframe. does
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pe
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es, in part or in w
t to the co
– Set up engine support - T10533- as shown in figure and tighten
bolts hand-tight.
rrectness of i
• -A- thin end
l purpos
• -B- thick end

Bolt -3- = original pendulum support bolt
nform
ercia
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded

m
a
com
t
hole for noise insulation.
ion in
r
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It may be necessary to push the gearbox forwards slightly in order
thi
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to attach the engine support - T10533- .
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– Force engine/gearbox as far forwards as possible by turning en

ng
t.
spindle of engine support - T10533- . Avoid collisions between
yi Co
op py
components and radiator cowl. t. C rig
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– Unbolt gearbox carrier.
co Vo
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– Unscrew bolts -1- and -2-, and remove carrier from bevel box.

gearbox.

olksw
AG. V agen AG
agen does
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– Loosen lower securing bolts securing bevel box db
yto
V gearbox
o gu
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and unscrew only as far as dimension -a-. orise nte
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Dimension -a- = 15 mm. s au ra
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an
itte
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
– Fit puller - T 10472- to bevel box.
rrectness of i
l purpos
nf
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orm
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Cop py
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from bevel box.
2. Bevel box 45

Installing
AG. Volkswagen AG d
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– Grease splines of differential with
Vol grease for clutch plate
ksw not
gu
splines - G 000 100- . se
d by ara
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th or eo
– Install new retaining ring
au -arrow A- and new O-ring -arrow B- ra
c
on right stub shaft. ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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Note
wit
, is n
h re
hole
Turn stub shaft if spline position is unfavourable (bevel box cannot
spec
be pressed to stop against gearbox).
es, in part or in w
t to the co
rrectness of i
l purpos
Caution nform
ercia

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at
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io

n
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or

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ate
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then tighten. Specified torque: ⇒ page 88 .
t. C rig
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– Install gearbox carrier. Observe installation location and tight‐
c by lksw
cted agen
ening sequence of bolts ⇒ page 88 . Prote AG.

– Mount drive shaft heat shield -1-, if present, on bevel box

shaft .
– Fit propshaft on bevel box.
AG. Volkswagen AG d
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nl
pt
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Note
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erm
ab
When removing and installing the bevel box, do not damage the
ility
ot p
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Join bevel box and propshaft by turning spindle of engine sup‐

port - T10533- .
nform
ercia
– Remove engine support - T10533- .

m
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.
– Bolt propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Propshaft;

Removing and installing propshaft .
– If present, install heat shield for propshaft.
2. Bevel box 47
Version 1:
Version 2:
– Secure pendulum support to gearbox using new bolts -1-.

Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings . . Volkswagen AG
gen AG does
swa
– Install right drive shaft ⇒ Running gear, axles, steering; Rep. by
Vol
k not
gu
gr. 40 ; Drive shaft; Removing and installing drive shaftris.ed ara
nte
tho eo
– Install parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust
au pipes/ ra
c
ss
silencers .
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
⇒ page 163 .
wit
is n
h re
ole,
spec
Specified torques: ⇒ page 88 t to the co
2.2.3 Removing and installing bevel box, Ti‐

rrectne
guan 2016 ►
ss o
cial p
f in
Note
form
mer
atio
m
The following procedure does not apply to vehicles with bi- tur‐
o
n
c
bocharger.
i
or
n thi
te
sd
iva
o
r
Removing and installing bevel box - vehicles with 2.0 l - 176 kW

p
cum
r
fo
TDI engine and bi-turbocharger ⇒ page 35

en
ng
t.
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equipment required
AG. Volkswagen AG d
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or eo
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aut ra
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nl
pt
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an
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erm
ab
ility
ot p
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, is n
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate

do
priv
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or

f
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t.
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op
♦ Supplementary set for engine and gearbox support - VW 540/1 C py
t. rig
B-
gh ht
pyri by
Vo
o
by c lksw
♦ Puller - T 10472- cted agen
Prote AG.
♦ Counter-hold tool - T10172A-
2. Bevel box 49
♦ Engine support - T10533-
Removing
height.
Note

Note
swage es n
So that the propshaft can be y Vturned later in order to loosen it:
olk ot g
d b ua
ran
ir se tee
ho
– Move selector leverau to »N« position.
t or
ac
ss
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
ce
le
un
pt
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation

an
d
itte
y li
erm
ab
Vehicles with petrol engine:

ility
ot p
wit
is n
– Remove connecting hose between charge air cooler and

h re
ole,
charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly

spec
overview - charge air system .

t to the co
Vehicles with diesel engine:

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

– Disconnect connector -1-.

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

sender - G266- .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Remove drive shaft heat shield -1-, au
ifsspresent, from bevel box ac
ce
e
nl
pt
shaft .
du
an
itte
y li
erm
ab
ility
Caution
ot p
wit
, is n
h re
Risk of damage to decoupling element.
hole
spec
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
es, in part or in w
t to the co
overview - emission control .
rrectness of i
– Remove front exhaust system from engine, raise it and tie it in
place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
l purpos
overview - silencer .
If fitted, remove heat shield for propshaft.
nf
ercia
orm
m
atio
– Unscrew bolts -A- and -B- from bevel box, and remove heat
om
n in
shield -1-.
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Bevel box 51
– Mark position of propshaft with flexible coupling relative to

output shaft of bevel box -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Unbolt front propshaft from bevel box -arrows-.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
– If necessary, counterhold at rear final drive when loosening or

um
r
fo
tightening propshaft.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
To loosen »next« bolt, turn propshaft further by turning rear
wheels at same time.
– Unscrew pendulum support bolts -1- from gearbox.

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

AG. Volkswagen AG d
agen oes
ksw
VArteon 2018 ➤ , Passat 2015 o➤ gu, Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
ol n t
d by ara
orise 7-speed ndual
tee clutch gearbox 0DL - Edition 07.2018
h
aut or
a
– Push ss propshaft back to stop. Make sure not to damagec
font
ce
le
seal -arrow- in centring bush.
un
pt
an
d
itte
y li
– Place front propshaft on heat shield or on subframe as appro‐
rm
ab
priate.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Set up engine support - T10533- as shown in figure and tighten

bolts hand-tight.
nform
ercia
• -A- thin end

m
a
com
tio
• -B- thick end
n in
r
te o
thi
Bolt -3- = original pendulum support bolt
s
iva
do
r
rp
c
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded
um
fo
en
g
hole for noise insulation.

n
t.
yi Co
op py
It may be necessary to push the gearbox forwards slightly in order
t. C rig
gh ht
yri
to attach the engine support - T10533- . p by
o Vo
by c lksw
cted agen
– Force engine/gearbox as far forwards as possible by turning
Prote AG.
spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
– Unbolt gearbox carrier for bevel box.
Diesel engine:
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box.
Petrol engine:
– Unscrew bolts -1- and -2-, and remove carrier from bevel box.
2. Bevel box 53
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant
olkswage2015 ➤ , Tiguan 2016 ➤ , ...
en AG. V n AG d
7-speed dual clutch gearbox 0DL
olksw-agEdition 07.2018 oes
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– Remove upper securing boltsho -arrows-
ris
securing bevel box to eo
gearbox. aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
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fo
en
ng
t.
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Cop py
t. rig
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from bevel box.

Installing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
splines - G 000 100- .
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nform
ercia

m

com
tion in
r
te o
thi
Caution
s
iva
do
r
rp
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fo

en
ng
t.
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op py
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ht ht
rig by
opy Vo
by c lksw
cted agen
Prote AG.
2. Bevel box 55

– Unbolt gearbox carrier for bevel box. Observe installation lo‐
cation and tightening sequence of bolts ⇒ page 88 .
– Mount drive shaft heat shield -1-, if present, on bevel box

shaft .
– Fit propshaft on bevel box.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
Note
nl
pt
du
an
itte
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erm
When removing and installing the bevel box, do not damage the
ab
ility
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Join bevel box and propshaft by turning spindle of engine sup‐

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

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

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

Removing and installing propshaft .
– If present, install heat shield for propshaft.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
– Secure pendulum support to gearbox
ss a using new bolts -1-. c
Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
ce
e
nl
pt
sembly overview - assembly mountings .
du
an
itte
y li
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
erm
ab
ility
gr. 40 ; Drive shaft; Removing and installing drive shaft .
ot p
wit
, is n
– Install parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/
h re
hole
silencers .
spec
es, in part or in w
Continue installation in reverse order of removal.

t to the co
rrectness of i
⇒ page 163 .
l purpos

nf
ercia
Specified torques: ⇒ page 88

rm
m
atio
om
n in
c
2.3 Detaching bevel box from gearbox -

or
thi
te
sd
gearbox removed
iva
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Bevel box 57
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d

itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
♦ Puller - T 10472-
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove gearbox with bevel box ⇒ page 89 .
– Secure gearbox with bevel box to assembly stand
⇒ page 158 .
In the following illustrations the bevel box is shown in installed
condition.
gearbox.


This prevents the bevel box from falling down immediately. Vwhen
olkswagen AG
loosened using multi-purpose tool - VW 771- . kswagen AG does
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– Bolt multi-purpose tool - VW 771- onto puller T10472 and
thi
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Installing
2. Bevel box 59

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


bevel box will slide against contact surface on gearbox.
Caution AG. Volkswagen AG d

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Retaining ring on stub shaft must engage correctly in differen‐sed b ara
nte
tial bevel gear. If retaining ring is not engaged, there is a risk
thori
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that stub shaft might move outwards. ss au ra
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Also, bevel box is not allowed to be bolted onto gearbox force‐

nl
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fully. Damage to gearbox or bevel box could result in both
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cases.
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– To ensure that the retaining ring engages properly in the dif‐
hole
ferential bevel gear, strike the face of the spline stub several
spec
es, in part or in w
times with a plastic hammer (weight 1000 - 2000 g).
t to the co
rrectness of i
– Installing gearbox ⇒ page 147
l purpos
– After installing gearbox, check oil level and top up

⇒ page 163 .
nform
mercia
at
om
ion
c
in t
or
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ate
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3 Selector mechanism
⇒ “3.1 Assembly overview - selector mechanism”, page 61
⇒ “3.2 Emergency release from position P”, page 64
⇒ “3.3 Removing and installing selector lever handle”,
page 65
⇒ “3.4 Moving push-button in the handle to installation position”,
page 70
⇒ “3.5 Removing and installing selector mechanism”, page 71
⇒ “3.6 Removing and installing gear selector cable”, page 78
⇒ “3.7 Checking selector mechanism”, page 83
⇒ “3.8 Checking and adjusting selector lever cable”, page 83
⇒ “3.9 Renewing selector shaft seal”, page 85
3.1 Assembly overview - selector mecha‐

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

2015 ►, Arteon 2018 ►
AG. Volkswagen AG d
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mer
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3. Selector mechanism 61
1 - Handle with selector cover

❑ Do not remove handle AG. Volkswagen AG d
without reason. For agen oes
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emergency release, on‐ d by gu
ara
ly the cover needs to be rise nte
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unclipped ⇒ page 64 . s aut ra
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⇒ page 65
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2 - Bolt
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❑ Qty. 4
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❑ 8 Nm
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spec
3 - Selector mechanism
t to the co
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
rrectne
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
ss
in P - F319- and selector
o
cial p
f
lever lock solenoid -
inform
N110-
mer
atio
om
n
⇒ page 71
c
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or
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4 - Selector lever cable
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❑ Selector lever cable is
um
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not greased yi
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⇒ page 78
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❑ Checking ⇒ page 83
by
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❑ Adjusting ⇒ page 83
5 - Securing clip
6 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
7 - Selector housing
8 - Cover
9 - Bolt
❑ For selector cable support bracket to gearbox
❑ Qty. 2
❑ 20 Nm + 90°
10 - Gearbox
11 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm

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

⇒ page 65
2 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid -
N110-
⇒ page 71
3 - Bolt
❑ Qty. 4
❑ 8 Nm n AG. Volkswagen AG do
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4 - Plug d byV ua
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5 - Hexagon flange nut utho
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❑ 8 Nm
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6 - Selector housing
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7 - Gearbox
ot
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8 - Bolt
hole
spec
❑ Always renew after re‐
es, in part or in w
t to the co
moving.
❑ For selector cable sup‐
port bracket to gearbox
rrectness of i
❑ Qty. 2
l purpos
❑ 20 Nm + 90°
9 - Bolt
nform
ercia
❑ Adjuster screw for selector lever cable

m
❑ 13 Nm
com
tion in
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te o
10 - Securing clip
thi
s
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❑ Always renew after removing.

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❑ Installation position: offset side points forwards towards front end.

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op
11 - Selector lever cable C py
t. rig
gh ht
❑ Selector lever cable is not greased yri
p by
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❑ Removing and installing ⇒ page 80 cted agen
Prote AG.
❑ Checking and adjusting ⇒ page 83
3.2 Emergency release from position P

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

Passat 2015 ►, Passat Variant 2015 ►,
Arteon 2018 ►
Do not remove handle agen
AG. Volkswagen AG d
oes
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– Depress brake pedal or set handbrake.
ed by ara
nte
ris
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– Open lid of storage compartment.
aut
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– Grasp under selector lever cover with one hand, and unclip
ce
le
un
pt
cover by pulling it upwards.
an
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erm
– Push selector cover to one side.
ab
ility
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– Using a screw driver, from right side, press yellow plastic part
cial p
f in
and hold in this position.
form
mer
atio
Selector lever can now be moved from position »P«.
om
n
c
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or
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te
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3.2.2 Emergency release from position P, Ti‐

guan 2016 ►
♦ -T10383/2-

Do not remove handle

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

hold in this position.
Selector lever can now be moved from position »P«.
3.3 Removing and installing selector lever

handle swa
gen AG
. Volkswagen AG
does
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Vol gu
⇒ “3.3.1 Removing and installing
ed
by selector lever handle, Passat ara
nte
2015 ►, Passat Estate 2015
oris ►, Arteon 2018 ►”, page 65 eo
th
au ra
⇒ “3.3.2 Removing and
ss installing selector lever handle, Tiguan c
ce
le
2016 ►”, page 67

un
pt
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3.3.1 Removing and installing selector lever

erm
ab
ility
handle, Passat 2015 ►, Passat Estate

ot p
wit
is n
2015 ►, Arteon 2018 ►

h re
ole,
spec

t to the co
♦ Hose clip pliers - V.A.G 1275-

rrectness o
cial p
f inform
mer
atio
om
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c
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Brief description C py
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Handle is removed together with selector cover. cop Vo
by lksw
cted agen
Prote AG.
Removing
– Shift selector lever to position “D”.
The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Disconnect electrical connector.
AG. Volkswagen AG d
agen oes
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– Cut open clamp -arrow- under boot using side cutters.
, is n
h re
hole
– Pull handle upwards off selector lever without pressing push

spec
button.
es, in part or in w
t to the co
Note
rrectness of i
Do not press button again after removal as it will no longer be

l purpos
possible to install the handle.

nform
ercia
Installing
m
Install in reverse order of removal, observing the following:

com
tion in
r
• Selector lever is in position “D”.

te o
thi
s
iva
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Note
erm
ab
ility
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wit
♦ It might be possible for the button to be pressed into the han‐
, is n
h re
dle. Never install a handle with the button pressed in.
hole
spec
♦ Move push-button to installation position ⇒ page 70 .
es, in part or in w
t to the co
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
rrectness of i
l purpos
nf
ercia
– Push on handle with new clamp -arrow- to stop. Do not tighten

orm
clamp yet.
m
atio
om
– Push button after installation.

n in
or c
thi
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Note
o
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If not installed correctly, the button remains inserted in the handle Cop py
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after being pressed. If this happens, pull handle off again and gh ht
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move push button to installation position again ⇒ page 70 . cop Vo
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Then, fit the handle again.
cted agen
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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg D4B804A300A

1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1 Distinguishing between different types of bevel boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.3 Detaching bevel box from gearbox - gearbox removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.9 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

39 - Final drive - differential

2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

2.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

2.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

2.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

3 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

3.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

3.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

1.1 General safety provisions

Risk of injury and accident by accidental engagement of gear

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

trical and electronic components, observe the following:

♦ Connect and disconnect measuring and testing devices only

with the ignition switched off.

To prevent damage to the electronic components when dis‐

♦ Take the necessary measures when disconnecting the

♦ Disconnect battery only after the ignition has been switch‐

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

Disconnecting and reconnecting battery .

1.2 Safety measures when working on ve‐

Injury hazard as a result of automatic engine start in vehicles

1.3 Notes on tow-starting/towing

Caution AG. Volkswagen AG d

1.4 Safety precautions when using testers

and measuring instruments during a

Observe the following if test and measuring equipment is required

during a road test:

Risk of accident due to distraction and inadequate securing of

2 Rep. gr.00 - Technical data

connecting the battery:

2.1 Gearbox identification

4 Rep. gr.00 - Technical data

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

3.2 Rules for cleanliness

♦ If repair work cannot be performed immediately, cover opened

3.3 General repair instructions

Guided Fault Finding, vehicle self-diagnosis and test instruments

of the fault as accurately as possible ⇒ Vehicle diagnostic

tester, Guided Fault Finding , Vehicle Self-Diagnosis

Always make sure that no dirt can enter an »open« gearbox. In

♦ If gearbox covers have been unbolted or gearbox has no fluid,

do not run engine or tow vehicle. tion in

♦ First thoroughly clean connecting points and surrounding

areas and then loosen bolts.