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Service

Workshop Manual
AG. Volkswagen AG d
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Sharan 2016 ➤
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Tiguan 2008 ➤
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7-speed dual clutch gearbox 0BH


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Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

AG. Volkswagen AG d
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00 - Technical data

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30 - Clutch
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34 - Controls, housing

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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 © 2017 Volkswagen AG, Wolfsburg D3E802C2DEC


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

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 Identification of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1 Clutch . . .ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.1 Assembly aut overview - dual clutch . . . . . . . . . . . . . . . . .o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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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........................................................................ 26
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1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
........................................................................ 31
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1.3 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 up to gearbox date 05/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38


2.1 Renewing bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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3 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41


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4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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4.1 Removing and installing handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42


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4.2 Moving push button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 45


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5 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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5.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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5.2 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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5.3 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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5.4 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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6 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54


6.1 Selector lever in “P” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 Selector lever in “N” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.3 Selector lever in position “Tiptronic” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.4 Ignition and light switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.5 Selector lever position indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Contents i
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56


7.1 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.3 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.1 Removing and installing bevel box, vehicles with 2.0 l - 100/103/130 kW diesel engine . . 87
10.2 Removing and installing bevel box, vehicles with petrol engine and vehicles with 2.0 l -
110/135 kW diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.3 Detaching bevel box from gearbox - gearbox removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11 Oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11.1 Renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11.2 Checking oil level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.3 Draining and filling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110


1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111


1 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3 Renewing seals on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2 Renewing right seal (between gearbox and bevel box) on gearbox . . . . . . . . . . . . . . . . . . 116
4 Renewing seals on bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.1 Renewing seals on left (between bevel box and gearbox) gen AG
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4.2 Renewing right seal (drive shaft side) . .y.V. . . . . . . . . . . . . . . . . . . . . s.n.ot. g.u . . . . . . . . . . . .
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4.3 Renewing output flange oil seal (bevel ris box removed) . . . . . . . . . . . . . . . . . . n.te.e . . . . . . . .
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4.4 Renewing needle bearing (polygon au bearing) for stub shaft . . . . . . . . . . . . . . . . . r .ac. . . . . .
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5 Checking and topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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5.1 Checking gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132


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5.2 Filling gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132


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5.3 Specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134


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ii Contents
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

00 – Technical data
1 Safety information
(VRL010440; Edition 05.2017)
⇒ “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


while engine is running.
♦ Before working on vehicle with engine running, move se‐
lector lever into position “P” and apply handbrake.

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


trical and electronic components, observe the following:
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;


Disconnecting and reconnecting battery .
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♦ In vehicles with the start/stop system activated (identifia‐
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♦ When working on the vehicle, always make sure that the

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1.3 Notes on tow-starting/towing


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50 km.

Note

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


flat or the starter is not functioning.

1.4 Safety precautions when using testers


and measuring instruments during a
road test
Observe the following if test and measuring equipment is required
during a road test:

WARNING

Risk of accident due to distraction and inadequate securing of


test and measuring equipment.
Danger as a result of activation of front passenger airbag in
event of an accident.
• Operation of test and measuring equipment while driving
results in distraction.
• Greater injury hazard as a result of unsecured test and
measuring equipment.
♦ Always strap in place test and measuring equipment on
rear seat and have a 2nd person sitting on the rear seat
to operate them.

2 Rep. gr.00 - Technical data


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

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
with the ignition switched off.

Caution

To prevent damage to the electronic components when dis‐


connecting the battery:
♦ Observe the necessary measures when disconnecting the
battery.
♦ Disconnect battery only after the ignition has been switch‐
ed off.

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


Disconnecting and reconnecting battery .

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1. Safety information 3
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

2 Identification

2.1 Identification of gearbox


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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4 Rep. gr.00 - Technical data


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

3 Repair notes
⇒ “3.1 General information”, page 5
⇒ “3.2 Rules for cleanliness”, page 5
⇒ “3.3 General repair instructions”, page 6
⇒ “3.4 Gaskets and seals”, page 7
⇒ “3.5 Nuts and bolts”, page 7

3.1 General information


Gearbox
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♦ The gearbox is structured like a manual gearbox. Through op‐

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le
un

posed hydraulic actuation of the dual clutch, it is operated like

pt
an
d

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


itte

y li
rm

automatically or manually via the Tiptronic system. There is no

ab
pe

ility
clutch pedal.
ot

wit
, is n

Selector mechanism

h re
hole

spec
The feedback for the gearbox concerning the selector lever po‐
es, in part or in w

sition is not transferred by mechanical means via the selector

t to the co
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 rrectness of i
l purpos

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‐
nform
ercia

cally via the selector lever cable.


m

Gear change point variations for gradients


com

tion in
r

An additional gear change map automatically selects gear


te o

thi

changes for gradients dependent upon accelerator pedal position


s
iva

do

and driving speed.


r
rp

cum
fo

en
g

• Gear change map for extreme uphill stretches is matched to


n

t.
yi Co
op
engine output. C py
t. rig
gh ht
yri
• Gear change map for extreme downhill stretches is matched
p by
co Vo
by lksw
to the braking effect of the engine. Prote
cted AG.
agen

• 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
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

♦ If repair work cannot be performed immediately, cover opened


parts carefully.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.

3.3 General repair instructions


To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
n AG. Volkswagen AG do
wage es n
Guided fault-finding, vehicle self-diagnosis and test instruments
yV
olks ot g
ua
b
ed ran
♦ Before performing repairs to the gearbox, determinehothe
ris cause tee
of the fault as accurately as possible ⇒ Vehicle sdiagnostic
au
t or
ac
tester, Guided Fault Finding , Vehicle Self-Diagnosis
s

ce
e
nl

or Test Instruments .

pt
du

an
itte

y li
Special tool
erm

ab
ility
ot p

For a complete list of special tools used in this workshop manual,

wit
, is n

see ⇒ "Workshop equipment and special tools" .

h re
hole

spec
Gearbox
es, in part or in w

t to the co
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.

rrectness of i
♦ If gearbox covers have been unbolted or gearbox has no fluid,
l purpos

do not run engine or tow vehicle.


♦ First thoroughly clean connecting points and surrounding

nf
ercia

areas and then loosen bolts.

orm
m

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

atio
om

tween the engine and gearbox are correctly located.

n in
or c

thi
e

Locking devices
t

sd
iva

o
r
rp

cu
♦ Do not overstretch retaining rings.
o

m
f

en
ng

t.
yi
♦ Always renew retaining rings which have been damaged or
Co
op py
overstretched.
t. C rig
gh ht
pyri by
Vo
♦ Retaining rings must locate properly in grooves.
co lksw
by
cted agen
Prote AG.
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.

6 Rep. gr.00 - Technical data


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

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
agen
AG. Volubricants
lkswagen AGwill cause
does
problems in function. Volksw not
g y ua
db r
♦ Coat O-rings with dualris clutch gearbox oil to prevent pinching ntee
e a
ho
of rings during assembly.
au
t or
a
ss c
♦ After renewing gaskets, O-rings and seals, check oil level in
ce
le
un

pt

gearbox and top up if necessary ⇒ page 103 .


an
d
itte

y li
rm

ab
pe

3.5 Nuts and bolts


ility
ot

wit
, is n

h re

♦ Loosen and tighten securing bolts and securing nut for covers
hole

spec

and housings diagonally.


es, in part or in w

t to the co

♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
rrectness of i

AMV 185 101 A1- .


l purpos

♦ Use a thread chaser to clear residual locking fluid from all


threaded holes into which self-locking bolts are to be screwed.
nform

Otherwise there is a danger of bolts shearing when subse‐


ercia

quently being removed.


m

a
com

tio

♦ Check pitch of thread, to ensure correct thread chaser is used


n in

to clean threads and to ensure the threads are not damaged.


r
te o

thi
s
iva

do

♦ Always renew self-locking bolts and nuts.


r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. Repair notes 7
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

4 Technical data

4.1 Allocation gearbox - engine


⇒ “4.1.1 Tiguan 2008 ►”, page 8
⇒ “4.1.2 Sharan 2016 ►”, page 8

4.1.1 Tiguan 2008 ►


Take account of the gearbox code if spare parts are required for
a repair.
Allocation: gearbox codes for petrol engines
LWT, MYC, NEZ NEZ, NYE, NZT, AG. Volkswagen AG d
RBV agen oes
olksw not
V gu
by
2.0 l - 125/147 kW 2.0 l - 132/155 kW ised ara
nte
TSI TSI ut
hor eo
ra
s a c
s
Allocation: gearbox codes for diesel engines

ce
le
un

pt
an
d

LWS, MYB, MYG, NYD, NZS, RBU QYQ


itte

y li
rm

NYD, NZS, RBU

ab
pe

ility
2.0 l - 100, 103 2.0 l - 130 kW TDI 2.0 l - 110, 135
ot

wit
, is n

kW TDI kW TDI

h re
hole

spec
4.1.2 Sharan 2016 ►
es, in part or in w

t to the co
Take account of the gearbox code if spare parts are required for
a repair.

rrectness of i
Allocation: gearbox codes for diesel engines
l purpos

QYQ, SCY
2.0 l - 110, 135

nform
ercia

kW TDI
m

a
com

4.2 Capacities tion in


r
te o

thi
s

Capacity Dual clutch gearbox 0BH


iva

do
r
rp

cum

Initial filling 7.0 l ± 0.1 l


fo

en
ng

t.
yi
Changing approx. 5.5 litres
Co
op py
♦ Change interval: ⇒ Maintenance manual and/
t. C rig
gh ht
yri
or ⇒ service tables “ELSA” p by
o Vo
by c lksw
cted agen
Prote AG.
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


Initial filling 0.9 l
Changing Filled for life, no change
Lubricant Gear oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .

8 Rep. gr.00 - Technical data


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Further information in the part number designates the container


size.

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

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

4. Technical data 9
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

5 Electrical components

5.1 Overview of fitting locations - electrical components

1 - Mechatronic unit for dual


clutch gearbox - J743-
❑ Removing and installing
⇒ page 26
2 - Gearbox input speed send‐
er - G182- and oil temperature
sender in multi-plate clutch -
G509-
❑ Both senders are com‐
bined in one component
and can be renewed to‐
gether only.
❑ Removing and installing
⇒ page 37
❑ Before removal of the AG. Volkswagen AG d
agen
sender, the mechatronic Volksw
oes
not
gu
unit for dual clutch d bgear‐
y ara
se nte
box - J743- must
thori be re‐ eo
moved ⇒ page
s au 26 . ra
c
s
❑ Discontinued as of gear‐
ce
le
un

pt

box date 06/15


an
d
itte

y li
rm

3 - Selector lever - E313-


ab
pe

ility

❑ For information about


ot

wit
, is n

selector lever, see


h re

⇒ page 47 Selector
hole

spec

mechanism
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

10 Rep. gr.00 - Technical data


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

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

1.1 Assembly overview - dual clutch


Replacement parts

1 - Retaining ring for dual


clutch end cover
❑ Renew after removal
2 - Retaining ring for dual
clutch
❑ Renew after removal
3 - Retaining ring for drive plate
4 - Dual clutch

Caution
The
♦ drive plate has to re‐
main engaged between
the teeth of the outer
plate carrier. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
If♦the drive plate de‐ ir se
d b ua
ran
taches, the plates in the tho tee
or
dual clutch can shift. It ss
au ac
may then not be possible
ce
e
nl

to adjust the clutch cor‐


pt
du

rectly when it is installed. an


itte

y li
erm

ab
ility
ot p

5 - Shims wit
, is n

h re
❑ 10 shims having differ‐
hole

spec

ent »thicknesses«.
es, in part or in w

They are sized in


t to the co

0.05 mm increments.
❑ Thickness of spacer ring
must be determined
rrectness of i

when installing dual


l purpos

clutch.
6 - Dual clutch end cover
nform
ercia

❑ Renew after removal


m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

1. Clutch 11
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Caution

♦ This figure is intended only to provide an overview of the


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

1.2 Removing and installing clutch end cov‐


er
Special tools and workshop equipment required
♦ Clean assembly sleeve - T10459- before using. Do not use a
scratched sleeve.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

Brief description
The cover is held in its seat by a retaining ring. After the retaining
ring has been removed, the cover can be levered out of its seat.
rrectness of i

Cover and retaining ring must always be renewed. Never install


a new cover with a hammer and never oil the centre seal or touch
l purpos

it with a hand! However, if this should happen, the cover is certain


to leak!
nform
ercia

Removing
m

a
com

ti

The gearbox must be removed for work on cover.


on in
r
te o

thi

– Drain gear oil ⇒ page 105 .


s
iva

do
r

– Remove gearbox ⇒ page 61 .


rp

cum
fo

en
ng

t.
– Secure gearbox to assembly stand ⇒ page 86 .
yi Co
Cop py
t. rig
Often, doubts arise as to whether the filter must be renewed or
gh ht
yri by
not.
op Vo
by c lksw
cted agen
Prote AG.

Note

It is not always necessary to change the oil filter ⇒ page 101 .

12 Rep. gr.30 - Clutch


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Remove filter if necessary ⇒ page 101 .

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.

rrectne
Cover can be levered out with a screwdriver.

ss o
cial p

f
Note

inform
mer

The removed cover and retaining may not be installed again.

atio
om

n
c

i
or

n thi
Install only a »new« cover.
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.

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
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Only handle cover as shown -in this picture-.

Note

There must be no stickers on the inside of the cover. If, however,


stickers are present, remove them carefully.

– The running surface on the end of the shaft of the clutch


-arrow- must be free of oil and dry.
– If necessary, thoroughly clean running surface.

WARNING

The centre seal of the new cover must be »preformed« before


installing:

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


a scratched sleeve. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
– Set sleeve on a flat surface. ed by ua
ran
ris tee
tho or
au ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Guide cover horizontally and evenly over entire sleeve


-as shown in this figure-. This will bring the sealing lip into in‐
stallation position.
rrectness of i

– Remove sleeve upwards out of cover and set sleeve on end


l purpos

of clutch shaft.
– Moisten outer seal of cover with oil.
nf
ercia

orm
m

atio

Caution
om

n in
or c

thi

Moisten only the outer seal of the cover with oil. Oiling the inner
te

sd
a

seal will always cause leaks.


iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

14 Rep. gr.30 - Clutch


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Guide cover horizontally over sleeve and press evenly onto its
seat.

Caution

Work carefully. Any sort of blow to the cover is certain to cause


leaks.

It is possible to lever cover carefully into its seat with a


-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring.

n AG. Volkswagen AG
– Do not remove
olks
wbush
age until retaining ring
does is installed.
no
V t gu
by ara
– Installing
ris
ed gearbox ⇒ page 82 nte
tho eo
– sTop
s a up gear oil ⇒ page 105 .
u ra
c
ce
e
nl

pt
du

an

WARNING
itte

y li
erm

ab
ility

Do not start engine if there is no oil in gearbox.


ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

1.3 Removing dual clutch


rrectness of i

Special tools and workshop equipment required


l purpos

♦ 2 x hooks - 3438-
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Clutch 15
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

♦ Puller - T10055-

♦ Puller - T10525-

n AG. Volkswagen AG do
Brief description olkswage es n
ot g
byV ua
• The axial play of the clutch is readjusted during installation
ir se
d ran
tee
procedure. utho
or
a ac
ss
• To remove or install clutch, gearbox must be securely attached

ce
le
un

to an assembly stand in vertical position ⇒ page 86 . Only

pt
an
d

this way is it possible later to adjust axial play of the clutch


itte

y li
rm

without error.

ab
pe

ility
ot

Removing

wit
, is n

h re
– Remove clutch end cover ⇒ page 12 .
hole

spec
es, in part or in w

Important! Installation location of drive plate


t to the co
– Check that marking on drive plate -arrow- aligns with the mark‐
ing on the outer plate carrier.
rrectness of i

If there is no marking:
l purpos

– Mark installation position of drive plate relative to periphery of


outer plate carrier with permanent marker, as shown in illus‐
nform
ercia

tration.
m

• During installation, drive plate must always be repositioned at


a
com

tio

marked position.
n in
r
te o

thi
s
iva

do
r

Note
rp

cum
fo

en
ng

t.
yi Co
The retaining ring is renewed together with the clutch. If the clutch Cop py
which is removed is reinstalled, the securing ring is to be used
t. rig
gh ht
yri by
again as well. cop Vo
by lksw
cted agen
Prote AG.

16 Rep. gr.30 - Clutch


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Lever out retaining ring -2- of drive plate using screwdriver


-1- -arrow-.

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

y li
erm

ab
ility
ot p

wit
is n

– Apply puller - T10525- together with puller - T10055- on

h re
ole,

splines and carefully pull drive plate off its seat -arrows-.

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Remove retaining ring -arrow- and save it for now.
AG.

Note

Do not dispose of the retaining ring yet because it will be needed


to measure axial clearance.

1. Clutch 17
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Remove shim -arrow-. AG. Volkswagen AG d


agen oes
olksw not
V gu
by
Caution rised ara
nte
ho eo
aut ra
Carefully remove the dual clutch. Take care sthat no parts fall
s c
out. Therefore, do not turn the clutch over!

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
– Remove dual clutch using hooks - 3438- . Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.4 Installing dual clutch


Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-

18 Rep. gr.30 - Clutch


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

♦ Dial gauge - VAS 6079-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

♦ Retaining pins - T10524-

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r

♦ Thrust piece - T10526-


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.

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
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Installing
AG. Volkswagen AG d
– Take great care when removing the dual clutch from its pack‐lkswagen oes
not
age. db
yV
o gu
ara
e nte
ris
– Turn piston rings by hand. They must move freelyuand
tho must eo
ra
not bind. ss a c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should

rrectness of i
align.
l purpos

– 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-.

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
Important! Position of drive plate gh ht
pyri by
Vo
co lksw
by
– Before installing, check if there is a marking -arrow- on dual Prote
cted AG.
agen
clutch.
– If there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the outer plate carrier.

– Insert retaining pin - T10524- .


The retaining pin - T10524- should be held by a second mechanic
while the dual clutch is being inserted.

20 Rep. gr.30 - Clutch


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

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


– If necessary, insert clutch by turning slightly.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
The dual clutch is properly fitted if there is horalmost
is no play in the nte
eo
retaining pin - T10524- . s aut ra
c
s

ce
e
nl

pt
du

an
Note
itte

y li
erm

ab
ility
ot p

♦ The retaining pin remains inserted until the clutch end cover

wit
is installed.
, is n

h re
hole

♦ The dual clutch must now not be rotated any more, as this can

spec
shift the position of the retaining pin - T10524- .
es, in part or in w

t to the co
rrectness of i
– Lever out retaining ring -2- of drive plate using screwdriver
l purpos

-1- -arrow-.

nf
ercia

o
Note

rm
m

atio
om

This retaining ring will be used again. Do not dispose of it.

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

1. Clutch 21
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– 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!
AG. Volkswagen AG d
agen oes
olksw not
– Temporarily install “old” retaining ring -arrow-. d by V gu
ara
rise nte
Before this ring is finally disposed of, 3 measurements
autho
must be eo
ra
made. ss c

ce
e
nl

First measurement (axial play of shaft)

pt
du

an
itte

y li
– Screw universal dial gauge - VW 387- to gearbox flange.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Set -tip of dial gauge- on input shaft.

rrectness of i
– Set -dial gauge- to 0 with preload.
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

22 Rep. gr.30 - Clutch


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.

Note

This value will be needed later for the check measurement so


save value “A” until the last measurement has been performed.

Second measurement
• The retaining pin - T10524- remains installed!

– Set tip of dial gauge -on hub of large plate carrier-.

Note

Tip must not sit on retaining ring.


. Volkswagen AG
gen AG does
– Set -dial gauge- Vto
olk0
swwith
a
preload again. not
y gu
db ara
– Lift dual clutch
or
ise with force to stop and note measurement. nte
eo
h
ut ra
– Call this
ss value “B”.
a c
ce
e
nl

Now calculate which shim must be fitted:


pt
du

an
itte

y li

– Use this formula:


erm

ab
ility
ot p

Value “B” minus value “A” minus 0.11 = thickness of shim to


wit
, is n

be fitted.
h re
hole

spec

– Note result.
es, in part or in w

t to the co

The shims are sized in 0.05 mm increments.


– Measure the shims and determine which one is closest to the
result.
rrectness of i
l purpos

WARNING
nf
ercia

Always use the next-largest shim, never the next-smallest.


orm
m

atio
om

n in
c

Example:
or

thi
te

sd
iva

Calculated dimension for shim New shim


o
r
rp

cu
o

m
f

1.28 mm 1.3 mm
en
ng

t.
yi Co
op
1.26 mm 1.3 mm
C py
ht. rig
rig ht
py by
co Vo
by lksw
– Remove old retaining ring -arrow-. cted agen
Prote AG.

Note

Do not dispose of ring yet; it will be needed once more.

1. Clutch 23
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH. V-oEdition
lkswage 05.2017
AG n AG d
agen oes
olksw not
– Fit calculated shim. db
yV gu
ara
rise nte
Third measurement (checktho measurement) eo
s au ra
c
s
To make sure that the shim is correct, a test measurement must

ce
e
nl
still be carried out. Proceed as follows:

pt
du

an
itte

y li
• The retaining pin - T10524- remains installed!
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Install old retaining ring -arrow- once more.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
– Set tip of dial gauge -on hub of large plate carrier-.
cop Vo
by lksw
cted agen
Prote AG.

Note

Set the tip of the dial gauge on the shim -1-.

– Set -dial gauge- to 0 with preload again.


– Lift dual clutch with force to stop and note measurement.
– Call this value “C”.
Now calculate which shim must finally be fitted:
– Use this formula:
Value “C” minus value “A” = specification
This specification must lie between 0.05 and 0.12 mm.
If the specification is not attained, then achieve the specification
by fitting a thicker or thinner shim.

– Install new retaining ring -arrow-.

24 Rep. gr.30 - Clutch


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Fit drive plate into dual clutch.


wage
n AG. Volkswagen AG do
es ks not
Vol g
• When installing, echeck
db
y if marking on drive plate is aligned
ua with
ran
marking on outer
thoris plate carrier -arrows-. If the markings were
tee
or
subsequently
s au make, align these. ac
s

ce
le

– A second mechanic must hold retaining pin - T10524- in its


un

pt
place and press outwards slightly.

an
d
itte

y li
rm

ab
– Carefully drive the drive plate onto its seat using thrust piece
pe

ility
- T10426- and a plastic mallet.
ot

wit
, is n

h re
– Install drive plate retaining ring.
hole

spec
– Starting at the opening, press retaining ring in clockwise di‐
es, in part or in w

t to the co
rection into its fitting position.
• The retaining ring must be fully engaged.

rrectness of i
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
l purpos

– Now remove retaining pin - T10524- from between dual clutch


and housing.

nform
ercia

– Install clutch end cover ⇒ page 12 .


m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

1. Clutch 25
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox installed)”, page 26
⇒ “1.2 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox removed)”, page 31
⇒ “1.3 Removing and installing gearbox input speed sender G182
and oil temperature sender in multi-plate clutch G509 up to gear‐
box date 05/15”, page 37

1.1 Removing and installing mechatronic


unit for dual clutch gearbox - J743-
(gearbox installed)
⇒ “1.2 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox removed)”, page 31
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

♦ Up to gearbox date 05/15 release tool - T10465-


rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi
Always make sure that no dirt can enter an »open« gearbox.
Co
Cop py
t. rig
gh
In particular, dirt entering an »exposed« mechatronic unit for dual
ht
pyri by
Vo
o
clutch gearbox - J743- can lead to gearbox failure. by c lksw
cted agen
Prote AG.
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 101 .
Remove mechatronic unit.
– Move selector lever to position “P”.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation

26 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Remove connecting hose between charge air cooler and


charge air pipe ⇒ Rep. gr. 21 ; Removing and installing parts
of charge air cooling .

n AG. Volkswagen AG do
Note lks wage es n
o ot g
byV ua
d ran
ir se
It is possible that parts having nothing
tho to do with the mechatronic tee
or
unit must be removed. This depends
ss
au
on the vehicle's equipment. ac
This will create enough space to remove the mechatronic unit.

ce
le
un

pt
an
d
itte

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

ab
nuts M6).
pe

ility
ot

wit
, is n

h re
– Release mechatronic unit connector by turning in
hole

-direction of arrow- and pull off connector.

spec
es, in part or in w

t to the co
– Raise lines near cover and tie.
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.

rrectness of i
– Drain oil ⇒ page 105 .
l purpos

nform
mercia

a
com

tion in
r
te o

thi
– Remove securing clip -3-.

s
iva

do
r
rp

cum
– Unscrew bolts -1- diagonally and remove.
fo

en
ng

t.
yi Co
– Remove cover -2- with seal. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note
cted agen
Prote AG.

Always renew bolts, securing clips and the cover with seal.

Before touching mechatronic unit, touch an earthed object again.

1. Mechatronic unit 27
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– If fitted, release connector -1- of gearbox input speed sender


- G182- and oil temperature sender in multi-plate clutch -
G509- using release tool - T10465- .

– Remove bolts -arrows- diagonally.


All 9 bolts have same length and are not allowed to be reused.

– Remove mechatronic unit -1- carefully.


agen
AG. Volkswagen AG d
w oes
olks not
byV gu
ara
d
Caution orise nte
eo
th
au ra
c
• Lift or ss mechatronic
put down unit only on housing and on
ce
e

solenoid valves.
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

28 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Lay mechatronic unit to side properly.


– Put down mechatronic unit so that sensors -arrows- are point‐
ing upwards.
Install mechatronic unit.
Install in reverse order of removal. During this procedure, observe
the following:

WARNING

Before installing the mechatronic unit, clean the sealing sur‐


face on the gearbox housing thoroughly
agen
AG. Vowithout using
lkswagen AG
doecleaning
agents. Always make sure olksw no dirt can get into the
that inside.
s no
t gu
yV b ara
ed nte
oris e
th or
au ac
ss
– Before installation, check that »sender« -1- is installed

ce
e
nl

⇒ page 37 .

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Before touching mechatronic unit, touch an earthed object again. nf


ercia

orm
m

Caution
atio
om

n in
or c

• Lift or put down mechatronic unit only on housing and on


thi
te

solenoid valves.
sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Mechatronic unit 29
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Carefully insert mechatronic unit -1- into gearbox.


– Screw in new bolts -arrows- diagonally until finger-tight.

– Tighten bolts in specified sequence to 8 Nm + 45°.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Push on connector -1-, if fitted, and engage.


nform
ercia

– After this, check that fastener -2- is not damaged.


m

at
om

io

Caution
n
c

in t
or

his
ate

• Work with great care. The fastener of the connector -2-


do
priv

can break. If this has happened, the connector will no


um
for

en
g

longer hold and the damaged part, e.g. mechatronic unit


n

t.
yi Co
for dual clutch gearbox - J743- must be renewed. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Continuation for all:
agen
Prote AG.

30 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Renew seal -arrow-.


A new mechatronic unit already has a new oil seal.
– Lubricate seal with ⇒ DSG oil.

– 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
agenclip -3-.
AG. Volkswagen AG d
oe w s no
olks t
– Attach wire
ed
byretainer to cover and tighten nutsguto
V
ara10 Nm.
is nte
or
– Push au
thon connector for mechatronic unit for dual clutch
eo
r agearbox
- J743-
ss and engage lock by turning. c
ce
e
nl

– Install connecting hose between charge air cooler and charge pt


du

an
itte

air pipe ⇒ Rep. gr. 21 ; Removing and installing parts of y li


erm

ab
charge air cooling . ility
ot p

wit
, is n

h re
hole

spec

– Do not start engine!


es, in part or in w

t to the co

– Fill with oil ⇒ page 105 .


– Install noise insulation ⇒ General body repairs, exterior; Rep.
rrectness of i

gr. 50 ; Noise insulation; Assembly overview - noise insulation


l purpos

– Conduct basic adjustment of mechatronic unit for dual clutch


gearbox - J743- .
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

1.2 Removing and installing mechatronic


unit for dual clutch gearbox - J743-
(gearbox removed)
⇒ “1.1 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox installed)”, page 26
Special tools and workshop equipment required

1. Mechatronic unit 31
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

♦ Torque wrench - V.A.G 1331-

♦ Up to gearbox date 05/15 release tool - T10465-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
Always make sure that no dirt can enter an »open«
hor gearbox. eo
aut ra
s c
In particular, dirt entering an »exposed« mechatronic
s unit for dual

ce
le

clutch gearbox - J743- can lead to gearbox failure.


un

pt
an
d
itte

y li
Please also refer to the notes on the oil filter change regarding
erm

ab
»dirty oil« ⇒ page 101 .

ility
ot p

wit
is n

Remove mechatronic unit.


h re
ole,

– Drain oil ⇒ page 105 . spec


urposes, in part or in wh

t to the co
– Remove securing clip -3-.
Always renew securing clip.
rrectne

– Unscrew bolts -1- diagonally and remove.


– Remove cover -2- with seal.
ss o
cial p

f inform

Note
mer

atio
om

Always renew bolts, securing clips and the cover with seal.
n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

32 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Before touching mechatronic unit, touch an earthed object again.

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

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
– If fitted, release connector -1- of gearbox input speed sender
es, in part or in w

- G182- and oil temperature sender in multi-plate clutch -

t to the co
G509- using release tool - T10465- .

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

c
– Remove bolts -arrows- diagonally. um
fo

en
ng

t.
yi
All 9 bolts have same length and are not allowed to be reused.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Mechatronic unit 33
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Remove mechatronic unit -1- carefully.

Caution

• Lift or put down mechatronic unit only on housing and on


solenoid valves. AG. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Lay mechatronic unit to side properly.

rrectness of i
– Put down mechatronic unit so that sensors -arrows- are point‐
l purpos

ing upwards.
Install mechatronic unit.

nform
ercia

Install in reverse order of removal. During this procedure, observe


m

a
com

the following:

tion in
r
te o

thi
s
WARNING
iva

do
r
rp

cum
fo

Before installing the mechatronic unit, clean the sealing sur‐


en
ng

t.
yi Co
face on the gearbox housing thoroughly without using cleaning Cop py
agents. Always make sure that no dirt can get into the inside.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Before installation, check that »sender« -1- is installed


⇒ page 37 .

34 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Before touching mechatronic unit, touch an earthed object again.

Caution

• Lift or put down mechatronic unit only on housing and on


solenoid valves.

– Carefully insert mechatronic unit -1- into gearbox.


– Screw in new bolts -arrows- diagonally until finger-tight. agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f in
– Tighten bolts in specified sequence to 8 Nm + 45°.

form
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

1. Mechatronic unit 35
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Push on connector -1-, if fitted, and engage.


– After this, check that fastener -2- is not damaged.

Caution

• Work with great care. The fastener of the connector -2-


can break. If this has happened, the connector will no
longer hold and the mechatronic unit for dual clutch gear‐
box - J743- must be renewed.

Continuation for all:

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Renew seal -arrow-. ss
au ac

ce
e

A new mechatronic unit already has a new oil seal.


nl

pt
du

an
itte

y li
– Lubricate seal with ⇒ DSG oil.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Set new cover -2- in place and tighten with new bolts -1- di‐
agonally in several stages to 10 Nm + 45°.

nform
ercia

– Install new securing clip -3-.


m

at
om

After installation of gearbox


ion
c

in t
or

– Fill with oil ⇒ page 105 .


his
ate

do
riv

– Conduct basic adjustment of mechatronic unit for dual clutch


p

cum
or

gearbox - J743- .
f

en
ng

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

36 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

1.3 Removing and installing gearbox input


speed sender - G182- and oil tempera‐
ture sender in multi-plate clutch - G509-
up to gearbox date 05/15

Note

♦ As of gearbox date 06/15, the gearbox input speed sender -


G182- and the oil temperature sender in multi-plate clutch -
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:
AG. Volkswagen AG d
agen
Reinstall »old« sender only if: Volksw
oes
not
by gu
d ara
• The sender has no defect orise nte
th eo
u ra
• The cable was not pulled on when
ss a it was removed c
ce
e
nl

– Moisten sender with dual clutch gearbox oil and install.


pt
du

an
itte

y li

– Tighten bolt -2- to 10 Nm.


erm

ab
ility
ot p

– Install mechatronic unit for dual clutch gearbox - J743-


wit
, is n

⇒ page 26 .
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
37
AG.
1. Mechatronic unit
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

2 Removing and installing gear oil cool‐


er
⇒ “2.1 Renewing bleeder”, page 40
Special tools and workshop equipment required
♦ Hose clamps to 25 mm - 3094-
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

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

♦ Torque wrench - V.A.G 1331-

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
Removing
yi Co
Cop py
t. rig
– Move selector lever to position “P”. gh ht
pyri by
Vo
co lksw
by
– Remove air filter housing. Prote
cted AG.
agen

♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐


ling air filter housing
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
ling air filter housing
– Remove battery with battery tray ⇒ Rep. gr. 27 ; Battery;
Removing and installing battery .
– Lay lint-free cloths on gear oil cooler and gearbox to catch
escaping coolant.
– Clamp off coolant hoses using hose clamps -3094- and re‐
move from cooler.

38 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Remove bolts -A- and remove gear oil cooler -B-.

Caution

No coolant must be allowed to drip into gearbox!

Installing
Install in reverse order of removal. During this procedure, observe
the following:

n AG. Volkswagen AG do
wage es n
– Renew O-rings -C-. yV
olks ot g
ua
b
ed ran
– Set gear oil cooler -B- in place. When doing tthis,
hor note O-rings
is tee
or
-C-. au ac
ss

ce
– Screw in new bolts -A- and tighten to 20 Nm + 45°.
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

io
– Attach coolant hoses to gear oil cooler and remove hose
n
c

in t
r

clamps -3094- .
o

his
ate

do
riv

Continue installation in reverse order of removal.


p

cum
for

– Install battery with battery tray ⇒ Rep. gr. 27 ; Battery; Re‐


en
ng

t.
yi Co
moving and installing battery . t. Cop py
rig
gh ht
– Install air filter housing. yri
p by
co Vo
by lksw
cted
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
agen
Prote AG.
ling air filter housing
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
ling air filter housing
– Check coolant level and top up with coolant as needed ⇒ Rep.
gr. 19 ; Removing and installing parts of cooling system .
– Checking and adjusting oil level ⇒ page 103 .

2. Removing and installing gear oil cooler 39


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

2.1 Renewing bleeder


Removing
– Pull off cap -arrow- by hand.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Insert screwdriver -1- between collar of gearbox and breather

ce
e
nl

pt
du

pipe -2-.

an
itte

y li
erm

ab
– Pry off breather pipe -2- with screwdriver -1-.

ility
ot p

Installing

wit
, is n

h re
hole

– Push on breather pipe -2- powerfully by hand.

spec
es, in part or in w

Breather pipe must be heard and felt to engage.

t to the co
– Put on cap.

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

40 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

3 Emergency release of selector lever


Special tools and workshop equipment required
♦ Wedges - T10383/1-

Do not remove knob.


– Depress brake pedal or set handbrake.
– Using wedge - T10383- , carefully lever gear lever gaiter off
centre console insert -arrows-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

– Press yellow plastic part -arrow- from above and hold in this

wit
, is n

position.
h re
hole

spec
Lever can now be moved from position »P«.
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. Emergency release of selector lever 41


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

4 Removing and installing selector lev‐


er handle
⇒ “4.1 Removing and installing handle”, page 42
⇒ “4.2 Moving push button in the handle to installation position”,
page 45

4.1 Removing and installing handle


Special tools and workshop equipment required
♦ Handle with clip: hose clip pliers - V.A.G 1275-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
♦ Wedges - T10383/1-

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
op py
Brief description
t. C rig
gh ht
pyri by
Vo
o
Handle is removed together with selector cover. by c 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.

42 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Using wedge - T10383- , carefully lever gear lever gaiter off


centre console insert -arrows-.
– Separate electrical connector.
Handle with locking sleeve:

– To release handle, slide


n AGplastic
. Volkswpart under
agen AG do handle in direction
of -arrow- wage es n
olks ot
yV gu
db ara
rise nte
tho eo
s au ra
c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

Handle with clamp:


– Cut open clamp -arrow- under boot using side cutters.
rrectness of i

Continuation for all handles:


l purpos

– Pull handle upwards off selector lever without pressing push


button.
nf
ercia

orm
m

atio
om

Note
n in
or c

thi
te

sd
a

Do not press button again after removal as it will no longer be


iv

o
r
rp

cu

possible to install the handle.


o

m
f

en
ng

t.
yi Co
op
Installing C py
t. rig
gh ht
yri by
Install in reverse order of removal, observing the following:
cop Vo
by lksw
cted agen
Prote
• Selector lever is in position “D”.
AG.

4. Removing and installing selector lever handle 43


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Note

♦ There is a chance that the button could be pressed into the


handle. Never install a handle with the button pressed in.
♦ Move push button to installation position ⇒ page 45 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.

Handle with locking sleeve:


– Push handle onto selector lever as far as stop and lock.
Volkswagen AG
– To lock, push sleeve downwards opposite direction ofswarrow.
agen
AG. does
olk not
yV gu
Handle with clamp: edb ara
nte
ris
tho eo
au ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo

44
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Push on handle with new clamp -arrow- to stop. Do not tighten


clamp yet.
Continuation for all handles:
– Press push button after installation.

Note

If not installed correctly, the button remains inserted in the handle


after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 45 . Then
fit the handle again.

Handle with clamp:


– If the press button moves back to its start position, the clamp
can be tightened using the hose clip pliers - V.A.G 1275- .
Continuation for all handles:
– Connect electrical connector.
– Clip in selector cover.

4.2 Moving push button in the handle to in‐


stallation position
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
lksw not
♦ Release tool - T10534- d by
Vo gu
ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
If the button was pressed by mistake, the installation position can
be restored.
l purpos

There are 2 ways of moving the push button into the installation
position, »with« and »without« installation guard. Both of them are
nform
ercia

described here.
m

a
com

Placing handle »with« release tool - T10534- in installation posi‐


ion in

tion:
r
te o

thi
s
iva

Instead of the release tool - T10534- , the installation guard which


do
r
rp

is delivered with new handles may also be used.


cum
fo

en
ng

t.
When using the installation guard, make sure that it has an eyelet
yi Co
op
-arrow- at the front. Other types of installation guard are not suit‐
C py
t. rig
gh
able.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Removing and installing selector lever handle 45


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Holding down push button, completely push in release tool -


T10534- installation guard with eyelet -arrow-. The installation
guard latches in place while doing so.
– Now, release push button. When the installation guard is
pulled out, the push button engages in installation position.
Placing handle »without« release tool - T10534- or installation
guard in installation position:

– Carefully unclip handle trim -A- upwards.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
– Using a screwdriver,
ss
a press the small lever -1- for the tie rod ac
into the groove -2-. This action presses the push button -3- into
ce
le
un

pt

installation position.
an
d
itte

y li

-I- = button pressed in


erm

ab
ility
ot p

-II- = button in installation position


wit
is n

h re
ole,

spec
urposes, in part or in wh

Note
t to the co

♦ Press the lever only into the groove and no further.


♦ Do not clip the handle trim onto selector mechanism until the
rrectne

handle has been fitted. This makes it possible to check wheth‐


er the small lever engages in the pull rod when the button is
ss

pressed.
o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

46 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
AG. Volkswagen AG d
agen 7-speed dualoeclutch gearbox
0BH - Edition 05.2017
olksw s no
t gu
y V
d b ara
e nte
ris
tho eo
5 Selector mechanism ss au ra
c

ce
le
⇒ “5.1 Overview - selector mechanism”, page 47

un

pt
an
d
itte

y li
⇒ “5.2 Removing and installing selector mechanism”, page 48
rm

ab
pe

ility
⇒ “5.3 Checking selector lever cable”, page 51
ot

wit
, is n

h re
⇒ “5.4 Adjusting selector lever cable”, page 52
hole

spec
es, in part or in w

t to the co
WARNING

Before working on vehicle with engine running, move selector

rrectness of i
lever into position “P” and apply handbrake.
l purpos

5.1 Overview - selector mechanism

nform
mercia

a
com

t
1 - Handle with selector cover

ion in
r

❑ Do not remove handle


te o

thi
without reason. For

s
iva

do
r

emergency release, on‐


rp

cum
fo

ly the cover needs to be

en
ng

t.
unclipped ⇒ page 41 .
yi Co
Cop py
t.
❑ Removing and installing
rig
gh ht
yri by
⇒ page 42 cop Vo
by lksw
cted agen
Prote
2 - Selector lever and selector
AG.

mechanism with selector lever


cable
❑ With selector lever lock
solenoid - N110-
❑ Selector mechanism
and selector lever cable
are not allowed to be
separated from one an‐
other. Both are removed
together.
❑ Removing and installing
⇒ page 48
❑ Do not grease Bowden
cable
❑ Checking ⇒ page 51
❑ Adjusting ⇒ page 52
3 - Bolt
❑ 8 Nm
4 - Hexagon flange nut
❑ 8 Nm
❑ Qty. 4
5 - Selector housing

5. Selector mechanism 47
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

5.2 Removing and installing selector mech‐


anism
⇒ “5.2.1 Removing and installing selector mechanism with selec‐
tor housing”, page 48
⇒ “5.2.2 Removing and installing selector mechanism without se‐
lector housing”, page 50

5.2.1 Removing and installing selector mech‐


anism with selector housing
Brief description
Selector mechanism and selector lever cable are not allowed to
be separated from one another. Both are removed together with
the selector housing.
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
The selector mechanism with selector lever cable can be re‐
moved and installed separately without removing and installing
the selector housing ⇒ page 50 .

Note

Following installation, cable must be checked for ease of move‐


ment and be adjusted.

Removing
– Remove selector lever handle ⇒ page 42 .
– Remove centre console ⇒ Rep. gr. 68 .
n AG. Volkswagen A
– Separate electrical connector from selector
olks
wagmechanism
e
to ve‐G does no
hicle wiring harness. db
y V t gu
ar
e an
ris tee
– Remove air filter housing. tho or
au ac
ss
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
ce
le
un

ling air filter housing


pt
an
d
itte

y li

♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐


rm

ab
pe

ling air filter housing


ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

48 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Pry selector lever cable -arrow- off lever using an open-ended


spanner.

Caution

Locks on selector lever cable break off very easily. If a locking


lug has broken off, complete selector mechanism with selector
lever cable must be renewed.

– Carefully push locking mechanisms of selector lever cable to‐


gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .

Note

To remove selector mechanism, a 2nd mechanic is required un‐


n AG. Volkswagen AG do
der the vehicle. olkswage es n
ot
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db ara
ir se nte
ho eo
– Remove nuts
aut -arrows- inside vehicle. ra
c
ss
– If fitted, remove bracket -A-.
ce
e
nl

pt
du

an
itte

– Remove selector mechanism -B- together with selector lever


y li
erm

ab

cable and selector housing downwards.


ility
ot p

Installing
wit
, is n

h re
hole

Install in reverse order of removal.


spec
es, in part or in w

– Before putting cable on selector shaft, position selector lever


t to the co

on selector mechanism forwards in direction to travel to posi‐


tion “P”.
rrectness of i

– Also move selector shaft on gearbox to position “P”. To do this,


push lever opposite to driving direction to rear stop.
l purpos

– Before ball head of cable is placed on selector shaft: check


selector lever cable ⇒ page 51 .
nf
ercia

orm

– Install centre tunnel heat shield below selector mechanism ⇒


m

atio
m

General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/


o

n in
c

extensions; Removing and installing floor heat shield .


or

thi
te

sd
a

– Install centre console ⇒ Rep. gr. 68 .


iv

o
r
rp

cu
o

– Install selector lever handle ⇒ page 42 .


f

en
ng

t.
yi Co
op
– Adjust selector lever cable after installing ⇒ page 52 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Selector mechanism 49
AG. Volkswagen AG d
agen oes
ksw not
Sharan 2016 by V ➤ , Tiguan 2008 ➤
ol
gu
ara
d
7-speed orise dual clutch gearbox 0BH - Edition 05.2017 nte
eo
th
au ra
s c
5.2.2 Removing and installing selector mech‐
s

ce
e
nl

pt
du

anism without selector housing

an
itte

y li
erm

ab
Brief description

ility
ot p

wit
, is n

Selector mechanism and selector lever cable are not allowed to

h re
be separated from one another. Both are removed together.
hole

spec
es, in part or in w

In the interior, the centre console must be removed.

t to the co
A cord must be attached to the Bowden cable before it is removed.
The cord is needed to guide the Bowden cable between the tunnel
and the heat shield.

rrectness of i
The selector mechanism with selector lever cable can also be
l purpos

removed and installed with the selector housing ⇒ page 48 .


Removing

nf
ercia

orm
m

– Remove selector lever handle ⇒ page 42 .

atio
om

n in
c

– Remove centre console ⇒ General body repairs, interior; Rep.


or

thi
gr. 68 ; Centre console; Removing and installing centre con‐
te

sd
iva

sole .

o
r
rp

cu
o

m
f

– Separate electrical connector from selector mechanism to ve‐ en


ng

t.
yi
hicle wiring harness.
Co
Cop py
t. rig
gh
– Remove air filter housing.
ht
pyri by
Vo
co lksw
by
cted
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
agen
Prote AG.
ling air filter housing
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
ling air filter housing

– Pry selector lever cable -arrow- off lever using an open-ended


spanner.

Caution

Locks on selector lever cable break off very easily. If a locking


lug has broken off, complete selector mechanism with selector
lever cable must be renewed.

– Carefully push locking mechanisms of selector lever cable to‐


gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.
– Then a long cord must be attached to the end of the Bowden
cable. The cord is needed to guide the Bowden cable between
the tunnel and heat shield during installation.

– Remove 4 bolts.

50 Rep. gr.34 - Controls, housing


AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor e o Sharan 2016 ➤ , Tiguan 2008 ➤
u ra
ss a 7-speed dual clutch c gearbox 0BH - Edition 05.2017

ce
le
un

pt
– Carefully pull selector mechanism with Bowden cable out of

an
d
itte

y li
the centre tunnel. Ensure that the cord remains accessible
erm

ab
from the engine compartment after being pulled by the Bow‐

ility
ot p
den cable.

wit
is n

h re
– Remove cord from Bowden cable.
ole,

spec
urposes, in part or in wh

Installing

t to the co
Install in reverse order of removal, observing the following:
A second mechanic is needed to guide Bowden cable from pas‐

rrectne
senger compartment into engine compartment.

ss o
Note
cial p

f inform
mer

♦ Do not bend or kink gear selector cable.

atio
om

n
♦ Do not grease selector lever cable.
c

i
or

n thi
te

sd
va

– Attach Bowden cable to cord which was drawn into the pas‐
i

o
pr

cum
r

senger compartment during removal.


fo

en
ng

t.
yi Co
– Carefully guide selector mechanism with Bowden cable Cop py
t. rig
through opening in centre tunnel. opyri
gh by
Vo
ht
c lksw
– Have the second mechanic pull cord with Bowden cable
by
cted agen
Prote
through tunnel from engine compartment until Bowden cable
AG.

can be attached to support bracket.


– Remove cord from Bowden cable.

– Secure selector mechanism to selector housing using 4 bolts.


Specified torque: 8 Nm
– Before fitting cable on selector shaft, position selector lever in
vehicle forwards to position “P”.
– Also move gearbox selector lever to position “P”. To do this,
push lever opposite to driving direction to rear stop.
– Before ball head of cable is placed on selector shaft: check
selector lever cable ⇒ page 51 .
– Install centre console ⇒ Rep. gr. 68 .
– Install selector lever handle ⇒ page 42 .
– Check selector lever cable after installing ⇒ page 51 .

5.3 Checking selector lever cable


Brief description
To check ease of movement of selector lever cable, it must be
removed from the gearbox and the free end must be placed so
that it does not bump against anything.
Then move selector lever and reinstall the cable.
Then the selector lever cable must be adjusted ⇒ page 52 .
Do not grease cable
Check
– Switch selector lever to »P« position.
– Remove air filter housing.
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
ling air filter housing

5. Selector mechanism 51
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐


ling air filter housing
– Pry selector lever cable -arrow- off lever using an open-ended
spanner.

Caution

Locks on selector lever cable break off very easily. If a locking


lug has broken off, complete selector mechanism with selector
lever cable must be renewed.

G. Volkswagen AG d
– Carefully push locking mechanisms of selector lever cable to‐ lkswagen A oes
not
gether -arrows- and remove selector lever cable upwardsdoutby
Vo gu
ara
of cable support bracket. or
ise nte
th eo
– Do not bend or kink cable. au ra
c
ss

ce
e
nl
– Shift selector lever several times from position »P« to »S« and

pt
du

an
back to »P«.
itte

y li
erm

ab
• Selector lever must move easily.

ility
ot p

wit
, is n

– Reinstall cable.

h re
hole

spec
– Adjust selector lever cable. ⇒ page 52
es, in part or in w

t to the co
Continue installation in reverse order of removal.

5.4 Adjusting selector lever cable

rrectness of i
Special tools and workshop equipment required
l purpos

♦ Torque wrench - V.A.G 1331-

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

52 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

The selector lever cable must be adjusted if


Volkswa AG. gen AG
agen do
♦ The selector lever cable
Vohas
lksw been removed from the
es n
gearbox.
ot g
by ua
ed ra
♦ The engine and/or
ho
ris gearbox has been removed and installed.
nte
e t or
au ac
♦ The cable with
ss the selector mechanism has been removed and
installed.

ce
le
un

pt
an
d
itte

♦ The position of the engine and gearbox is shifted, for example

y li
erm

ab
to install it free of tension.

ility
ot p

Adjusting:

wit
is n

h re
ole,

– Move selector lever in vehicle to “P” position.

spec
urposes, in part or in wh

– Selector shaft on gearbox is also in position “P”. To check,

t to the co
push lever opposite to driving direction to rear stop.

rrectne
Note

ss
Raise vehicle, to be sure that the gearbox is in “P” (parking lock

o
cial p

f
engaged). It should not be possible to turn both front wheels to‐

inform
gether in the same direction.
mer

atio
om

n
c

i
– Loosen bolt -2- of the Bowden cable -1-.
or

n thi
te

sd
va

– Gently push knob of selector lever forwards and backwards


i

o
pr

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

en
ng

t.
yi
In this way the ⇒ inner cable of the Bowden cable finds it optimal
Co
Cop py
position.
t. rig
gh ht
pyri by
Vo
o
– Tighten bolt -2- to 15 Nm.
c by lksw
cted agen
Prote AG.

5. Selector mechanism 53
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

6 Checking selector mechanism


lksw
agen
AG. Volkswagen AG d
oes
n o ot g
yV ua
⇒ “6.1 Selector lever in P positionisand
ed ignition switched on”, page
b ran
54 ut
hor tee
or
sa ac
⇒ “6.2 Selector lever in N position
s and ignition switched on”, page

ce
54 e
nl

pt
du

an
itte

y li
⇒ “6.3 Selector lever in position Tiptronic ”, page 54
erm

ab
ility
ot p

⇒ “6.4 Ignition and light switched on”, page 55

wit
, is n

h re
⇒ “6.5 Selector lever position indicator”, page 55
hole

spec
It must not be possible to start the engine in the selector lever
es, in part or in w

t to the co
positions “R”, “D” or “S”.
On right-hand drive vehicles, the starter must operate only in se‐
lector lever positions “P” and “N” when the locking button in the

rrectness of i
selector lever handle is not pressed.
l purpos

Over 5 km/h
When the selector lever is shifted to “N”, the selector lever lock

nf
ercia

o
solenoid must not lock the selector lever. Selector lever can be

rm
m

shifted back into a driving range.

atio
om

n in
c

Under 5 km/h
or

thi
te

sd
a

When the selector lever is shifted to “N”, the selector lever lock
iv

o
r
rp

cu
solenoid must lock the selector lever only after approx. 1 second.
o

m
f

Selector lever cannot be shifted out of “N” position until brake


en
ng

t.
yi
pedal is depressed.
Co
Cop py
t. rig
gh ht
6.1 Selector lever in “P” position and ignition pyri by
Vo
o
by c lksw
switched on
cted agen
Prote AG.

• Brake pedal not depressed:


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

6.2 Selector lever in “N” position and ignition


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

6.3 Selector lever in position “Tiptronic”


– Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
Symbols in the dash panel insert must change from “P R N D S”
to “7 6 5 4 3 2 1”.

54 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

6.4 Ignition and light switched on


The respective symbol in the shift mechanism cover lights up.

6.5 Selector lever position indicator


Simultaneous illumination of all selector lever position display
n AG. Volkswagen AG do
segments indicates gearbox emergency running lksw
agemode. es n
o ot g
yV ua
edb ran
ris tee
tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

6. Checking selector mechanism 55


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

7 Dismantling and assembling gearbox


⇒ “7.1 Assembly overview - gearbox”, page 56

7.1 Assembly overview - gearbox


⇒ “7.1.1 Renewing bleeder”, page 58
⇒ “7.1.2 Renewing sealing cap”, page 58

1 - Retaining ring
❑ Renew
2 - Clutch end cover
❑ A cover which has been
removed must not be in‐
stalled again.
❑ Lubricate external seal
with dual clutch gearbox
oil - G 052 182 A2- be‐
fore installing.
❑ Removing and installing
⇒ page 12
3 - Retaining ring
❑ Renew
4 - Shim
❑ Determine thickness
again if a new clutch has
been fitted ⇒ page 11 agen
AG. Volkswagen AG d
oes
olksw not
5 - Tapered ring ed byV gu
ara
ris nte
6 - Clutch aut
ho eo
ra
s c
❑ Removing and installing s
ce
le

⇒ page 11
un

pt
an
d
itte

y li

7 - Seal, right
erm

ab
ility

❑ Removing and installing


ot p

wit

⇒ page 116
is n

h re
ole,

8 - Breather pipe
spec
urposes, in part or in wh

❑ Removing and installing


t to the co

⇒ page 40
9 - Breather cap
rrectne

10 - Plug
s

11 - Seal
s o
cial p

❑ Renew
inform
mer

12 - Gear oil cooler


atio
m

❑ Removing and installing gear oil cooler ⇒ page 38


o

n
c

i
or

n thi

13 - Bolt, 20 Nm + 45°
te

sd
va

❑ Renew
i

o
pr

cum
r
fo

en
ng

14 - Filter housing, 20 Nm
t.
yi Co
Cop py
15 - Seal ht. rig
rig ht
py by
❑ Renew co Vo
by lksw
cted agen
Prote AG.

56 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

16 - Heat shield
17 - Oil filter
n AG. Volkswagen AG do
❑ Renewing ⇒ page 101 lkswage es n
o ot g
byV ua
d
18 - Bolt, 5 Nm + 90° o
ir se
ran
tee
th or
❑ Renew au ac
ss

ce
le
19 - Cable support bracket

un

pt
an
d
❑ For selector lever cable to gearbox

itte

y li
erm

ab
20 - Gearbox selector lever

ility
ot p

wit
21 - Bolt, 10 Nm + 90° is n

h re
ole,

❑ Renew

spec
urposes, in part or in wh

22 - Gearbox

t to the co
23 - Seal, left
❑ Removing and installing ⇒ page 114

rrectne
24 - Seal

ss
❑ Renew

o
cial p

f in
25 - Oil drain plug, 20 Nm

form
mer

❑ For mechatronic unit

atio
om

n
c

26 - Oil level pipe, 3 Nm

i
or

n thi
te

sd
iva

o
pr

c
Caution

um
r
fo

en
ng

Comply
♦ with the torque
t.
yi Co
op
setting precisely.
C py
t. rig
gh ht
yri by
The
♦ oil level pipe can cop Vo
by lksw
break between the
cted agen
Prote AG.
thread and the collar.

Note

♦ The oil level pipe comes in dif‐


ferent lengths and colours.
♦ If the oil level pipe is renewed, it
is essential that the oil level pipe
appropriate for the gearbox is in‐
stalled ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Do not install the oil level pipe
from another gearbox! The oil
level pipe determines the oil level
in the gearbox.
♦ Fitting a different oil level pipe
can result in the oil level in the
gearbox being too high or too
low.
❑ Drain and fill oil ⇒ page 105
27 - Seal
❑ Renew
28 - Oil drain plug, 45 Nm
29 - Bolt, 10 Nm
30 - Gearbox input speed sender - G182- and oil temperature sender in multi-plate clutch - G509-
❑ Removing and installing ⇒ page 37

7. Dismantling and assembling gearbox 57


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

31 - Mechatronic unit for dual clutch gearbox - J743- n AG. Volkswagen AG do


wage es n
❑ Removing and installing ⇒ page 26 yV
olks ot g
ua
d b ran
32 - Bolt, 8 Nm + 45° ir se tee
tho
u or
❑ Renew ss
a ac

ce
e
nl
33 - Cover

pt
du

an
itte
❑ With seal

y li
erm

ab
❑ Renew

ility
ot p

wit
, is n
34 - Bolt, 10 Nm + 45°

h re
❑ Renew hole

spec
es, in part or in w

35 - Securing clip

t to the co
❑ Renew
36 - Seal

rrectness of i
❑ Renew
l purpos

nf
ercia

o
7.1.1 Renewing bleeder

rm
m

atio
m

Removing
o

n in
or c

thi
e

– Pull off cap -arrow- by hand.


t

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.

– Insert screwdriver -1- between collar of gearbox and breather


pipe -2-.
– Pry off breather pipe -2- with screwdriver -1-.
Installing
– Push on breather pipe -2- powerfully by hand.
Breather pipe must be heard and felt to engage.
– Put on cap.

7.1.2 Renewing sealing cap


Special tools and workshop equipment required

58 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

♦ -1- Internal puller - Kukko 21/2-

♦ -4- Counter support - Kukko 22/1-


♦ Special wrench - T40297-

♦ Knife, commercially available n AG. Volkswagen AG do


lkswage es n
o ot g
yV
Removing ir se
d b ua
ran
o tee
h
– Raise vehicle. All 4 supports
aut
of lifting platform must be at same or
ac
height. ss
ce
le
un

pt

– Switch selector lever to »P« position.


an
d
itte

y li
rm

ab

– Remove front left wheel.


pe

ility
ot

– Remove front left wheel housing liner ⇒ General body repairs,


wit
, is n

h re

exterior; Rep. gr. 66 ; Wheel housing liners; Removing and


hole

installing front wheel housing liner .


spec
es, in part or in w

– Pierce centre of cap with a knife -1- and remove rubber coating
t to the co

around it. Diameter of opening approx. 15 mm.


rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

7. Dismantling and assembling gearbox 59


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Pull sealing cap out of gearbox housing . Volkusing


swageninternal puller
14 … 19 mm -B-, e.g. -Kukko w gen AG, and counter
a21/2- AG do
support
e
olks s not g
-A-, e.g. -Kukko 22/1-d.by V ua
r e an
ris tee
– Thoroughly clean ut sealing surface on gearbox housing with a
ho or
lint-free cloth. ss a ac

ce
le
un

Installing

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Using key - T40297- , drive new sealing cap into gearbox
housing to stop. Take care not to cant sealing cap.

rrectne
– Check gear oil level ⇒ page 103 .
– Install front left wheel housing liner ⇒ General body repairs,

ss
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and

o
cial p

f i
installing front wheel housing liner .

nform
mer

– Install front left wheel ⇒ Running gear, axles, steering; Rep.

atio
m

gr. 44 ; Wheels, tyres; Changing wheels .


o

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.

60 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

8 Removing and installing gearbox


⇒ “8.1 Removing gearbox”, page 61
⇒ “8.2 Installing gearbox”, page 82
⇒ “10.3 Detaching bevel box from gearbox - gearbox removed”,
page 97
⇒ “8.3 Specified torques”, page 82

8.1 Removing gearbox

8.1.1 Removing gearbox, Tiguan 2008 ►


Brief description
The gearbox is removed downwards together with the bevel box.
»From above«
The battery, air filter and starter are removed. Wiring harness of
steering rack is disconnected and »moved clear«. This allows it
to be lowered together with subframe and steering rack. The en‐
gine and gearbox must be supported before the left and right
assembly mounting is removed.
»From below«
Remove noise insulation beneath engine and cover in front left
wheel housing.
Remove -subframe- together with -pendulum support-,
-steering rack- and -both suspension links-.
Both drive shafts are pushed out of gearbox and left installed in
wheel bearing housings. They are only swivelled to one side, but AG. Volkswagen AG d
are left on vehicle. lksw
agen oes
n o ot g
yV ua
edb ran
ris tee
tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

8. Removing and installing gearbox 61


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Special tools and workshop


equipment required

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

♦ Support - 10 - 222 A-
h re
hole

spec

♦ Hook - 10 - 222 A /10-


es, in part or in w

t to the co

♦ Adapter - 10 - 222 A /18-


♦ Adapter - 10 - 222 A /22-
rrectness of i

♦ Tensioning strap - T10038-


l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

62 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

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


♦ Gearbox support - 3282-
♦ Adapter - 10 - 222 A /28- or adapter - 10 - 222 A /19-
♦ Wedge - T10161-
♦ Engine support, basic set - T40091-
♦ Insert tool, 18 mm - T10179-

8. Removing and installing gearbox 63


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

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

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi
♦ Adapter - 10 - 222 A /16-
Co
Cop py
t. rig
gh
♦ Hose clamps up to 40 mm - 3093- if available, or hose clamps
ht
pyri by
Vo
o
up to 25 mm - 3094-
c by lksw
cted agen
Prote AG.
♦ Socket insert - T10035-
♦ Socket insert - T10061-
♦ Counter-hold tool - T10172-
♦ Drip tray for workshop hoist - VAS 6208-

64 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
♦ Shackle - 10 - 222 A /12- ility
ot p

♦ Shock absorber tool set - T10001-


wit
, is n

h re
hole

Removing
spec
es, in part or in w

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


t to the co

height.
– Turn steering to straight-ahead position.
rrectness of i

– Switch selector lever to »P« position.


l purpos

– Remove both front wheels.


– Remove air filter housing.
nform
ercia

♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐


m

at
om

ling air filter housing


on
c

in t
or

♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐


his
ate

ling air filter housing


do
priv

cum
for

– Remove battery and battery tray ⇒ Electrical system; Rep. gr.


en
ng

t.
yi
27 ; Battery; Removing and installing battery .
Co
Cop py
t. rig
gh
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
ht
pyri by
Vo
o
and installing starter
c by lksw
cted agen
Prote AG.

8. Removing and installing gearbox 65


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

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

Caution

Locks on selector lever cable break off very easily. If a locking


lug has broken off, complete selector mechanism with selector
lever cable must be renewed.

– Carefully push locking mechanisms of selector lever cable to‐


gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.

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


or hose clamps to 25 mm - 3094- and remove.
– Remove air intake pipe. ⇒ Rep. gr. 21 ; Turbocharging/su‐
percharging

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– Remove upper engine/gearbox connecting bolts.


an
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es, in part or in w

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rrectness of i
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ercia

– Upper engine/gearbox connecting bolts can also be removed


using a suitable socket from shock absorber set - T10001- .
m

a
com

tion in
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Prote AG.

66 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

A bolt is located in the starter motor hole. Bit - T10061- can be


used instead of an 18 mm socket.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .

Remove subframe with steering rack. ⇒ Rep. gr. 40 ; Removing


and installing subframe with steering rack

olkswagen AG
en AG. V
– Remove drive shaft kswheat shield, if present, efrom
ag do s
not bevel box ⇒
Vol
Running gear, ed b axles, steering; Rep. gr. 40 ; Repairing
y gu
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shafts . horis nte
e
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au a
– Pressss both drive shafts off gearbox and remove. ⇒ Rep.c gr.
40 ; Removing and installing drive shaft
ce
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nl

pt
du

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itte

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ility
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wit
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hole

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es, in part or in w

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Secure both drive shafts to suspension struts using tensioning


rrectness of i

straps - T10038- .
l purpos

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ercia

orm
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atio
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8. Removing and installing gearbox 67


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7-speed
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Gearbox carrier for 2.0 l - 100/103/130 kW diesel engine

y li
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pe

– Unscrew bolts -B- from gearbox carrier on bevel box. Only

ility
ot

loosen bolts -A-, do not remove them.

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Gearbox carrier for 2.0 l - 135 kW diesel engine


m

a
com

tio
– Unscrew bolts -A and B-, and remove gearbox carrier for bevel

n in
r

box.
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Cop py
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Gearbox carrier for petrol engine:


– Unscrew bolts -1- and -3- from gearbox carrier on bevel box.
Only loosen bolts -2-, do not remove them.

– Mark position of propshaft with flexible coupling relative to


output shaft of bevel box -arrows-.

68 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Unbolt propshaft from bevel box -arrows-.

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– If necessary, counterhold at rear final drive when loosening or

wit
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tightening propshaft.

h re
hole

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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
– Secure support - T10323- with a bolt on inside rear threaded
c

in t
or

hole for subframe.

his
ate

do
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– A securing bolt from the subframe is suitable for this.


p

cum
for

en
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– Place cloth -A- on support and lay propshaft on that.


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Note

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


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

– Remove front cable holder from »black« gearbox cover.

8. Removing and installing gearbox 69


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Release mechatronic unit connector by turning in


-direction of arrow- and pull off connector.
– Remove all but one »easily accessible« connecting bolt be‐
tween engine and gearbox.

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agen oes
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– Set up support device - 10 - 222 A- . Attach hooks to support
ed b ara
nte
is
eyes on engine and support engine and gearbox. Dothnoto raise.
r eo
au ra
c
Adapter - 10-222A/28- may be used in place of adapter
s - 10-222A/
s

ce
le
19- .
un

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Note

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Support eyes may differ from those shown in illustration. Support
hole

spec
engine and gearbox with the available support eyes.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

ti
– Remove securing bolts -arrows- of assembly mounting for en‐

on in
gine⇒ Rep. gr. 10 ; Removing and installing engine .
r
te o

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cum
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– Remove securing bolts -arrows- of assembly mounting for


gearbox.

70 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Then use spindles of support bracket - 10 - 222 A- to lower


engine/gearbox »only« on gearbox side as far as dimension
-a-.
Dimension -a- = about 110mm
The gearbox is separated from the engine in this position.
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐
box support - 3282- under gearbox.

– Mount safety support -1- and hook -2- on gearbox as shown.

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– Mount safety support -3- and pin -4- onaugearbox as shown.
th or
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– Remove »last« connecting bolt between engine and gearbox.

ce
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pt
du

an
– Push gearbox off engine and lower it carefully, ensuring
itte

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»clearance« to other components.

ab
ility
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– Detach bevel box from gearbox ⇒ page 97

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

8.1.2 Removing gearbox, Sharan 2016 ►


Brief description
nform
ercia

The gearbox is removed downwards separately. »From above«


m

at
om

ion

The battery with battery tray, air filter and starter are removed.
c

in t
or

The coolant hoses must be clamped off. Support engine and


his
ate

gearbox before left subframe mounting is unbolted.


do
priv

cum
or

»From below«
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Remove noise insulation beneath engine and cover in front left C py
t. rig
wheel housing.
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Remove -subframe- together with -pendulum support-. cted agen
Prote AG.

Both drive shafts are pushed out of gearbox and left installed in
wheel bearing housings. They are only swivelled to one side, but
are left on vehicle.

8. Removing and installing gearbox 71


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

Special tools and workshop


equipment required

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♦ Support - 10 - 222 A-
wit
is n

h re

♦ Sharan adapter - 10-222 A /8-


ole,

spec
urposes, in part or in wh

♦ Hook - 10 - 222 A /10-


t to the co

♦ Shackle - 10 - 222 A /12-


♦ Bars - 2024 A / 1- of lifting tackle - 2024 A-
rrectne

♦ Gearbox support - 3282-


ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

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

72 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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en
ng

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by
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Prote AG.

♦ Engine and gearbox jack - VAS 6931-


♦ Adjustment plate - 3282/67-
♦ Hose clamps to 25 mm - 3094-
♦ Tensioning strap - T10038-
♦ Set of plugs for engine - VAS 6122-
♦ Insert tool, 18 mm - T10179-

8. Removing and installing gearbox 73


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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ss c

ce
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pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

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tion in
r
te o

thi
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♦ Socket insert - T10061- C py
t. rig
gh ht
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♦ Counter-hold tool - T10172A-
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o Vo
by c lksw
cted agen
♦ Support bridge - T10323-
Prote AG.

♦ Rectangular tube - T40091 / 1- of basic engine support bracket


set - T40091-
♦ Connector - T40091/3- of basic engine support bracket set -
T40091-
♦ Adapter - T40093/3- of supplementary engine support bracket
set - T40093-
♦ Adapter - T40093/3-5 - of supplementary engine support
bracket set - T40093-
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .

74 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Then pull off grommet -arrow- so that it is not damaged when


supporting engine.
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing
– Remove battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .

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

Caution

Locks on selector lever cable break off very easily. If a locking


lug has broken off, complete selector mechanism with selector
lever cable must be renewed.

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– Carefully push locking mechanisms of selectorkleverwage cable to‐
n AG does
gether -arrows- and remove selector leverbcable
Vol s upwards out not
gu
y ara
of cable support bracket. ris
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tho eo
– Do not bend or kink cable. ss au ra
c

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e
nl

pt
du

– Clamp off coolant hoses using hose clamps to 25 mm Ø -

an
itte

y li
3094- and remove.
erm

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ility
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– Seal connecting necks of gear oil cooler using suitable plugs

wit
, is n

from engine bung set - VAS 6122- .

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– Disconnect connector -1- for mechatronic unit for dual clutch


gearbox - J743- . To do this, turn rotary locking mechanism
m

at
om

anti-clockwise -arrow-.
ion
c

in t
or

– Remove charge air line. ⇒ Rep. gr. 21 ; Charge air system;


his
ate

Assembly overview - charge air system


do
priv

cum
for

en
ng

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

8. Removing and installing gearbox 75


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
AG. Volkswagen AG d
agen oes
– Remove upper engine/gearbox connecting bolts. olksw not
y V gu
d b ara
rise nte
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ss c

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pt
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d
itte

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erm

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ility
ot p

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
A bolt is located in the starter motor hole -arrow-. This bolt can be

rrectne
removed using socket - T10061- .

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

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t.
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Cop py
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• Please note the assembly of the following special tools at this
p by
co Vo
by lksw
point: Prote
cted AG.
agen

• Adapters - 10-222 A /8- must be mounted with support bracket


put on, as shown.
• Rubber blocks -A- must face outwards.
• -Arrow- = vehicle driving direction.

76 Rep. gr.34 - Controls, housing


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

• Bolt adapter - T40093/3-5 - onto adapter - T40093/3- .


• Connect 2 bars - 2024 A / 1- of support bracket - 2024 A- to‐
gether using shackle - 10 - 222 A /12- .
• 2 holes -arrows- each point in one direction.

Adapter - T40093/3-5 - or adapter - 10-222 A /8- for the support


bracket - 10-222 A- are positioned near radiator grille and plenum
chamber cover.
Therefore, remove following components:
♦ Radiator grille ⇒ Rep. gr. 66 ; Radiator grille
♦ Windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wash/wipe system
♦ Plenum chamber cover ⇒ Rep. gr. 50 ; Plenum chamber
cover G. Volkswagen nA AG do
wage es n
– Set up support bracket - 10-222 A- behind
yV
olks bonnet support: ot g
ua
b
ed ran
– Use: thoris tee
or
au ac
♦ Adapter - 10-222 A /8- ss

ce
e
nl

pt
♦ Spindle - 10 - 222 A /10-
du

an
itte

y li
erm

♦ Connector - T40091/3-
ab
ility
ot p

– First put on adapter -10-222A/8- -A- next to bolts -arrow- on


wit
, is n

left side.
h re
hole

spec
– Then fit support bracket - 10-222A- behind bonnet support.
es, in part or in w

Position the right adapter - 10-222A/8- next to the bolts as well


t to the co

-arrow-.
– Bolt support bracket - 10-222A- onto left adapter - 10-222A/
rrectness of i

8- .
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

8. Removing and installing gearbox 77


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017

– Attach bars - 2024 A / 1- in engine support eyes.


• 2 holes -arrows- each point towards front end.
– Connect lugs - 2024 A / 1- to spindle - 10 - 222 A /12- using
shackle - 10 - 222 A /10- .
(⇒ previous illustration)
– Set up adapter - T40093/3- with adapter - T40093/3-5 - (notch
-A-) on sheet metal fold of bumper carrier.
– Push one spindle onto square tube - T40091/1- .
– Assemble square tube - T40091/1- with adapter - T40093/3-
and support bracket - 10-222A- .
– Then attach spindle in front engine support eye.
– Take up weight of engine/gearbox assembly on spindle .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
sembly overview - front wheel housing liner .

– Remove electrical wiring and retainers from sump at front


-arrows-.
– Raise wiring in area of sump and secure it.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
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pt
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d
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ab

– Disconnect connector -1- from oil level and oil temperature


ility
ot p

sender - G266- .
wit
is n

h re

Remove subframe. ⇒ Rep. gr. 40 ; Subframe; Assembly over‐


ole,

spec

view - subframe
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

78 Rep. gr.34 - Controls, housing


AG. Volkswagen AG d
agen Sharan 2016 ➤ oes, Tiguan 2008 ➤
olksw not
V
7-speed
d by dual clutch gearbox 0BH - Edition
gu
ara 05.2017
r ise nte
tho eo
– Remove drive shaft heat shield -1-, if present,
ss au
from bevel box ra
c
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive

ce
e
nl
shaft .

pt
du

an
itte

y li
– Disconnect both drive shafts from gearbox ⇒ Running gear,

erm

ab
axles, steering; Rep. gr. 40 ; Drive shaft: Removing and in‐

ility
ot p
stalling drive shafts .

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Secure both drive shafts to suspension struts using tensioning


straps - T10038- .

nf
ercia

o
The surface protection of the shafts must not be damaged.

rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
box.

– Mark position of propshaft with flexible coupling relative to


output shaft of bevel box -arrows-.

8. Removing and installing gearbox 79


Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Volkswagen AG
– Unbolt propshaft from bevel box -arrows- ⇒ Rep. gr. 39 ;swagen AG. does
Propshaft; Removing and installing propshaft . by
Vol
k not
gu
ara
ed nte
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th
au ra
c
ss

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nl

pt
du

an
itte

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erm

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ility
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wit
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hole

spec