0am 7 Speed Audi VW PDF

Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤ AG olk w g
Jetta 2011y ol➤ AG do .V s a en
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7-speed dual clutch gearbox 0AM au
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front 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 © 2011 Volkswagen AG, Wolfsburg MEX5R008520

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 09.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . .ge. n. A. G. ..V.o.lk.sw. a. g.e.n.A.G.d. . . . . . . . . . . . . . . . . . . . . . . 1
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2 Overview - power transmission . .b.y V. o. l . . . . . . . . . . . . . . . . . . . . . .o.t g. u.a. . . . . . . . . . . . . . . . 2
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3 Code, engine allocation . . . t.ho.ri.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . te. e.o . . . . . . . . . . . . 3
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4 Capacities . . . . . . . . . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . 4
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5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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5.1 During work on vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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5.2 During work on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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6 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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7 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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spec
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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7.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.3 Working with vehicle diagnostic testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
rrectness of i
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1 Removing and installing dual clutch, gearboxes made up to 05.2011 . . . . . . . . . . . . . . . . 12

1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.2 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Adjusting position of clutch engagement bearings „K 1“ and „K 2“ . . . . . . . . . . . . . . . . . . 17
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1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2 Removing and installing dual clutch, gearboxes made from 06.2011 onwards . . . . . . . . . . 37
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2.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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2.2 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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2.3 Adjusting position of clutch engagement bearings „K 1“ and „K 2“ . . . . . . . . . . . . . . . . . . 42
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2.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Removing and installing oil seals at clutch end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1 Renewing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.1 Overview - selector mechanism in vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 69
2.2 Removing and installing selector lever cable - vehicles up to 02.2009 . . . . . . . . . . . . . . . . 70
2.3 Overview of selector mechanism - vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 78
2.4 Removing and installing selector mechanism with selector lever and selector lever cable -
vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.5 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.6 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.7 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.8 Removing and installing selector lever knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.9 Moving pushbutton to installation position in the handle . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.10 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3 Mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.1 Safety note on mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . 89
3.2 Overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3 Removing mechatronic unit for dual clutch gearbox J743 with gearbox installed . . . . . . . . 91
3.4 Moving mechatronic unit for dual clutch gearbox J743 into »removal position« by hand . . 101
3.5 Installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.6 View of selector forks with mechatronic unit removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4 Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ►, Golf Variant 2010 ►
........................................................................ 112
4.1 Information about gearboxes with different output shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Contents i
4.2 Removing gearbox, vehicles with 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine
........................................................................ 113
4.3 Removing gearbox, vehicles with 1.6 l/75 kW MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.4 Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine . . . . . . . . . . . . . . . . . . . . . . 131
4.5 Removing gearbox - vehicles with 1.6 l/77 kW TDI CR engine . . . . . . . . . . . . . . . . . . . . . . 138
4.6 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.7 Torque settings »Gearbox to engine« and notes on assembly mounting . . . . . . . . . . . . . . 148
5 Removing and installing gearbox, Jetta 2011 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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wage Jetta 2011 withes1.6 not l/77 kW TDI CR engine . . . . . . . . . . . . . . . . . . . . 152
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arakW TDI CR engine . . . . . . . . . . . . . . . . . . . . . . 160
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5.3 Specified
h or torques . . . . . . . . . . . . . . . . . . . .te.e o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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6 ss Transporting gearbox and securing to assembly stand c ............................ 165
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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1.1 Renewing oil seal for right stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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1.2 Renewing oil seal for left stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.3 Renewing oil seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
rrectness of i
1.4 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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ii Contents
00 – Technical data n AG. Volkswagen AG do

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1 Gearbox identification o
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KHN - Gearbox code letters
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0026 - Serial number
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The gearbox code also appears on the vehicle identification

plates.
1. Gearbox identification 1
2 Overview - power transmission

The 7-speed dual clutch gearbox 0AM is configured as a 5 shaft
gearbox. There are two input shafts and three output shafts.
A1 - Input shaft 1
A2 - Input shaft 2
B1 - Output shaft 1
B2 - Output shaft 2
B3 - Output shaft 3
C - Front final drive
K1 - Dual clutch 1
K2 - Dual clutch 2
M - Engine
T1 - Sub-gearbox 1
❑ with gears 1, 3, 5 and 7
T2 - Sub-gearbox 2
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2 Rep. gr.00 - Technical data

3 Code, engine allocation

Allocation: gearbox codes for petrol engines
KHN, LKG, LKM KUT, LPL LSU
1.4 l/90 kW TSFI 1.4 l/118 kW TSI 1.6 l/75 kW MPI
Allocation: gearbox codes for diesel engines

KHM, LKL, LKF LQN, LST
1.9 l/77 kW TDI PD 1.6 l/77 kW TDI
common rail
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3. Code, engine allocation
4 Capacities
The 7-speed dual clutch gearbox has two separate and different
oil systems. One for the gear oil part -arrow A- and one for the
hydraulic fluid part -arrow B-.
Capacities Gear oil part
Initial filling 1.7 l
Change No change necessary
Lubricant Gear oil for dual clutch gearbox 0AM
Part number ⇒ Electronic parts catalogue
„ETKA“
Capacities Hydraulic fluid part in mechatronic unit for

dual clutch gearbox -J743-
Initial filling 1l
Change No change necessary
Lubricant Hydraulic fluid
Part number ⇒ Electronic parts catalogue
„ETKA“
Further information in the part number designates the container
size.
Caution
Risk of damage to gearbox.

♦ Only the gear oil for the 7-speed dual clutch gearbox 0AM,
which is available through the replacement parts system,
may be used ⇒ Electronic parts catalogue „ETKA“ .
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♦ It is not possible to check the fill level of the hydraulic
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♦ If any oil escapes from the hydraulic fluid part of the me‐
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chatronic unit for dual clutch gearbox -J743- , it is not

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♦ If oil escapes from the gear oil part, it can only be rectified
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by changing the gear oil. It is not possible to check the oil

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♦ If the level of oil/fluid is too high or too low in either of the

parts, the function of the gearbox will be impaired.
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5 Safety precautions
Overview:
♦ ⇒ „5.1 During work on vehicle“, page
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WARNING
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Risk of injury and accident by accidental engagement of gear
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while engine is running.
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♦ Before work is done with the engine running, move the
selector lever to the „P“ position and apply the parking
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brake.
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To prevent personal injury and damage to or destruction of elec‐
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♦ Connect and disconnect measuring and testing devices only
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♦ Disconnect battery only after the ignition has been switch‐

ed off.
– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .
5.2 During work on vehicles with start/stop

system
During work on vehicles with start/stop system, observe the fol‐
lowing:
WARNING
Injury hazard as a result of automatic engine start in vehicles

with start/stop system
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication on the combi-instrument) the engine
can start automatically if required.
♦ When working on the vehicle, therefore, ensure that the
start/stop system is deactivated (switch ignition off, then
switch ignition back on when required).
5. Safety precautions 5
6 Notes on tow-starting/towing
Caution
Danger of irreparable damage to gearbox.

♦ If the vehicle has to be towed, the selector lever must be
in the „N“ position and the vehicle must not be towed at a
speed no greater than 50 km/h and for a distance not ex‐
ceeding 50 km.
Note
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7 General repair notes
7.1 Tools
A summary of the special tools and workshop equipment used in
the workshop manual precedes each repair procedure and can
be found in „Special tools/Workshop equipment“ binder.
The catalogue is also available on CD-ROM and can be ordered
the usual way from Bertelsmann.
Uncertainty often occurs with smaller bolts having low tightening
forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with
these bolts.
7.2 Gearbox
The torque of the engine is transmitted via the flywheel to the dual
clutch gearbox. The flywheel and the dual clutch are joined to‐
gether by a toothed connection. Together they take on the func‐
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On some gearboxes, this opening is sealed with a cap.

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– Ensure that no small parts fall into this opening during repairs
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-arrow-. Cover opening with a cloth.

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7. General repair notes 7

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es, in part or in w
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rrectness of i
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ion
c
Make sure that no dirt can enter an »open« gearbox.

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

do
priv
do not run engine. Do not tow vehicle.

um
for
en
ng
t.
♦ First thoroughly clean connecting points and surrounding
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areas and then loosen bolts. t. C rig
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♦ During installation, ensure that the dowel sleeves between the
co Vo
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engine and gearbox are correctly located.
agen
Prote AG.
♦ Place removed parts on a clean surface. Cover parts to pre‐

vent soiling. Use plastic sheeting and paper. Use lint-free
cloths only!
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
♦ If repair work cannot be performed immediately, cover opened
parts carefully.

In some vehicles, a cover is fitted over the engaging levers.

Volkswagen AG
The cover prevents dirt getting
swa
genin.
AG. does
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Tightening torque sof ed bsecuring bolts: 8 Nm ara
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es, in part or in w
t to the co
rrectness of i
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nform
ercia
Assembly overview of gearbox

m
a
1- Gearbox breather cap
com
tion in
2- Cover
r
te o
thi
s
iva
do
3- Lever/selector shaft
r
rp
cum
fo
4- Breather cap of mechatronic unit for dual clutch gearbox -

en
ng
t.
yi
J743-
Co
Cop py
ht. rig
5- Mechatronic unit for dual clutch gearbox -J743-
rig ht
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6- Dual clutch
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7- Flange shaft
8- Oil drain plug, 30 Nm
9- Dual clutch gearbox
Gearbox oil
Only the gear oils available through the replacement parts system
may be used for the dual clutch gearbox 0AM. Other oils will lead
to malfunctions or failure of the gearbox, part number ⇒ Elec‐
tronic parts catalogue „ETKA“ .
The oil level in the gearbox cannot be checked. The oil level can
only be adjusted by changing the gear oil.
Oil which has been drained out cannot be added again.
Caution
Use caution when handling oil. Dispose of used oil properly.
O-rings, radial oil seals, gaskets

♦ Always renew O-rings, radial oil seals and gaskets. AG. Volkswagen AG d
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♦ After removing gaskets and seals, always inspect ed b contact sur‐ ara
nte
is
face of housing or shaft for burrs resulting from
hor removal or for eo
ut
other signs of damage. ss a ra
c
ce
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♦ Before installing a radial oil seal, coat sealing lips and area
nl
pt
du
an
between -arrow- with sealing grease -G 052 128- and outer
itte
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circumference with gear oil.
erm
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ility
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♦ The open side of the oil seal faces the side with fluid filling.
wit
, is n
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♦ Moisten O-rings with gear oil or Vaseline to prevent crushing
hole
spec
of the rings during assembly.
es, in part or in w
t to the co
♦ Never use any other types of lubrication in the gear oil area.
Otherwise there is a risk of malfunctions in the hydraulic gear‐
box control.
rrectness of i
Nuts and bolts
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♦ Loosen and tighten securing bolts and securing nuts for covers
and housings in diagonal sequence.
nf
ercia
o
♦ Torque settings are specified for unoiled bolts and nuts.
rm
m
atio
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♦ Threads of bolts secured with locking fluid must be cleaned

o
n in
c
with a wire brush. Then insert bolts with locking fluid -

or
thi
e
AMV 185 101 A1- .

t
sd
iva
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rp
cu
♦ Threaded holes into which self-locking bolts or bolts coated
o
m
f
en
ng
with locking fluid are screwed, must be cleaned (e.g. with a yi

t.
Co
thread chaser). Otherwise there is a danger of bolts shearing t. Cop py
when subsequently being removed.
rig
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♦ Always renew self-locking bolts and nuts.
lksw
cted agen
Prote AG.
Electrical components
You have probably at some time received an electrical shock

when touching a metal object. This is due to the electrostatic
charge of the human body. This charge can disturb the function
of electrical components of the gearbox and of the selector mech‐
anism.
– Before beginning work on electrical components, touch an
earthed object, for example a water pipe or lifting platform. Do
not touch connectors or »open« electronic components direct‐
ly.
7.3 Working with vehicle diagnostic testers

• Only work with vehicle diagnostic testers from Volkswagen.
♦ Vehicle diagnosis and service information system -VAS 5052
A-
♦ Vehicle diagnosis, testing and information system -VAS
5051B-
♦ Vehicle diagnostic tester -VAS 5053-

AG. Volkswagen AG d
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Various functions are available in the oloperating
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functions and Guided fault edfinding . The 3 most important
b ran
ris tee
functions are: utho
or
sa ac
♦ Adapting installation information
s
ce
e
nl
pt
du
♦ Reading measured values for mandatory reporting
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itte
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ab
♦ Initiating basic adjustment
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7.3.1 Adapting installation information
, is n
h re
hole
spec
The mechatronic unit detects other control units in the vehicle by
es, in part or in w
means of signals on the data bus. Pressing the Adapt instal-
t to the co
lation information button instructs the mechatronic unit to
forget all communication partners.
rrectness of i
All »active partners« are detected once again the next time the
ignition system is switched on.
l purpos
You cannot »generate« any faults using this function. Please al‐
ways perform the Adapt installation information function
nform
ercia
after the following activities:

m
at
om
i
♦ After a selector lever has been installed.
on
c
in t
or
♦ After another control unit has been installed, e.g. engine, ABS
his
ate
or gateway.
do
priv
cum
for
♦ After work on the steering wheel paddle.
en
ng
t.
yi Co
op
7.3.2 Reading measured values for mandato‐
C py
ht. rig
rig ht
by
ry reporting copy Vo
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cted agen
Prote AG.
You must read these measured values before contacting your
Technical Service Center or your importer.
Save the measured values in the diagnosis log so that all neces‐
sary gearbox data will be available for fault analysis.
7.3.3 Initiating basic adjustment

This teaches important settings into the mechatronic unit. Even
important adjustments are taught in again, or reset to program‐
med points. These include, for example, the synchronisation
points and »reference points« for the engaging lever and gear
actuator.
WARNING
Do not carry out basic adjustment without a reason unless re‐

quested to do so!
– Press the button DSG Mechatronic -J743- performing

basic measurement only:
♦ if you are prompted to do so in „guided fault finding“

♦ after you have processed a fault entry
♦ after you have installed a dual clutch
♦ or after you have installed a mechatronic unit

30 – Clutch
1 Removing and installing dual clutch,
gearboxes made up to 05.2011
Transporting gearbox and securing to assembly stand
⇒ page 165 .
Removing and installing dual clutch, gearboxes made from
06.2011 onwards ⇒ page 37 .
Overview:
♦ ⇒ „1.1 Assembly overview - dual clutch“, page 12
♦ ⇒ „1.2 Removing dual clutch“, page 14
♦ ⇒ „1.3 Adjusting position of clutch engagement bearings K 1
and K 2 “, page 17
♦ ⇒ „1.4 Installing dual clutch“, page 29
1.1 Assembly overview - dual clutch
Caution
Risk of damage from clutch adjustment

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n AG. Volkdevice.
swagen AG
doe
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♦ The clutch is self-adjusting. Shocks can have an effect gu on
V t
by ara
ed
this adjustinghdevice.
oris Do not allow clutch to fall into gear‐ntee
box durings installation.
au
t or
ac
s
♦ A clutch that has fallen onto a hard surface or shows signs
ce
e
nl
pt
du
of damage must not be reinstalled.

an
itte
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Vo
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by
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Prote AG.
12 Rep. gr.30 - Clutch

. Volkswagen AG
gen AG
kGolf
swa Variant 2007 ➤ , d Golf
oes Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
ol not
d by
V
7-speed gudual clutch gearbox 0AM - Edition 09.2011
ara
ise nte
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1 - Retaining ring
aut ra
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❑ Renew
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le
un
pt
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d
2 - Hub
itte
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pe
3 - Retaining ring
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❑ Renew
, is n
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hole
4 - Large engaging lever for „K
spec
1“
es, in part or in w
t to the co
❑ With large engagement
bearing
❑ ⇒ „1.3 Adjusting position
rrectness of i
of clutch engagement
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bearings K 1 and K 2 “,
page 17
nform
ercia
5 - Small engaging lever for »K

2«
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tio
6 - Bolts
n in
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❑ 8 Nm + 90° further
s
iva
do
❑ Renew
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7 - Retainer
n
t.
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❑ For engaging lever t. C rig
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8 - Clip
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❑ For small engaging lev‐
AG.
er
❑ No present in some old‐
er gearboxes
9 - Oil seal
❑ For inner input shaft
❑ Renewing ⇒ page 61
10 - Oil seal
❑ For outer input shaft
11 - Outer input shaft
12 - Shim „SK 2“
❑ Determining thickness ⇒ page 17
13 - Shim „SK 1“
❑ Determining thickness ⇒ page 17
14 - Small engagement bearings for »K 2«
❑ ⇒ page 17
15 - Dual clutch
❑ Removing ⇒ page 14
❑ Installing ⇒ page 29
1. Removing and installing dual clutch, gearboxes made up to 05.2011 13

1.2 Removing dual clutch
Special tools and workshop

equipment required
♦ Hook -3438-
♦ Engine bung set -VAS
6122-
♦ Support device -T10323-
♦ -T10356/5- from assembly
tool -T10356-
♦ Puller -T10373-
♦ Thrust piece -T10376-
AG. Volkswagen AG d
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– Removing gearbox:
pe
ility
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♦ ⇒ „4 Removing and installing gearbox, Jetta 2005 ►, Golf Var‐

h re
iant 2007 ►, Golf Variant 2010 ►“, page 112

hole
spec
♦ ⇒ „5 Removing and installing gearbox, Jetta 2011 ►“,

es, in part or in w
t to the co
page 152
– Pull off both breather caps -arrows- and seal using suitable
plugs from engine bung set -VAS 6122- to achieve an oil-tight
rrectness of i
seal.
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.

Turn gearbox with dual clutch upwards.

For information about how to transport the gearbox securely and
attach it to the assembly stand ⇒ page 165 .
Note
The dual clutch is pulled off upwards. The mechatronic unit re‐
mains on the gearbox.
– Remove retaining ring -arrow- for hub.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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nl
pt
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ility
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– Remove hub with hook -3438- and a screwdriver.

wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
– Remove retaining ring -arrow- for clutch.

in t
or
his
ate
If retaining ring cannot be removed:

do
priv
cum
for
en
ng
t.
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Note Cop py
t. rig
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♦ If the retaining ring cannot be removed it is because the clutch
o Vo
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cted
has »clamped« the retaining ring at the bottom.
agen
Prote AG.
♦ In this case, push the clutch down slightly (see following de‐
scription) and release the load on the retaining ring. Never
strike the clutch or shaft with a hammer!
♦ Always renew retaining ring.

– Position support bracket -T10323- parallel to gearbox flange

as shown in illustration.
– If necessary, balance out gaps using -T10356/5- , for example.
– Screw in bolts -A- hand-tight.
Note
Bolts -A-, secure with nut as required.
Caution AG. Volkswagen AG d

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Risk of damage to clutch and otheroricomponents!
se nte
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h
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• Push down clutch using onlyss a very light force. c
ce
e
nl
pt
du
an
itte
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– To press down, turn spindle against thrust piece -T10376- .
erm
ab
ility
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– Detach special tool and remove retaining ring -arrow- for
wit
, is n
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clutch.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
Continuation once retaining ring has been removed:

o
his
ate
do
riv
– Fit puller -T10373- in clutch and pull off clutch.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove clutch together with puller -T10373- .

– Remove small engagement bearing.

– Remove large engaging lever.
– Undo bolts and remove small engaging lever.

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
– Remove retainer for engaging lever.
t to the co
Before installing clutch, please refer to ⇒ page 17 to see wheth‐
er »clutch needs adjusting during assembly or not.«
rrectness of i
Adjusting ⇒ page 17 .
l purpos
Install dual clutch ⇒ page 29 .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
1.3 Adjusting position of clutch engagement

n
t.
yi Co
op py
bearings „K 1“ and „K 2“
t. C rig
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Vo
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by
The position of the engagement bearings must be adjusted after Prote
cted AG.
agen
the following tasks:
♦ Dual clutch was renewed.
♦ Engaging levers were renewed.
♦ Retainer of engaging levers was renewed.
♦ Engagement bearings were renewed.
Note
There is no need to adjust anything if all the named parts have

only been removed and reinstalled.
Brief description
♦ Position of engagement bearings is comparable with clutch
play of a manual gearbox. In the 7-speed dual clutch gearbox
0AM there are tolerances in the engagement system of the

gearbox and in the gearbox itself. Even within the dual clutch
there are tolerances. These tolerances must be taken into ac‐
AG. Volkswagen AG d
count separately during adjustment.
lksw
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♦ The following procedure ris
edfirst describes how to measure all
b ara
nte
necessary dimensions uth on the gearbox so that the appropriate
o eo
ra
shim can be selected.
ss
a In addition are the tolerances in the c
clutch that the manufacturer has already calculated. Toleran‐
ce
le
un
pt
ces on gearbox and tolerances in clutch determine thickness
an
d
itte
of shim.
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rm
ab
pe
ility
♦ Adhere to the sequence of work steps.
ot
wit
, is n
Overview of clutch actuation
h re
hole
spec
es, in part or in w
1 - Small engaging lever for »K
t to the co
2«
2 - Shim for »K 2«
rrectness of i
3 - Engagement bearings for
l purpos
»K 2«
nform
ercia
1“
m
a
❑ With large engagement
com
tio
bearing
n in
r
te o
thi
5 - Shim for „K 1“
s
iva
do
r
rp
6 - Bolts cum
fo
en
ng
t.
yi Co
Cop py
❑ Always renew
t. rig
gh ht
pyri by
Vo
o
7 - Clip
c by lksw
cted agen
Prote AG.
❑ No present in some old‐
er gearboxes
8 - Retainer
Special tools and workshop equipment required

♦ Gauge block -T10374-
♦ Ruler -T40100-
lkswage es n
o ot g
byV ua
d ran
ir se tee
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u or
a ac
ss
ce
le
un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
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♦ Digital depth gauge 300 mm e.g. -VAS 6594-
h re
hole
♦ Adhesive -AMV 195 KD1 01-
spec
es, in part or in w
t to the co
♦ Micrometer caliper
Requirement:
rrectness of i
• The gearbox flange must be level to assure good contact with
the ruler.
l purpos
• Mechatronic unit for dual clutch gearbox -J743- must be re‐

moved.
nform
ercia
• Torque settings
m
a
com
⇒ „1.1 Assembly overview - dual clutch“, page 12 .

ion in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
t.
If a further tightening angle is specified for certain bolts, these
yi Co
op
must be renewed.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
Risk of damage to clutch and other components!

• Mounting for engaging lever and entire mechanism of en‐
gagement bearing must be dry and free of oil or grease.

AG. Volkswagen AG d
1st step: Prepare dual clutch for measurement. ksw
agen oes
not
Vol
y gu
– Insert retainer for engaging lever. ise
d b ara
nte
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install small engaging lever with clip.
rrectness of i
l purpos
Note
Only a few, »older« gearboxes do not have a clip.
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
– Tighten bolts for small engaging lever. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
– Insert large engaging lever.

– Check both engaging levers are seated correctly.

. Volkswagen AG
a gen AG d
– Install previously
Vol
ksw used retaining ring -arrow-
oes
not of outer input
gu
shaft. ed by ara
n
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
2nd step: Determine dimension „B“ for clutch „K 1“ and „K 2“.
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.
– Place ruler -T40100- upwards across end of shaft onto gear‐

box flange.
Caution
Risk of false measurements.

♦ The ruler -T40100- should remain in this position for the
following measurements. Do not turn over, do not remove.
– Place digital 300 mm depth gauge -VAS 6594- on top of ruler

-T40100- and position depth gauge rod on outer input shaft.
– Set depth gauge to „0“.

– Position depth gauge rod on retaining ring, as show in dia‐

gram. n AG. Volkswagen A ge G do
swa es n
– In this position, determine dimension „Bb1y “Voto
lk retaining ring. ot g
ua
ed ran
ris tee
• Example: dimension „B1“ = 2.92 umm
tho or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– In the opposite position, determine dimension „B2“ to retaining
ring.
rrectness of i
Note
l purpos
Do not measure on retaining ring joint. It is possible that the re‐
nform
ercia
taining ring will be pushed away and thus falsify the reading.
m
a
com
ti
• Example: dimension „B2“ = 3.00 mm
on in
r
te o
thi
– Calculate mean value from dimension „B1“ and „B2“.
s
iva
do
r
rp
c
Formula: B1 + B2 2
um
fo
en
ng
t.
yi Co
Example: ht. Cop py
rig
rig ht
• 2,92 + 3,002 = 2.96 mm py by
co Vo
by lksw
cted agen
• Result: Dimension „B“ = 2.96 mm Prote AG.
– Remove and dispose of retaining ring.
3rd step: Determine dimension „A1“ for clutch engaging lever

„K 1“.

– Place end gauge -T10374- on large engagement bearing with

large opening upwards.
– To ensure that end gauge -T10374- sits properly on engage‐
ment bearing, press down and turn end gauge .
• Engagement bearing will turn with end gauge -T10374- .

• Ruler -T40100- is lying upwards across end of shaft on gear‐
box flange.
Caution

– Position depth gauge rod on end gauge -T10374- , as show in

diagram.
– In this position, determine dimension „A 1a“ to end gauge -
T10374- .
• Example: Dimension „A 1a“ = 2.61 mm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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
23
AG.
1. Removing and installing dual clutch, gearboxes made up to 05.2011
– In the opposite position, determine dimension „A 1b“ to end

gauge -T10374- .
• Example: Dimension „A 1b“ = 2.81 mm
– Calculate mean value from dimension „A 1a“ and „A 1b“.
Formula: A 1a + A1b 2
Example:
• 2,61 + 2,812 = 2.71 mm
• Result: Dimension „A 1“ = 2.71 mm
4th step: Calculate installation depthagof
enclutch
AG. Volkengagement
swagen AG
doesbear‐
ing „K 1“. V olksw not
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db ran
rise tee
tho or
Note au ac
ss
ce
le
un
pt
On the basis of dimension „A 1“ and dimension „B“, the actual
an
d
itte
installation depth of the clutch engagement bearing „K 1“ is now
y li
erm
ab
calculated based on the following calculus.
ility
ot p
wit
is n
h re
Dimension „A 1“
ole,
spec
– Dimension „B“
t to the co
+ Exterior height end gauge -T10374- (51.81 mm; fixed val‐
ue)
= Actual installation depth of clutch engagement bearing „K
rrectne
1“
s
Example:
s o
cial p
f in
• 2.71 mm – 2.96 mm + 51.81 mm = 51.56 mm

form
mer
• Result: Installation depth of clutch engagement bearing „K 1“

atio
m
= 51.56 mm
o
n
c
i
or
n thi
e
5th step: Calculate clearance of clutch „K 1“.

t
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
With the actual value and specification for the engagement bear‐ yri
p by
o Vo
ing installation depth, the clearance of clutch „K 1“ is now deter‐ by c lksw
cted agen
mined using the following calculus.
Prote AG.
Actual value of engagement bearing installation depth

– Specification of engagement bearing installation depth
(50.08 mm; fixed value)
= Clearance of clutch „K 1“
Example:
• 51.56 mm – 50.08 mm = 1.48 mm
• Result: Clearance of clutch „K 1“ = 1.48 mm

6th step: Calculate clutch tolerance of clutch „K 1“.

– Take clutch tolerance value from new clutch.
wage es n
• Example: Read off clutch tolerance value on clutch yV
olks ot g
ua
„K 1 = +0.2“, as shown in diagram. ir se
d b ran
o tee
h
7th step: Determining thickness of shim „SK au1“.
t or
ac
ss
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
ot p
On the basis of the clearance value and clutch tolerance „K 1“,
wit
the thickness of shim „SK 1“ is now calculated using the following , is n
h re
calculus.
hole
spec
es, in part or in w
t to the co
Clearance of clutch „K 1“
–/+ Clutch tolerance of clutch „K 1“
rrectness of i
= Calculated thickness of shim „SK 1“
l purpos
Example:
• 1.48 mm + 0.20 mm = 1.68 mm
nform
ercia
• Result: Calculated thickness of shim „SK 1“ = 1.68 mm

m
at
om
ion
c
– From the shims supplied, measure the required shim and have
in t
or
his
e
it ready for installation.

at
do
priv
cum
Calculated thickness of shim Available shims
for
en
g
mm Thickness in mm
n
t.
yi Co
op py
0.31 … 0.90 0.80
t. C rig
gh ht
pyri by
0.91 … 1.10 1.00
co Vo
by lksw
cted agen
Prote
1.11 … 1.30 1.20
AG.
1.31 … 1.50 1.40

1.51 … 1.70 1.60
1.71 … 1.90 1.80
1.91 … 2.10 2.00
2.11 … 2.30 2.20
2.31 … 2.50 2.40
2.51 … 2.70 2.60
2.71 … 3.30 2.80
Example:
• Chosen shim thickness = 1.60 mm
Caution
Risk of damage to gearbox

♦ Mark shim „SK 1“ and have it ready for assembly.
♦ For adjustment, only this shim „SK 1“ may be inserted for
the small engaging lever.

8th step: Determine dimension „A 2“ for clutch engaging lever

„K 2“
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
– Only insert small engagement bearing.
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
• Small engagement bearing only fits in one position due to 4

en
ng
t.
yi
grooves.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– By turning -arrows-, check whether small engagement bearing

is properly installed and that grooves are seated correctly.

– Place end gauge -T10374- on small engagement bearing with

large opening upwards.

box flange.
Caution


diagram. gen AG
. Volkswagen AG
d a oes
lksw not
– In this position, determine dimensiond „A
by 2a“ to end gauge -
Vo gu
ara
e
T10374- . ho
ris nte
eo
t
au ra
• Example: Dimension „A 2a“ =ss2.50 mm c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


gauge -T10374- .
– Calculate mean value from dimension
gen „A
AG.2Vao“lkand
swage„A
n A2
Gbd“. a oes
ksw not
Vol
Formula: A 2a + A 2b 2 ed by gu
ara
ris nte
ho eo
Example: au
t ra
c
ss
• 2,50 + 2,542 = 2.52 mm
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
9th step: Calculate installation depth of clutch engagement bear‐
ility
ot
ing „K 2“.
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
On the basis of dimension „A 2“ and dimension „B“, the actual
installation depth of the clutch engagement bearing „K 2“ is now
rrectness of i
calculated based on the following calculus.
l purpos
Dimension „A 2“
nform
ercia
m
+ Interior height end gauge -T10374- (36.20 mm; fixed val‐
a
com
tio
ue)
n in
r
te o
= Actual installation depth of clutch engagement bearing „K

thi
s
iva
2“
do
r
rp
cum
fo
Example:
en
ng
t.
yi Co
op py
• 2.52 mm – 2.96 mm + 36.20 mm = 35.76 mm t. C rig
gh ht
pyri by
• Result: Installation depth of clutch engagement bearing „K 2“
o Vo
by c lksw
cted
= 35.76 mm
agen
Prote AG.
10th step: Calculate clearance of clutch „K 2“.
Note
With the actual value and specification for the engagement bear‐
ing installation depth, the clearance of clutch „K 2“ is now deter‐
mined using the following calculus.
Actual value of engagement bearing installation depth

– Specification of engagement bearing installation depth
(34.35 mm; fixed value)
= Clearance of clutch „K 2“
Example:
• 35.76 mm – 34.35 mm = 1.41 mm
• Result: Clearance of clutch „K 2“ = 1.41 mm


• Example: Read off clutch tolerance value on clutch „K 2 = –
0.2“, as shown in diagram.
12th step: Determining thickness of shim „SK 2“.
Note
On the basis of the clearance value and clutch tolerance „K 2“,

the thickness of shim „SK 2“ is now calculated using the following
calculus.
Clearance of clutch „K 2“
Example:
• 1.41 mm – 0.20 mm = 1.21 mm
– From the shims supplied, measure the required shim and have
it ready for installation.
mm Thickness in mm
0.31 … 0.90 0.80
0.91 … 1.10 1.00 agen AG. Volkswagen AG do
ksw es n
1.11 … 1.30 Vol
y1.20
ot g
ua
d b ran
1.31 … 1.50 ir se 1.40 tee
tho
u or
1.51 … 1.70 ss
a
1.60 ac
ce
le
1.71 … 1.90 1.80

un
pt
an
d
itte
1.91 … 2.10 2.00

y li
rm
ab
pe
2.11 … 2.30 2.20

ility
ot
wit
, is n
2.31 … 2.50 2.40

h re
hole
2.51 … 2.70 2.60

spec
es, in part or in w
2.71 … 3.30 2.80

t to the co
Example:
rrectness of i

l purpos

nform
ercia
Caution
m
a
com
Risk of damage to gearbox

ion in
r
te o
♦ Mark shim „SK 2“ and have it ready for assembly.

thi
s
iva
do
♦ For adjustment, only this shim „SK 2“ may be inserted.

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
– Install dual clutch ⇒ page 29 .
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
1.4 Installing dual clutch
agen
Prote AG.

♦ -T10356/5- from assembly tool -T10356-
AG. Volkswagen AG d
agen
♦ Puller -T10373- Volksw
oes
not
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
♦ Adhesive -AMV 195 KD1 01- by c lksw
cted agen
Prote AG.
Perform the following steps:
• Torque settings
⇒ „1.1 Assembly overview - dual clutch“, page 12 .

Note
If a further tightening angle is specified for certain bolts, these

must be renewed.
AG. Volkswagen AG d
Caution ksw
agen oes
not
Vol
by gu
d ara
Risk of damage to dual clutch and other components!
horise nte
eo
ut ra
• Clutch parts must be free of oil and grease.
ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
The following four work steps are only necessary if the position
hole
spec
of the engagement bearings did not have to be adjusted.
es, in part or in w
t to the co
– Insert retainer for engaging lever.
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
op
– Install small engaging lever with clip. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Note Prote AG.
Only a few, »older« gearboxes do not have a clip.
– Secure small engaging lever with 2 new bolts.


Caution
Risk of damage to dual clutch and other components!

• The positions of the engagement bearings must be set
correctly.
Adjustment can only be carried out before the dual clutch is
installed.
The position of the engagement bearings must be adjusted af‐
ter the following tasks:
olkswagen AG
en AG. V
♦ Dual clutch was renewed.
Vol
ksw
ag does
not
y gu
db ara
♦ Engaging leversoriwere
se renewed. nte
h eo
ut
♦ Retainer of sengaging levers was renewed.
a ra
s c
ce
le

un
pt
an
d
itte
y li
If one of the above work measures was carried out, the position
rm
ab
of engagement bearings „K 1 and K 2“ must now first be set
pe
ility
⇒ page 17 and the newly calculated shims inserted.
ot
wit
, is n
h re
Do not continue with assembly until the setting is correct!
hole
spec
es, in part or in w
If no new parts have been installed, insert removed shims.

t to the co
For adjustment, only one shim per engagement bearing may
be installed.
rrectness of i
l purpos
– Insert small engagement bearings -1- with measured shim

-item 2- for „K 2“.
nform
ercia
Shim should be under small engagement bearing. Therefore, in‐

m
sert shim first.

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.

grooves.

ks bearing wage es n
– By turning -arrows-, check whether small engagement Vol ot g
by ua
is properly installed and that grooves are seated
ris
ed correctly. ran
tee
tho or
s au ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Fix »large« shim -1- for „K 1“ in place with 3 drops of adhesive
rrectne
-AMV 195 KD1 01- -arrows-.
This prevents shim from slipping out of its seat when clutch is
ss
inserted.
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
yri
– Turn back spindle of puller -T10373- . p by
co Vo
by lksw
cted agen
Prote AG.
Caution
Risk of damage from clutch adjustment device.

♦ The clutch is self-adjusting. Shocks can have an effect on
this adjusting device. Do not allow clutch to fall into gear‐
box during installation.
– Install clutch with puller -T10373- in gearbox, as shown in di‐

agram.

– If necessary, balance out gaps using -T10356/5- from assem‐
bly tool -T10356- , for example.
Note
– Press on clutch as far as it will go.
Note
Place a hand on the clutch when pressing it on. A slight »rattling«

will be felt. Rattling indicates that the clutch is being pressed onto
its press seat. This also enables detection of the limit stop once
the clutch has been seated correctly.

– Take hold of new retaining ring with retaining ring pliers, as

shown in the illustration.
• Installation position: narrow surface of retaining ring on top.
– Inserting retaining ring -arrow-.
Note
If the retaining ring cannot be inserted, the clutch has not been
pressed in onto its limit stop.
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
b ara
– To ensure that the clutch reaches its operating rise
d position right nte
from this stage, turn it against puller -T10373-
utho
-arrow- by hand eo
ra
without using any other tools. ss a c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Note
ss o
cial p
f i
♦ By pressing on, the clutch sits at the bottom against the limit
nform
stop on the input shaft. This is not the optimum position.

mer
atio
m
♦ Clutch should only be pulled up far enough for it to contact

o
n
c
retaining ring.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
Only turn by hand. In this way, clutch slides against retaining ring.
ht
pyri by
Vo
o
Do not use any other tool.
c by lksw
cted agen
Prote AG.

– Insert hub.
• Hub has »large tooth« -arrow- and only fits in one position.
• »Large tooth« has a mark on engine end -arrow-.
– Insert retaining ring -arrow- of hub.

• Joint of retaining ring must point towards »hub« of clutch.
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
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 Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Turn clutch by hand and observe small engaging lever whilst

turning.
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
• While the clutch is being turned, it must be ensured that the
ab
ility
small engaging lever remains absolutely still. It must be en‐
ot p
wit
sured that it does not move up and down.
, 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
c
Note
or
thi
te
sd
iva
♦ If an engaging lever moves up and down, the shim is not prop‐

o
r
rp
cu
erly seated.
o
m
f
en
ng
t.
yi Co
♦ In this case, remove clutch again ⇒ page 14 . Cop py
t. rig
gh ht
yri
♦ Check shims -arrows-. p by
co Vo
by lksw
cted agen
♦ The shims must be properly seated and must not be damaged. Prote AG.
– Remove plugs and put both breather caps -arrows- back on.
– After installation of gearbox, perform Complete reset by
means of Guided functions ⇒ Vehicle diagnostic tester.

2 Removing and installing dual clutch,

gearboxes made from 06.2011 on‐
wards
Removing and installing dual clutch, gearboxes made up to
05.2011 ⇒ page 12
Caution

♦ A clutch that has fallen onto a hard surface or shows
gen AG
. Volkswsigns
agen AG
does
of damage must not be reinstalled.Volkswa not
y gu
db ara
rise nte
tho eo
Overview: ss
au ra
c
ce
e
♦ ⇒ „2.1 Assembly overview - dual clutch“, page 38

nl
pt
du
an
itte
y li
♦ ⇒ „2.2 Removing dual clutch“, page 39
erm
ab
ility
ot p
♦ ⇒ „2.3 Adjusting position of clutch engagement bearings K 1
wit
, is n
and K 2 “, page 42
h re
hole
♦ ⇒ „2.4 Installing dual clutch“, page 54
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Removing and installing dual clutch, gearboxes made from 06.2011 onwards 37
2.1 Assembly overview - dual clutch

swa
gen AG
. Volkswagen AG
does
olk not
yV gu
edb ara
ris nte
1 - Hinge mounting tho eo
au ra
❑ For large engaging lever ss c
ce
le
„K 1“
un
pt
an
d
❑ Is not renewed
itte
y li
erm
ab
2 - Ball stud
ility
ot p
wit
❑ Small small engaging
is n
h re
lever „K 2“
ole,
spec

t to the co
page 42
rrectne
3 - Shim „SK 1“
❑ Determining thickness
ss
⇒ „2.3 Adjusting position
o
cial p
f
inform
mer
page 42
atio
om
n
4 - Shim „SK 2“
c
i
or
n thi
e
❑ Determining thickness
t
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
page 42
C py
ht. rig
rig ht
py by
5 - Small engagement bear‐ co Vo
by lksw
ings for „K 2“
cted agen
Prote AG.
page 42
6 - Dual clutch
❑ Installing ⇒ page 54
❑ Renewing
of clutch engagement bearings K 1 and K 2 “, page 42
7 - Retaining ring
❑ Renew
8 - Hub
9 - Retaining ring
❑ Renew
10 - Large engaging lever for „K 1“
❑ With engagement bearing
❑ ⇒ „2.3 Adjusting position of clutch engagement bearings K 1 and K 2 “, page 42
11 - Upper section of bushing
❑ Small small engaging lever „K 2“
❑ Is removed and installed together with lower section of bushing
12 - Small engaging lever for „K 2“
❑ Is removed and installed together with upper and lower section of bushing

. Volkswagen AG
wa gen AG does
13 - Bolts olks not
byV gu
ara
❑ 8 rNm ise + 90° further
d
nte
ho eo
❑ au Always renew
t ra
c
ss
14 - Lower section of bushing
ce
e
nl
pt
du
an
itte
y li
erm
ab
❑ Is removed and installed together with upper section of bushing
ility
ot p
wit
15 - Oil seal
, is n
h re
❑ For inner input shaft
hole
spec
es, in part or in w
t to the co
16 - Oil seal
❑ For outer input shaft
rrectness of i
l purpos
2.2 Removing dual clutch
nform
mercia
at
om
ion
c
in t
or
equipment required
his
ate
do
riv
♦ Hook -3438-
p
cum
for
en
g
♦ Engine plug set -VAS 6122-

n
t.
yi Co
Cop py
.
t rig
gh ht
pyri by
Vo
co
♦ -T10356/5- from assembly
by lksw
cted agen
Prote
tool -T10356-
AG.
♦ Puller -T10373-
Requirement:
• Gearbox removed and secured to engine and gearbox jack
⇒ page 165 .
• Mechatronic unit for dual clutch gearbox -J743- built into gear‐
box.
– Pull off both breather caps -arrows- and close using clean
plugs from engine bung set -VAS 6122- to achieve an oil-tight
seal.
WARNING
The breather cap on the mechatronic unit is destroyed during

removal and must be renewed.
– Turn gearbox on engine and gearbox jack upwards together

with clutch..
Note
The clutch is pulled off upwards. The mechatronic unit remains

on the gearbox.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Remove retaining ring of hub u-arrow-.
tho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
– Remove hub with hook -3438- and a screwdriver.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
If parts of clutch are renewed, the position of engagement bear‐
op Vo
by c lksw
ings „K 1“ and „K 2“ must be set later. It is therefore advisable to
cted agen
Prote AG.
determine dimension „B“ for the measurements now
⇒ page 42 .

Volkswagen AG
– Remove retaining ring -arrow- for clutch swagen AG. does
. by
Vol
k not
gu
ara
d
se nte
If retaining ring cannot be removed:
tho
ri eo
au ra
c
ss
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
♦ If the retaining ring cannot be removed it is because the clutch
ility
ot p
has »clamped« the retaining ring at the bottom.
wit
, is n
h re
♦ In this case, push the clutch down slightly (see following de‐
hole
spec
scription) and release the load on the retaining ring. Never
es, in part or in w
strike the clutch or shaft with a hammer!
t to the co
rrectness of i
l purpos
– If necessary, balance out gaps using -T10356/5- , for example.

nform
mercia
at
om
io
Note
n
c
in t
or
his
te

a
do
priv
cum
for
en
ng
t.
yi Co
Caution Cop py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
• Push down clutch using only very light force.
– To press down, turn spindle against thrust piece -T10376- .
– Remove retaining ring -arrow- for clutch.
WARNING
It is not permissible to reuse the retaining ring.
Continuation once retaining ring has been removed:

– Insert puller -T10373- into clutch and bore out clutch.
wage es n
– Remove clutch togetherolks
y V with puller -T10373- .
ot g
b ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove »large« engagement lever together with »small« en‐
rrectness of i
gagement bearings.
l purpos
Note
nform
ercia
The upper section of bushing cannot be removed or installed

m
at
om
alone. It is always removed or installed together with lower section
ion
c
of bushing and »small« engagement lever.
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Undo and remove bolts and remove »small« engagement lev‐
p by
co Vo
by lksw
er together with upper and lower section of bushing. Prote
cted AG.
agen
If no parts are renewed, the ball stud -2- remains installed.

The hinge mounting -1- is not removed.
Note
If dimension „B“ has already been determined, it is now possible

to proceed with step „2“ of the measurement ⇒ page 48 .
2.3 Adjusting position of clutch engagement

bearings „K 1“ and „K 2“
The position of the engagement bearings must be adjusted after
the following tasks:
♦ Clutch has been renewed.

♦ Small ball stud for engaging lever „K 2“ has been renewed.

Note
G. Volkswage
♦ There is no need
lksw
to
ageadjust
nA anythingn AifGall
doethe
s n named parts have
only been bremoved
yV
o and reinstalled. ot g
ua
ed ran
ris
♦ Theuretaining
tho ring must be renewed in each case.tee or
a ac
ss
ce
Brief description
e
nl
pt
du
an
itte
♦ Position of engagement bearings is comparable with clutch
y li
erm
ab
play of a manual gearbox. In the 7-speed dual clutch gearbox
ility
ot p
0AM there are tolerances in the engagement system of the
wit
, is n
gearbox and in the gearbox itself. Even within the dual clutch
h re
there are tolerances. These tolerances must be taken into ac‐
hole
spec
count separately during adjustment.
es, in part or in w
t to the co
♦ The following procedure first describes how to measure all
necessary dimensions on the gearbox so that the appropriate
shim can be selected. In addition are the tolerances in the
rrectness of i
clutch that the manufacturer has already calculated. Toleran‐
ces on gearbox and tolerances in clutch determine thickness
l purpos
of shim.
♦ Adhere to the sequence of work steps. nform
ercia
Overview of clutch actuation:

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.
page 42
1“
❑ With engagement bear‐
ing
3 - Hinge mounting
❑ For large engaging lever
„K 1“
❑ Is not renewed
4 - Small engagement bear‐
ings for „K 2“
page 42
AG. Volkswagen AG d
agen
6 - Upper section of bushing olksw
oes
not
byV gu
ara
❑ Small small engaging rised
nte
lever „K 2“ ut
ho eo
ra
a c
❑ Is removed and installed ss
ce
e
together with lower sec‐

nl
pt
du
an
tion of bushing
itte
y li
erm
ab
7 - Small engaging lever for „K
ility
ot p
2“
wit
, is n
h re
❑ Is removed and installed
hole
together with upper and spec

lower section of bushing
es, in part or in w
t to the co
8 - Ball stud
❑ Small small engaging
rrectness of i
lever „K 2“
l purpos
9 - Bolts
nform
ercia
m
❑ Always renew
at
om
ion
c
10 - Lower section of bushing

in t
or
his
te

a
do
priv
❑ Is removed and installed together with upper section of bushing

um
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Special tools and workshop equipment required py by
co Vo
by lksw
cted
♦ Depth gauge, digital 300 mm -VAS 6594-
agen
Prote AG.

♦ Gauge block -T10466-
AG. Volkswagen AG d
agen oes
ksw not
♦ Ruler -T40100- by
Vol
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
t to the co
rrectne
Requirement:
• The gearbox flange must be level to assure good contact with
ss
the ruler.
o
cial p
f in
• Mechatronic unit for dual clutch gearbox -J743- must be re‐
form
mer
moved.
atio
om
n
c
i
or
Caution
thi
te
sd
iva
o
pr

um
r
fo
en
ng
t.
• Mounting for engaging lever and entire mechanism of en‐
yi Co
op py
gagement bearing must be dry and free of oil or grease. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove installed ball stud using pliers.
– Push in »new« ball stud by hand, if necessary using a plastic

hammer and drift to tap it in.
Note
To avoid damage to ball stud, only tap the drift lightly with the
hammer.
– Install previously used retaining ring of outer input shaft.
swage es n
2nd step: Determine dimension „B“ for clutch „K 1“ and b
„K
yV
o 2“.
lk ot g
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
io
– Place ruler -T40100- upwards across end of shaft onto gear‐

n
c
in t
r
box flange.
o
his
ate
do
priv
cum
Caution
for
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
♦ The ruler -T40100- should remain in this position for the cop Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
lksw not
– Place digital 300 mm depth gauge -VAS b6594-yV
o on top of ruler gu
ara
-T40100- and position depth gauge rod ris on outer input shaft.
ed
nte
ho eo
ut
– Set depth gauge to „0“. ss a ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Position depth gauge rod on retaining ring, as show in dia‐
rrectne
gram.
– In this position, determine dimension „B1“ to retaining ring.
ss o
cial p
f i
nform
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
– In the opposite position, determine dimension „B2“ to retaining co Vo
by lksw
cted
ring.
agen
Prote AG.
Note
Do not measure on retaining ring joint. It is possible that the re‐

taining ring will be pushed away and thus falsify the reading.

– Calculate mean value from dimension „B1“ and „B2“.
Formula: B1 + B2 2
Example:
• 2,62 + 2,582 = 2.60 mm
• Result: Dimension „B“ = 2.60 mm
Note
If the dual clutch is still in place after this measurement, it must

now be removed ⇒ page 41 .
agen AG olksw
Golf Variant 2007 ➤ , Golf Variant 2010
wage ➤ , Jetta 2005 ➤do, eJetta
n AG. V
s no
2011 ➤
olks
7-speed dual clutch gearbox d0AM
by - Edition 09.2011
V t gu
a
e ran
ris tee
– Remove and dispose of tho
outerauinput shaft. or
ac
ss
ce
le
un
pt
WARNING
an
d
itte
y li
erm
ab
It is not permissible to reuse the retaining ring.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
2nd step: Determine dimension „A1“ for clutch engaging lever
ss
„K 1“.
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.
WARNING
Do not insert any shim!
– Check that engaging lever is seated correctly.
– Place end gauge -T10466- on large engagement bearing. Flat

side faces upwards.
ment bearing, press down and turn end gauge.


and position depth gauge rod on outer input shaft.
box flange.
Caution


diagram.
T10466- .

gauge -T10466- .
. Volkswagen AG
– Calculate mean value from dimension „A 1a“ and „A
swa
gen1AbG“. does
olk not
yV gu
Formula: A 1a + A 1b 2 edb ara
nte
ris
tho eo
Example: ss
au ra
c
ce
le
• 4,93 + 4,912 = 4.92mm

un
pt
an
d
itte
y li

erm
ab
ility
ot p
3rd step: Calculate height tolerance of clutch engagement bear‐

wit
is n
ing „K 1“.
h re
ole,
spec
Note
t to the co
On the basis of dimension „A 1“ and dimension „B“, the height

tolerance of the clutch engagement bearing „K 1“ is now calcula‐
rrectne
ted according to the following calculus.

ss o
Dimension „A 1“
cial p
f inform
mer
atio
= Actual height tolerance of clutch engagement bearing „K

om
1“
n
c
i
or
n thi
te
sd
a
Example:
iv
o
pr
cum
r
fo
• 4.92 mm – 2.60 mm = 2.32 mm

en
ng
t.
yi Co
op
• Result: Height tolerance of clutch engagement bearing „K 1“ C py
t. rig
= 2.32 mm gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

• Example: Read off clutch tolerance value on clutch
„K 1 = +0.2“, as shown in diagram.
5th step: Determining thickness of shim „SK 1“.
Note
On the basis of the clutch tolerance „K 1“, the thickness of shim

„SK 1“ is now calculated according to the following calculus.
Height tolerance of engagement bearing „K 1“

Example:
• 2.32 mm + 0.20 mm = 2.52 mm
– Select required shim from the table with the help of the part
number -magnifying glass- and have it ready for installation.
Calculated thick‐ Available shims Part number of shim
ness of shim Thickness in mm
mm
1.21 … 1.60 1.50 0AM 141 383
1.61 … 1.80 1.70 0AM 141 383 A
1.81 … 2.00 1.90 0AM 141 383 B
2.01 … 2.20 2.10 0AM 141 383 C
. Volkswagen AG
2.21 … 2.40 2.30 a0AM 141
gen AG 383 D does
olksw not
2.41 … 2.60 2.50 ed b y V
0AM 141 383 E gu
ara
ris nte
2.61 … 2.80 2.70
utho 0AM 141 383 F eo
ra
a c
2.81 … 3.00 s2.90
s
0AM 141 383 G
ce
e
nl
pt
3.01 … 3.20 3.10 0AM 141 383 H

du
an
itte
y li
3.21 … 3.40 3.30 0AM 141.383 J

erm
ab
ility
ot p
3.41 … 3.80 3.50 0AM 141 383 K

wit
, is n
h re
Example:
hole
spec

es, in part or in w
t to the co
• Chosen shim thickness = 2.50 mm = part number DAM 141

383 E
rrectness of i
WARNING
l purpos
To avoid damage to clutch, only fit this shim later.

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
50
AG.
Rep. gr.30 - Clutch
– Remove end gauge -T10466- and large engagement lever

again. Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
rise nte
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
6th step: Determine dimension „A 2“ for clutch engaging lever
t to the co
„K 2“
rrectness of i
Note
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.
– Install »small« engagement lever together with upper and low‐

er section of bushing. Insert and tighten bolts.
Torque setting: ⇒ page 44 .
– Insert »small« engagement bearing without shim.
WARNING
Do not insert a shim!

grooves.
– By turning, check whether small engagement bearing has
been installed correctly and that grooves are seated correctly.
– Place end gauge -T10466- on small engagement bearing. Flat

side faces upwards.
ment bearing, press down and turn end gauge.

and position depth gauge rod on outer input shaft. G. Volkswagen nA AG do
wage es n
• Ruler -T40100- is lying upwards across end of shaft
Vol on gear‐
ks ot g
by ua
box flange. ise
d ran
tee
r
ho
aut or
ac
Caution 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

diagram.
rrectness of i

l purpos
T10466- .
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.


gauge -T10466- .
– Calculate mean value from dimension „A 2a“ and „A 2b“.
Formula: A 2a + A 2b 2
Example:
• 4,79 + 4,752 = 4.77 mm
7th step: Calculate height tolerance of clutch engagement bearing
„K 2“.
Note
On the basis of dimension „A 2“ and dimension „B“, the height

tolerance of the clutch engagement bearing „K 2“ is now calcula‐
ted according to the following calculus.
Dimension „A 2“
= Actual height tolerance of clutch engagement bearing „K
2“ gen AG
. Volkswagen AG
d
a oes
ksw not
Vol
Example: ed b y gu
ara
is nte
or
• 4.77authmm – 2.60 mm = 2.17 mm eo
ra
ss c
• Result: Height tolerance of clutch engagement bearing „K 2“
ce
le
un
pt
= 2.17 mm
an
d
itte
y li
rm
ab

pe
ility
ot
wit
, is n

h re
hole
spec
• Example: Read off clutch tolerance value on clutch „K 2 = –

es, in part or in w
0.2“, as shown in diagram.

t to the co
9. step: Determining thickness of shim „SK 2“-

rrectness of i
Note
l purpos
On the basis of the clutch tolerance „K 2“, the thickness of shim

nform
„SK 2“ is now calculated according to the following calculus.

mercia
a
com
ti
Height tolerance of engagement bearing „K 2“

on in
r
te o

thi
s
iva
do

r
rp
cum
fo
en
g
Example:
n
t.
yi Co
Cop py
t.
• 2.17 mm – 0.20 mm = 1.97 mm
rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
olkswagen AG
7-speed dual clutch gearbox 0AM - Edition 09.2011 swagen AG. V does
k not
Vol gu
d by ara
– From the shims supplied, measure the required shimorand
ise have nte
it ready for installation. auth eo
ra
ss c
ce
e
nl
pt
du
mm Thickness in mm
an
itte
y li
erm
0.31 … 0.90 0.80
ab
ility
ot p
0.91 … 1.10 1.00
wit
, is n
h re
1.11 … 1.30 1.20
hole
spec
1.31 … 1.50 1.40
es, in part or in w
t to the co
1.51 … 1.70 1.60
1.71 … 1.90 1.80
rrectness of i
1.91 … 2.10 2.00
2.11 … 2.30 2.20
l purpos
2.31 … 2.50 2.40
nf
ercia
2.51 … 2.70 2.60
orm
m
2.71 … 3.30 2.80
atio
om
n in
c
Example:
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
WARNING yri
p by
co Vo
by lksw
cted agen
Prote
To avoid damage to clutch, only fit this shim later.
AG.
The adjusting work has now been completed and the »small« en‐
gagement lever has already been installed. The next step now is
to install the clutch again.
– Install clutch ⇒ page 54 .
2.4 Installing dual clutch


♦ -T10356/5- from assembly tool -T10356-
♦ Puller -T10373-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Installing
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Replace all bolts tightened with further tightening angle.

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
co lksw
by
cted agen
Prote AG.
Caution

• The positions of the engagement bearings must be set
correctly.
Adjustment can only be carried out before the clutch is instal‐
led.
The position of the engagement bearings must be adjusted af‐
ter the following tasks:
♦ Clutch has been renewed.
♦ Small ball stud for engaging lever „K 2“ has been renewed.
If you have performed any of the above work, you must now
adjust the position of engagement bearings „K 1 and K 2“
⇒ page 42 .
Do not continue with assembly until the setting is correct!
If no new parts have been installed, insert removed shims.
For adjustment, only one shim per engagement bearing may
be installed.
• Clutch parts must be free of oil and grease.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Hinge mounting -1- and ball stud -2-orisehave been installed. nte
th eo
au ra
ss c
ce
e
Note
nl
pt
du
an
itte
y li

erm
ab
ility

ot p

wit
, is n
h re
hole
spec
The following work is only necessary if all the named parts have
es, in part or in w
merely been removed and reinstalled.

t to the co
rrectness of i
– Install »small« engagement lever together with upper and low‐

l purpos
er section of bushing. Insert and tighten new bolts.

Torque setting ⇒ page 44
nform
ercia
Continuation for all vehicles:

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.

– Insert »large« engaging lever with measured shims for „K 1“

and „K 2“ and with small engagement bearing.
Note
♦ The large shim is inserted into the large engagement bearing,

with the hemispherical side of the shim facing downwards.
♦ The small shim goes under the small engagement bearing.
Therefore, insert shim first.
The shim and the small engagement bearing only fit in one posi‐
tion due to the 8 grooves.
– By turning, check that parts have been installed correctly and
that grooves are seated correctly.
– Turn back spindle of puller -T10373- .
Caution

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Install clutch with puller -T10373- in gearbox,
ut
h as shown in di‐
o eo
ra
agram. 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
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.

– If necessary, balance out gaps using -T10356/5- from assem‐
bly tool -T10356- , for example.
Note
– Press on clutch as far as it will go.
Note
AG. Volkswagen AG d
Place a hand on the clutch when pressing it on. A slight »rattling«lkswagen oes
not
will be felt. Rattling indicates that the clutch is being presseddontoby
Vo gu
ara
its press seat. This also enables detection of the limit stop ris once
e nte
the clutch has been seated correctly. tho eo
au ra
c
ss
ce
le
un
pt
– Take hold of new retaining ring with retaining ring pliers, as
an
d
itte
y li
shown in the illustration.
erm
ab
ility
ot p
• Installation position: narrow surface of retaining ring on top.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Inserting retaining ring -arrow-.
mer
atio
om
n
c
i
Note
or
n thi
te
sd
iva
o
r
If the retaining ring cannot be inserted, the clutch has not been
p
cum
r
fo
pressed in onto its limit stop.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– To ensure that the clutch reaches its operating position right

from this stage, turn it against puller -T10373- -arrow- by hand
without using any other tools.

Note
♦ By pressing on, the clutch sits at the bottom against the limit
stop on the input shaft. This is not the optimum position.
♦ Clutch should only be pulled up far enough for it to contact
retaining ring.
Note
Only turn by hand. In this way, clutch slides against retaining ring.
Do not use any other tool.
– Insert hub.
• Hub has »large tooth« -arrow- and only fits in one position.
• »Large tooth« has a mark at engine end.
– Insert retaining ring -arrow- of hub.

AG. Volkswagenn AG do
wage e
• yV
olks ring must point towardss n»hub«
Joint of retaining ot g
u
of clutch.
b ara
ed nte
oris e
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
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.
– Turn clutch by hand. It should be possible to turn it without

difficulty.
Note
♦ If the clutch is difficult to turn or if the clutch lining is being

rubbed hard, remove clutch again ⇒ page 39 .
♦ Check installation position of shims -arrows-.
♦ The shims must be properly seated and undamaged
⇒ page 54 .
♦ A mathematical error could have been made. Check meas‐
urements again ⇒ page 42 .
♦ If no error has been made, the clutch may have been moved
out of position due to transport/assembly and a new clutch now
has to be installed. The position of the engagement bearings
must then be readjusted ⇒ page 42 . wage
e ks s no
Vol t gu
d by ara
e nte
ris
– Remove two plugs and put breather ucaps
tho -arrows-on. eo
ra
a c
ss
ce
le
WARNING
un
pt
an
d
itte
y li
rm
ab
The breather cap on the mechatronic unit is destroyed during

pe
ility
removal and must be renewed.

ot
wit
, is n
h re
hole
spec
– After installation of gearbox, perform Complete reset by

es, in part or in w
means of Guided functions ⇒ Vehicle diagnostic tester.

t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
r
te o
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iva
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Cop py
t. rig
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co
60
by lksw
cted agen
Rep. gr.30 - Clutch Prote AG.
3 Removing and installing oil seals at

clutch end
There are 2 oil seals in gearbox at clutch end. Both oil seals
-arrows- can be renewed without gearbox being dismantled. If
only oil seals are renewed, there is no need to adjust clutch.

♦ Tube -VW 415 A-
AG. Volkswagen AG d
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es, in part or in w
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♦ Oil seal extractor -T10420-
rrectness of i
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nform
mercia
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tion in
r
te o
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iva
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rp
cum
fo
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
3. Removing and installing oil seals at clutch end 61

♦ Puller hooks -T20143/2-
AG. Volkswagen AG d
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spec
– Removing gearbox:
es, in part or in w
t to the co
rrectness of i
page 152
l purpos
– Removing dual clutch:

nform
ercia
♦ Up to gearbox manufacturing date 05.2011 ⇒ page 12

m
♦ From gearbox manufacturing date 06.2011 onwards

com
tion in
⇒ page 37
r
te o
thi
s
iva
do
r
Caution
rp
cum
fo
en
ng
t.
yi
It is essential to check the clutch in case of leaks. Renew dou‐
Co
Cop py
ble clutch if it is oily.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove outer oil seal.

– Drive in outer, »new« oil seal with a plastic mallet until flush
with clutch housing.
• Shoulder of pipe section -VW 415 A- points upwards -arrow-.
WARNING
Only drive in oil seal until flush with clutch housing, in order to
avoid closing off oil drilling located behind it. Otherwise, ball
bearing of outer input shaft can no longer be supplied with
enough oil.
– Unscrew spindle of oil seal extractor -T10420- .
– Screw oil seal extractor -T10420- into »small«, inner oil seal.
Press oil seal extractor when doing this.
Oil seal extractor jams very tightly when oil seal is turned. You
can »feel« when oil seal starts to turn in its seat as well.
– Now screw in spindle.

– Pull out oil seal using spindle.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
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nl
pt
du
– Knock in »new« oil seal up to stop.

an
itte
y li
erm
ab
– Installing dual clutch:

ility
ot p
♦ Up to gearbox manufacturing date 05.2011 ⇒ page 29

wit
, is n
h re
hole
♦ From gearbox manufacturing date 06.2011 onwards

spec
⇒ page 54
es, in part or in w
t to the co
– Installing gearbox:
rrectness of i

l purpos

page 152
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
by
63
copy Vo
by lksw
cted 3. Removing and installing oil seals at clutch end
agen
Prote AG.
34 – Controls, housing
1 Renewing gear oil
♦ Used oil collection and extraction unit -V.A.G 1782-
AG. Volkswagen AG d
agen oes
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♦ Adapter for filling oil -VAS 6262 A- with -VAS 6262/4-
ce
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♦ Adapter -VAS 6262/6- , if necessary

nf
ercia
orm
♦ Bottle of gear oil for 7 gear dual clutch gearbox 0AM; part
m
atio
m
number ⇒ Electronic parts catalogue „ETKA“

o
n in
or c
Measure length of breather pipe attached to adapter for filling oil

thi
te
sd
a
-VAS 6262 A- and, if necessary, shorten it.

iv
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o
In order to ensure that the breather pipe of the -VAS 6262 A-

f
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t.
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adapter for oil filling does not touch the bottom of some oil bottles,
Co
op py
the pipe must be shortened to the length -a-.
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py
• Dimension -a- = 210 mm
co Vo
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cted agen
Prote AG.
Note
The dimension -a- is measured from the shaft (green area in the
counting glass) of the adapter for oil filling -VAS 6262 A- .
If dimension -a- is greater than 210 mm:
64 Rep. gr.34 - Controls, housing

– Mark dimension on the breather pipe and shorten pipe with

pipe cutter -6056/2- .
– Clean adapter for filling oil -VAS 6262 A- .
Procedure
AG. Volkswagen AG d
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Note rised ara
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♦ The gearbox is filled for life. Therefore,
ss there is no need to c
check the oil level of this gearbox.
ce
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nl
pt
du
an
itte
♦ This explains why there is no oil level check.
y li
erm
ab
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♦ In case of leaks on gearbox, find out what is the cause and
ot p
rectify the faults.
wit
, is n
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hole
♦ After this, the gear oil must be drained off completely and
spec
gearbox filled with new oil.
es, in part or in w
t to the co
– Raise vehicle.
rrectness of i
– Remove noise insulation ⇒ Rep. gr. 50 ; Assembly overview
- noise insulation .
l purpos
– Position used oil collection and extraction unit -V.A.G 1782- or

a drip tray under gearbox.
nf
ercia
orm
m
– Unscrew oil drain plug of gearbox.
atio
om
n in
c
– Allow oil to drain off, then screw in oil drain plug firmly again.
or
thi
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sd
iva
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Note
o
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t.
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op py
♦ The oil level in the gearbox cannot be checked. t. C rig
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pyri by
♦ The prescribed amount to be put in the gearbox must be ad‐
o Vo
by c lksw
cted
hered to exactly.
agen
Prote AG.
♦ Only in this way is the gearbox correctly filled.

♦ If too little or too much oil is put in the gearbox, the latter will
not function correctly.
Caution

♦ Only the gear oil for the 7-speed dual clutch gearbox 0AM,
which is available through the replacement parts system,
may be used ⇒ Electronic parts catalogue „ETKA“ .
♦ Other oils will lead to malfunctions or failure of the gear‐
box.
1. Renewing gear oil 65

– Remove battery and battery tray -arrows- ⇒ Rep. gr. 27 ;

Battery; Removing and installing battery .
– Pull off breather cap -arrow- next to lever for parking interlock.
Note
To make this clearer, see the installation position with the gearbox
removed.
Caution

♦ The adapter for filling oil -VAS 6262 A- with -VAS 6262/4-
must be clean and it must be ensured that the gear oil is
not mixed with any other oils!
– Shake bottle before opening.
– Screw bottle of gear oil for 7 gear dual clutch gearbox 0AM
onto oil filling adapter -VAS 6262 A- ; part number ⇒ Electronic
agen
AG. Volkswagen AG d
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parts catalogue „ETKA“ . yV
olksw not
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au ac
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un
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t to the co
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mer
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om
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i
or
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pr
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Cop py
t. rig
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Vo
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Prote AG.

7-speed dualenclutch
AG. Volkgearbox 0AM - Edition 09.2011
swagen AG
ag does
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y Vol gu
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Note au
th eo
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If the thread of the bottle does not fit onto the oil filling adapter -
un
pt
VAS 6262 A- , use adapter -VAS 6262/6- .
an
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ab
ility
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– Position bottle in such a way that oil does not run into the filling
wit
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is n
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mer
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c
i
– Connect adapter -VAS 6262/4- to filling hose and attach to
or
n thi
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bleeder hole in gearbox.

t
sd
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– Turn oil bottle upside down and pour in 1.7 litres of oil.
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– After filling, remove oil filling adapter -VAS 6262 A- . Clean

area around breather hole with a cloth and fit the breather cap
-arrow-.
– Install battery tray and battery -arrows- ⇒ Rep. gr. 27 ; Battery;
Removing and installing battery .
– Install noise insulation⇒ Rep. gr. 50 ; Assembly overview -
noise insulation .
1. Renewing gear oil 67

2 Selector mechanism
WARNING
Before working on vehicle with engine running, move selector

lever into position „P“ and apply handbrake.
AG. Volkswagen AG d
agen oes
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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.

⇒ „2.1 Overview - selector mechanism in vehicles up to 02.2009“,

page 69
⇒ „2.2 Removing and installing selector lever cable - vehicles up
to 02.2009“, page 70
⇒ „2.3 Overview of selector mechanism - vehicles from 03.2009
onwards“, page 78
⇒ „2.4 Removing and installing selector mechanism with selector
lever and selector lever cable - vehicles from 03.2009 onwards“,
page 79
⇒ „2.5 Checking selector lever cable“, page 81
⇒ „2.6 Adjusting selector lever cable“, page 82
⇒ „2.7 Emergency release of selector lever“, page 84
⇒ „2.8 Removing and installing selector lever knob“, page 85
⇒ „2.9 Moving pushbutton to installation position in the handle“,
page 86
⇒ „2.10 Checking selector mechanism“, page 87
2.1 Overview - selector mechanism in vehicles up to 02.2009

Selector mechanism from 03.2009 onwards ⇒ page 78 .
1 - Selector cover with knob

❑ Do not remove knob
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped ⇒ page 84 .
❑ Before removal of knob,
pull pushbutton out past agen
AG. Volkswagen AG d
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its pressure point. Se‐ olksw not
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wire. This will prevent ss a c
the pushbutton from be‐
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ing accidentally pressed
du
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into the knob. y li

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ab
❑ Removing and installing ility
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selector lever knob wit

, is n
⇒ page 85
h re
hole
spec
2 - Selector mechanism with

es, in part or in w
selector lever
t to the co
❑ With selector lever lock

solenoid -N110-
rrectness of i
❑ Emergency release
⇒ page 84 .
l purpos
❑ Brief instructions for re‐

moving and installing:
nf
ercia
or
– Remove centre con‐

m
m
atio
sole.
om
n in
or c
– Remove Bowden cable

thi
te
sd
a
from gearbox
iv
o
r
rp
cu
⇒ page 70 .
o
m
f
en
ng
t.
yi Co
– If necessary, disconnect Cop py
or remove parts of ex‐
t. rig
gh ht
yri
haust system ⇒ Rep.
p by
o Vo
by c lksw
gr. 26 ; Removing and Prote
cted AG.
agen
2. Selector mechanism 69
installing parts of ex‐

haust system .
– Remove heat shield beneath selector mechanism.
– Adjust selector lever cable after installing ⇒ page 82 .
3 - Bolt with spring

❑ 3 Nm
4 - Pin
❑ Do not grease
5 - Securing clip
❑ Always renew after removing
6 - Nut
❑ 9 Nm
❑ Qty. 4
7 - Selector housing
❑ With seal
8 - Selector lever cable
❑ Bowden cable is not greased
AG. Volkswagen AG d
❑ Removing and installing ⇒ page 70 lkswagen oes
not
Vo gu
❑ Checking ⇒ page 81 d by ara
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❑ Adjusting ⇒ page 82 ut
ho eo
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a ac
ss
9 - Securing clip
ce
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un
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ab
10 - Hexagon flange nut

pe
ility
❑ 8 Nm
ot
wit
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❑ Qty. 4
hole
spec
es, in part or in w
t to the co
Torque setting , selector lever to selector shaft ⇒ page 64 .
2.2 Removing and installing selector lever

rrectness of i
cable - vehicles up to 02.2009

l purpos
nform
ercia
Note
m
a
com
ti
Following installation, Bowden cable must be checked for ease

on in
of movement and be adjusted.

r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Move selector lever to position „S“ position.
– Remove securing clip in -direction of arrow-.

Securing clips for selector lever cable must always be renewed.
Note
♦ Use pliers to removegethe

n AGsecuring clip on
doethe cable support
. Vol wagen AG ks
swa s
bracket. Do bnot y V use a sharp-edged lever. Thet gselector
olk no
ua lever
cable could ir se otherwise be damaged.
d ran
tee
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♦ aut
If necessary, remove the cable support bracket -A-
or
with ac the
ss
selector lever cable from the gearbox. To do so, remove bolts
ce
e
nl
-arrows-. These bolts must be renewed.

pt
du
an
itte
y li
♦ Torque setting of bolts -arrows-: 8 Nm + turn 90° further

erm
ab
ility
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wit
– Remove cable from ball head e.g. using removal lever -80 -
, is n
h re
200- .
hole
spec
– Raise vehicle.
es, in part or in w
t to the co
– To remove Bowden cable and/or selector mechanism, heat

shield under selector mechanism and, if necessary, parts of
exhaust system must now be removed ⇒ Rep. gr. 26 ; Re‐
rrectness of i
moving and installing parts of exhaust system .

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove -selector housing- beneath selector lever.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Remove locking plate of cable support bracket. Always renew
wit
, is n
h re
locking plate.
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
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rp
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o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

-Selector housing- is pushed forwards slightly on cable.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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ce
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un
pt
an
d
To remove cable, securing tab must be pushed forwards

itte
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-arrow 1-.
erm
ab
ility
ot p
– At same time, push -pin- up with a screwdriver -arrow 2-.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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op
– Please insert -screwdriver- from underneath whilst pushing
C py
t. rig
securing tab forwards.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
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ility
ot
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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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Clarification:
♦ -Arrow 1- Push tab forwards
♦ -Arrow 2- Push pin up

AG. Volkswagen AG d
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un
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ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove selector lever cable.

Remove selector housing from cable.
Installing
– Route selector lever cable without tension. Also insert into ca‐
ble support bracket on gearbox. Do not secure with securing
clips yet. Do not clip in ball head.
– Ensure that selector lever cable is properly routed during in‐

stallation.
If the sheet metal is bent downwards, it may cause noises. The
cable will vibrate against the sheet metal.
– Observe sheet metal. Press it back up in the tunnel during
installation.
Loosen adjustment screw -arrow-.
lkswage es n
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byV ua
d ran
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ce
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pt
du
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erm
ab
ility
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wit
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hole
– Put selector housing onto cable.
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
riv
– Insert selector lever cable into selector mechanism.

p
cum
for
en
g
– Insert cable into bearing and insert pin from above, down‐
n
t.
yi Co
wards through eye. t. Cop py
rig
gh ht
yri
When you have checked freedom of movement of cable p by
co Vo
⇒ page 81 , insert locking plate.
by lksw
cted agen
Prote AG.
– Attach cable with new locking plate on cable support bracket

of selector mechanism.

wage es n
Golf Variant 2007 ➤ , Golf yV
o Variant 2010 ➤ , Jetta 2005
lks o➤
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b
ir se7-speed dual clutch gearbox 0AM - Edition nte 09.2011
d ara
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au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove selector housing, heat shield and exhaust system ⇒

Rep. gr. 26 ; Removing and installing parts of exhaust system .
– Check cable ⇒ page 81 .
olkswagen AG
en AG. V
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ ks,wJetta 2005 ➤ , Jetta 2011
ag does ➤
not
Vol
7-speed dual clutch gearbox 0AM - eEdition
d by 09.2011 gu
ara
ris nte
utho eo
ra
2.3 Overview of selector mechanism - vehicles from 03.2009 onwards ss
a c
ce
e
nl
pt
du
an
itte
y li
1 - Selector cover with knob
erm
ab
ility
❑ Do not remove knob
ot p
wit
without reason. For
, is n
h re
emergency release, on‐
ly the cover needs to be hole
spec
es, in part or in w
unclipped ⇒ page 84 .
t to the co
❑ Before removal of knob,
pull pushbutton out past
its pressure point. Se‐
rrectness of i
cure pushbutton with a
cable tie or suitable
l purpos
wire. This will prevent

the pushbutton from be‐
nf
ercia
ing accidentally pressed
or
into the knob.
m
m
atio
m
❑ Removing and installing

o
n in
c
selector lever knob

or
thi
e
⇒ page 85
t
sd
iva
o
r
rp
cu
2 - Selector mechanism with
o
m
f
en
ng
selector lever and selector lev‐

t.
yi Co
er cable Cop py
t. rig
gh
❑ With selector lever lock
ht
pyri by
Vo
o
solenoid -N110-
c by lksw
cted agen
Prote AG.
❑ Bowden cable must not
be greased
❑ Removing and installing
⇒ page 79
❑ Checking ⇒ page 81
❑ Adjusting ⇒ page 82
3 - Bolt
❑ 8 Nm
4 - Hexagon flange nut
❑ 8 Nm
❑ Qty. 4
5 - Selector housing
❑ Only available together with selector mechanism ⇒ Electronic parts catalogue „ETKA“
6 - Securing clip
Note

AG. Volkswagen AG d
agen
2.4 Removing and installingby
Vol
ksw selector mech‐
oes
not
gu
anism with selector lever and selector
d ara
ise nte
or eo
h
lever cable
ss a -
ut
vehicles from 03.2009 on‐ ra
c
wards
ce
e
nl
pt
du
an
itte
y li
Perform the following steps: erm
ab
ility
ot p
Selector mechanism and selector lever cable are not allowed to
wit
be separated from one another. Both are removed together. In
, is n
h re
the engine compartment, it may be necessary to provide instal‐
hole
spec
lation space. Often, it is necessary to remove air filter.
es, in part or in w
t to the co
In the interior, it may be necessary to remove centre console.
rrectness of i
Note
l purpos
Following installation, Bowden cable must be checked for ease

of movement and be adjusted.
nform
mercia
at
om
– Move selector lever to position „P“ position.
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– Remove selector lever handle ⇒ page 85 , pulling off con‐

nector -2- from cover in process.
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims .
– Separate electrical wiring connector -1- from selector mecha‐
nism to vehicle wiring harness.
– If necessary, remove engine cover ⇒ Engine mechanics; Rep.
gr. 10 ; Removing and installing engine cover .
– Pull off securing clip -1- for selector lever cable.

– Remove selector lever cable -2- from lever/selector shaft, e.g.
using removal lever -80 - 200- .
Note
♦ Use pliers to remove the securing clip -1- on the cable support
bracket. Do not use a sharp-edged lever. The selector lever
cable could otherwise be damaged.
♦ If necessary, remove the cable support bracket -A- with the
Caution
Risk of damage to selector lever cable.

♦ Do not push selector lever cable backwards out of cable
support bracket. The selector lever cable is not guided out
of the cable support bracket until the selector mechanism
is removed.
– Raise vehicle.
– Remove tunnel bridges from body ⇒ General body repairs,
exterior; Rep. gr. 50 ; Tunnel bridge .
– Remove exhaust pipe beneath heat shield for middle tunnel

⇒ Engine mechanics; Rep. gr. 26 ; Exhaust system .
– Unhook centre and rear silencer from retaining straps and tie
up to body using wire, for example ⇒ Engine mechanics; Rep.
gr. 26 ; Exhaust system .
. Volkswage
– Remove heat shield for middle tunnelksbeneath
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To remove selector mechanism, a 2nd mechanic is required un‐

itte
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– Remove nuts -arrows- inside vehicle.

hole
spec
– If fitted, remove bracket -A-.

es, in part or in w
t to the co
– Remove selector mechanism -B- together with selector lever

cable and selector housing downwards.
rrectness of i
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Prote AG.

Note
♦ The selector mechanism can also be removed without remov‐

ing the selector housing.
♦ Remove the 4 bolts ⇒ Item 3 (page 78) to do this.
♦ Then remove selector mechanism with selector lever cable
inside vehicle in direction of -arrow-.
♦ The selector mechanism is only available together with the
selector housing and selector lever cable ⇒ Electronic parts
catalogue „ETKA“ .
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Install in reverse
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♦ Do not bend or kink selector lever cable.

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♦ Do not grease selector lever cable.

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♦ Torque settings ⇒ page 78 .

h re
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spec
– Install heat shield beneath selector mechanism.

es, in part or in w
t to the co
– Install exhaust system and align free of stress ⇒ Engine me‐

chanics; Rep. gr. 26 ; Exhaust system .
rrectness of i
– Fit tunnel bridges onto body ⇒ General body repairs, exterior;

Rep. gr. 50 ; Tunnel bridge .
l purpos
– Install centre console ⇒ General body repairs, interior; Rep.

gr. 68 ; Compartments, covers and trims .
nform
ercia
– Install selector lever handle ⇒ page 85 .

m
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tion in
– Before you put on ball head: check selector lever cable

r
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⇒ page 81 .
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– Adjust selector lever cable after installing ⇒ page 82 .

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– If removed, install engine cover ⇒ Engine mechanics; Rep.

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gr. 10 ; Removing and installing engine cover .
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2.5 cted
Checking selector lever cable
agen
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Brief description
Selector lever cable must be removed from gearbox so that its
ease of movement can be checked. Put removed end down so it
does not rub against anything.
Then the selector lever must be moved and after that, the Bowden
cable must be reattached to the gearbox.
Then the selector lever cable must be adjusted ⇒ page 82 .
Do not grease connections of cable!
Checking
– Move selector lever to position »P« position.
– Remove cable from lever on gearbox.
– Move selector lever repeatedly from »P« to »S« and back to
»P«.
• Selector lever must move easily.
– Reinstall cable with »loosened« adjustment screw.
If you remove the securing clip, you must always install a »new«
securing clip.
– Adjust cable ⇒ page 82 .
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2.6 Adjusting selector lever cable ss
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♦ Torque wrench -V.A.G 1331-
ility
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The selector lever cable must always be adjusted whenever

o
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♦ The selector lever cable has been removed from the gearbox.
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♦ The engine and/or gearbox has been removed and installed.

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♦ Parts of the assembly mounting have been removed and in‐
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♦ The cable itself or the selector mechanism has been removed cop Vo
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and installed.
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♦ The position of the engine and gearbox is shifted, for example

to install it free of tension.
Adjusting
– Move selector lever in vehicle to „P“ position.

Adjuster screw -arrow- must be »loosened«.

– Shift lever on gearbox to position „P“.
The gearbox lever must be pressed »completely to right side of

vehicle« in the direction of selector lever cable support bracket.
AG. Volkswagen AG d
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This figure shows you the view of gearbox from »behind«. -P- in
ility
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direction of cable support bracket.
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spec
es, in part or in w
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nf
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m
atio
m
– Install Bowden cable with loosened adjusting screw -arrow-

o
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c
and new securing clip.

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WARNING
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Be sure that the parking lock is engaged. Cop py
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– To do this, turn both front wheels simultaneously »under the Prote AG.
car« in the same direction until the parking lock can be head
to engage.
• The parking lock is engaged when both front wheels cannot
be turned in the same direction at the same time.
– Gently push knob of selector lever forwards and backwards
but under no circumstances must you shift out of „P“.
In this way the core of the Bowden cable finds it optimal position.
– Tighten adjusting screw -arrow- to 13 Nm.

This completes the adjustment.
2.7 Emergency release of selector lever

Do not remove knob.
– Unclip selector cover and hold to side.
– Depress brake pedal or set handbrake.
Vehicles up to 02.2009
– Press yellow plastic part -arrow- from right to left.
– Or press on the pin of the solenoid.
AG. Volkswagen AG d
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Vehicles from 03.2009 onwards
h re
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spec
– Press onto yellow plastic part -arrow-.
es, in part or in w
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Prote AG.

2.8 Removing and installing selector lever

knob
On all types of handle it is possible for the pushbutton in the han‐
dle to be pressed. Do not install a knob with the pushbutton
pressed in.
– Before removal, pull pushbutton out past its pressure point.
– Secure pushbutton with a cable tie or wire to prevent it being
pressed in.
– Unclip cover.
– Push sleeve upwards to release knob.

– Lock knob again after installing. To do this, press the sleeve
under the handle back down.
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– You only have to remove transport guard from »new« handles. wit
is n
The pushbutton is already in installation position.

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– Pull connector from cover.

t to the co
– Pull off knob upwards.

– Lock knob again after installing. Press sleeve under knob back
down.
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In vehicles with pushbutton at front on handle -arrow-

• Pushbutton is in installation position -arrow-.
If the pushbutton was pressed by mistake, the installation position
can be restored.
– Move pushbutton to installation position ⇒ page 86 .
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2.9 Moving pushbutton to installation posi‐
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2.9.1 Handle with pushbutton on side
spec
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– First pull button far enough out of knob that a small gap is
visible between knob and button. Button locks when released.
– Hold button in this position with a cable tie or wire to prevent
rrectness of i
it from being pressed in.
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There are 2 ways of moving the pushbutton into the installation Prote AG.
position, »with« and »without« installation guard. Both of them are
described here.
Place handle »with« installation guard in installation position:
When using the installation guard, make sure that it has an eyelet
-arrow- at the front. Other types of installation guard are not suit‐
able.

– Holding the button down, completely push in installation guard

with eyelet -arrow- until the installation guard engages, then
release the button. When the installation guard is pulled out,
the pushbutton engages in the installation position.
Place handle »without« installation guard in installation position:
– Carefully unclip trim of handle -A- upwards. AG. Volkswagen AG d

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– Using a screwdriver, press the small lever -1- for the tie rod
m
a
com
t
into the groove -2-. When this is done, the pushbutton -3- is
ion in
pressed into the installation position.
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-I- Pushbutton in pressed position

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-II- Pushbutton in installation position

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Prote AG.
♦ Only press the lever into the groove and no further.
♦ Do not clip the trim of the handle onto the selector mechanism
until the handle has been fitted. This makes it possible to check
whether the small lever engages in the tie rod when the push‐
button is pressed.
2.10 Checking selector mechanism

Faults which can be detected electrically can be determined with
guided fault finding . In the case of mechanical faults, skill
is required to localise and repair a faulty system or defective
»part«.
It must not be possible to start the engine in the selector lever
positions „R“, „D“ or „S“.
When selector lever is shifted to position „N“ at speeds above 5
km/h, solenoid for selector lever lock must not engage and block
selector lever. Selector lever can be shifted into a driving range.
When travelling at speeds below 5 km/h (almost stationary) and

shifting into selector lever position „N“, solenoid for selector lever
lock should only engage after about 1 second. Selector lever can‐
not be shifted out of „N“ position until brake pedal is depressed.
Selector lever in „P“ position and ignition switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of „P“ position
when the button is pressed. Solenoid for selector lever lock blocks
selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐ AG. Volkswagen AG d
sible to shift into a driving gear. Slowly shift selector lever from agen oes
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„P“ through to „S“, checking whether selector lever position in ed byV gu
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dash panel insert corresponds to selector lever position. horis nte
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Selector lever in „N“ position and ignition switched on ss
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nl
• Brake pedal not depressed:
pt
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Selector lever is locked and cannot be shifted out of „N“ position
erm
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with the push button pressed. Solenoid for selector lever lock
ility
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blocks selector lever.
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• Brake pedal is depressed:
spec
es, in part or in w
Solenoid for selector lever lock releases selector lever. It is pos‐
t to the co
sible to shift into a driving gear.
Selector lever in position „Tiptronic“
rrectness of i
– Shift selector lever into Tiptronic gate.
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Symbols must change from „P R N D S“ to „7 6 5 4 3 2 1“.

Ignition and light switched on
nf
ercia
orm
m
The respective symbol in the shift mechanism cover lights up.
atio
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Selector lever position display

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Simultaneous illumination of all selector lever position display

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segments indicates gearbox emergency running mode.
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Prote AG.

3 Mechatronic unit for dual clutch gear‐

box -J743- Volkswage es n
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db ran
⇒ „3.1 Safety note on mechatronic
ris
e
unit for dual clutch gearbox tee
J743 “, page 89 utho or
a ac
ss
⇒ „3.2 Overview - mechatronic unit“, page 90
ce
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un
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⇒ „3.3 Removing mechatronic unit for dual clutch gearbox J743

itte
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with gearbox installed“, page 91
ab
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ility
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⇒ „3.4 Moving mechatronic unit for dual clutch gearbox J743 into
wit
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removal position by hand“, page 101
h re
hole
spec
⇒ „3.5 Installing mechatronic unit for dual clutch gearbox J743 “,
es, in part or in w
page 104
t to the co
⇒ „3.6 View of selector forks with mechatronic unit removed“,
page 111
rrectness of i
3.1 Safety note on mechatronic unit for dual clutch gearbox -J743-
l purpos
nform
mercia
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com
tion in
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Cop py
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Prote AG.
3. Mechatronic unit for dual clutch gearbox J743 89

WARNING
Do not work on pressure accumulator. The accumulator is un‐

der pressure and is not allowed to be opened.
3.2 Overview - mechatronic unit
1 - Bolt
❑ 10 Nm
❑ M8 x 35
❑ Always renew
Note
2 - Bolt
❑ 10 Nm
❑ M8 x 90 lkswage es n
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❑ Always renew d b ua
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3 - Mechatronic unit for dual aut or
ac
clutch gearbox -J743- ss
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Note
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ility
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es, in part or in w
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Take care with the breather when handling the mechatronic unit. cop Vo
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cted agen
Prote
– When doing any work on the mechatronic unit, please remove
AG.
cap -arrow- from breather and seal with a suitable plug.

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

3.3 Removing mechatronic unit for dual

clutch gearbox -J743- with gearbox in‐
stalled
This description only applies to installed gearboxes. If gearbox
has been removed, first remove clutch then mechatronic unit.
♦ Move mechatronic unit for dual clutch gearbox -J743- into »re‐
moval position« by hand ⇒ page 101 .
♦ Assembly lever -T10407-
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♦ Drip tray for workshop hoist -VAS 6208-
rrectness o
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♦ Vehicle diagnostic tester
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Perform the following steps: cted agen
Prote AG.
In order to remove the mechatronic unit, sufficient space must be

available in front of the gearbox. Depending on the vehicle, parts
must be removed which do not have anything to do directly with
the gearbox. For example, the air filter housing and, if present,
charge air lines or coolant lines.
Any retainers fitted on the cover of the mechatronic unit must also
be removed.
The vehicle diagnostic tester brings the mechatronic unit into the
correct position for removal. All gear actuators are moved into
»neutral position«.
In this position, insert assembly lever -T10407- between release
lever and gearbox housing. This makes it possible to remove load
from plungers of mechatronic unit so that they may be removed
by hand from cups of engaging levers.
Mechatronic unit can be removed and inserted. When installing,
make sure clutch plungers are correctly seated in cups of engag‐
ing levers.
Therefore, please follow description below step by step.

Note
♦ The clutch is self-adjusting. Shocks can have an effect on this

adjusting device. Even if the mechatronic unit has been re‐
moved, the »sudden removal« of the assembly lever -T10407-
from under the engaging levers can have a negative effect on
the adjusting mechanism.
♦ In order to remove the mechatronic unit, sufficient space must
be available in front of the gearbox. In some vehicles, parts
must be removed which do not have anything to do directly
with the gearbox. Remove any charge air lines or coolant lines
that may be present.
♦ Any retainers fitted on the cover of the mechatronic unit must
also be removed.
n AG. Volkswagen A
♦ A »new« mechatronic unit isolcorrectly
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yV t gu
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♦ Do not drain oil. A »removed« mechatronic unit is sent back arante
ise
with its oil in. or e th or
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Mechatronic unit remains filled with oil.

un
pt
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Removing:
erm
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– Raise vehicle. All 4 supports of lifting platform must be at same
ole,
height.
spec

- noise insulation . t to the co
– Connect vehicle diagnostic tester and then select „7-speed

rrectne
dual clutch gearbox“, Moving gear actuator into -neu-

tral- position under Guided functions .
ss o
– Switch off ignition.

cial p
f inform
– Raise vehicle.
mer
atio
m
– Remove complete air filter housing.

o
n
c
i
or
♦ Vehicles with petrol engines ⇒ Rep. gr. 24 ; Removing and

thi
te
sd
a
installing air filter

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o
pr
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fo
♦ Vehicles with diesel engines ⇒ Rep. gr. 23 ; Removing and

en
ng
t.
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Co
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– Remove battery and battery tray ⇒ Rep. gr. 27 ; Battery; Re‐
gh ht
pyri by
moving and installing battery .
co Vo
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cted agen
Prote AG.


The cover prevents dirt getting in.
Torque setting: 8 Nm
– If this cover is fitted, remove it.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter .
Caution
Risk of damaging mechatronic unit for dual gearbox -J743- be‐

yond repair through static discharge.
♦ Do not touch the contacts in the connector of the mecha‐
tronic unit for dual clutch -J743- by hand.
– To become electrostatically discharged, touch an earthed ob‐

ject by hand (without gloves) ⇒ page 10 .
– Release mechatronic unit connector by pulling in

-direction of arrow- and pull off connector.
– Place drip tray under gearbox.
– Drain gear oil, then reinstall drain plug ⇒ page 64 .
AG. Volkswagen AG d
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– Pull cap off breather and close using a suitable plug to achieve
an
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an oil-tight seal.
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Note
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es, in part or in w
Protective cover -0AM 325 120- is well suited.
t to the co
rrectness of i
l purpos
nform
ercia
– Remove all retainers and brackets from front of gearbox.

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at
om
ion
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ate
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en
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– Using a screwdriver, carefully unclip gearbox input speed

sender 3 -G641- from housing in -direction of arrow-.
– Unscrew bolts of mechatronic unit for dual clutch gearbox -

J743- »in diagonal sequence«.
»There are 4 long and 3 short bolts.«
Do not remove more than 7 bolts!
. Volkswagen AG
gen AG does
– Please look carefully to check which bolts you are unscrewing. olks
wa not
Do not unscrew any cover bolts. byV gu
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The gearbox is shown here again from the side to make this sit‐
wit
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uation clearer.
h re
hole
spec
The mechatronic unit must be removed. The cover does not have
es, in part or in w
to be removed.
t to the co
Therefore, do not remove more than 7 bolts!
rrectness of i
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nf
ercia
orm
m
atio
om
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The next step is »difficult«:

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Now press both engaging levers of dual clutch »away« from

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plungers of mechatronic unit. Otherwise, levers will jam mecha‐

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tronic unit at plungers and prevent mechatronic unit from being

t.
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removed. Cop py
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– Please read through this description all the way to the end first. py by
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This will help you to perform the following steps »correctly«.
by
cted agen
Prote AG.
Both levers must now be carefully pressed away from the plung‐
ers.
– First take a look at -reddish-brown- engaging lever in this pic‐
ture.

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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
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
– On right of it, insert assembly lever -T10407- .

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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
– Far enough until groove lines up with housing rib -arrow-.

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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
No further.
h re
hole
spec
– Assembly lever -T10407- should make contact with gearbox

es, in part or in w
housing with its entire »rear face«.

t to the co
Caution
rrectness of i
• Housing rib and groove of lever must be flush with one

l purpos
another. Do not insert tool as far as stop.

nform
ercia
– Apply a bit of force to tip of lever when turning.

m
at
om
io
This stops lever from slipping out when turning.

n
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.

Turn assembly lever -T10407- anticlockwise. In this way, engag‐

ing levers are pressed away from plungers -direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
Do not take out assembly lever -T10407- . It must remain inserted

p
cum
for
between engaging lever and gearbox housing for the entire proc‐
en
ng
t.
yi
ess.
Co
Cop py
t. rig
gh
– If necessary, press assembly lever -T10407- against gearbox
ht
pyri by
Vo
o
using a screwdriver.
c by lksw
cted agen
Prote AG.

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
If lever slips off, this indicates you applied a bit of leverage to

do
riv
handle whilst turning.

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

– Apply a bit of force to tip of lever when turning.

This stops lever from slipping out when turning.
Caution
Risk of damaging gearbox components beyond repair.

♦ Do not touch or remove the mechatronic unit for dual
clutch gearbox -J743- until you have electrostatically dis‐
charged yourself by touching an earthed object, e.g. skin
contact with earth.
♦ Do not under any circumstances touch the contacts in the
gearbox connector by hand. Static discharge could de‐
stroy the control unit and, consequently, the mechatronic
unit.
olksw
– To become electrostatically discharged, touch agan
en Aearthed
G. V ob‐
agen AG
does
ksw
ject by hand (without gloves) ⇒ page 10
by
Vo. l not
gu
ara
ed nte
– Remove mechatronic unit. ris
tho e or
au ac
Mechatronic unit remains filled with
ss oil.
ce
le
un
pt
an
d
itte
– Make sure no oil runs out of breather.
y li
rm
ab
pe
Mechatronic unit is delivered for reconditioning with its oil in.
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
If mechatronic unit »jams« and cannot be removed:

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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
Sometimes, the mechatronic unit cannot be removed. In this cum

for
case, the gear actuator is »caught« at the »top left« of the gearbox
en
ng
t.
yi
housing.
Co
Cop py
t. rig
gh ht
In this case, mechatronic unit is not allowed to be removed with yri
p by
o Vo
significant force.
c by lksw
cted agen
Prote AG.
– First reposition mechatronic unit on gearbox housing and se‐
cure it with one bolt.
– Move mechatronic unit into »removal position« by hand
⇒ page 101 .
Installing mechatronic unit ⇒ page 104 .
3.4 Moving mechatronic unit for dual clutch gearbox -J743- into »removal po‐
sition« by hand
Sometimes, the mechatronic unit cannot be removed. In this
case, the gear actuator is »caught« at the »top left« of the gearbox
housing -arrow-.

• Only if you cannot set the mechatronic unit to removal position

with the vehicle diagnostic tester , you must move the unit by
hand to this position.
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
The »sticking« gear actuator -arrow- can be pressed by hand into

its »removal position«. To do this, push a selector fork behind the
parking lock cover. How to do this is described in the following
rrectness of i
work procedure:
l purpos
– First reposition mechatronic unit on gearbox housing and se‐

cure it with one bolt.
nform
ercia
– Move selector lever to position „P“ position.

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.


Note
♦ Use pliers to remove the securing clip on the cable support

200- .
– Use your hand to press lever to stop in direction of cable sup‐
port bracket.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– Remove lever of selector shaft.

erm
ab
ility
ot p
– Unbolt cover.
wit
is n
h re
ole,
spec
Caution
t to the co
The mechatronic unit will not be »stuck« after the next step.
That means that it could fall out. If it has not already been done,
secure mechatronic unit on gearbox with one bolt to prevent it
rrectne
from falling down.

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

– Working through opening, push selector fork to side

-direction of arrow-.
(Press to left in direction of travel.)
This presses back »sticking« gear actuator and mechatronic unit
can be removed.
– Please do not assemble parking lock until you have filled oil.
– Grease oil seal in cover with sealing grease -G 052 128 A1- .
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
– Fit cover and lever again.
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
– Press selector lever cable back onto ball head and install new
en
ng
t.
yi
securing clip.
Co
Cop py
t. rig
gh
– Securing clips for selector lever cable must always be re‐
ht
pyri by
Vo
newed.
o
by c lksw
cted agen
Prote AG.
– Add gear oil after completing work on mechatronic unit. Fill oil
into gearbox ⇒ page 64 .
– Adjust selector lever cable ⇒ page 82 .
– Place plug on removed mechatronic unit.
This way, the mechatronic unit can be sent sealed in oil-tight con‐
dition.
3.5 Installing mechatronic unit for dual

clutch gearbox -J743-

♦ Guide pin -T10406-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ A »new« mechatronic unit is correctly filled with oil.
spec
es, in part or in w
♦ Do not drain oil. A »removed« mechatronic unit is sent back
t to the co
with its oil in.
rrectness of i
Installing
• All selector forks must be »in neutral position« before instal‐
l purpos
lation of mechatronic unit.

nf
ercia
orm
Note
m
atio
om
n in
c
Make sure that all selector forks are located in -N-, »in the middle«, and therefore that the gearbox is in neutral.
or
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.

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
– Therefore, check each of 4 selector forks by hand.

Every selector fork has 3 positions: »gear selected - neutral - gear
l purpos
selected«.
nf
– Also, move each fork into each position in succession. Then

ercia
disengage all gears and return selector forks to middle position

rm
m
atio
»neutral«.
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng
»Neutral, neutral, neutral«, or gearbox will not function!

t.
yi Co
Cop py
t. rig
gh ht
You can turn the front gear slightly for assistance. This makes it yri
p by
o Vo
»easier« to shift the forks. by c lksw
cted agen
Prote AG.
– Please clean sealing surface where mechatronic unit will
make contact later on.
Oil residues on sealing surface will later result in a misdiagnosis
of »leaking«.

– Screw in guide pin -T10406- hand-tight.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Make sure that all 4 gear actuators project 25 millimetres -a-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
Handle with care. When levering the plungers out of the me‐
chatronic unit, make sure that you do not brace yourself on the
sensors.

lkswage es n
Golf Variant 2007 ➤ , Golf Variant 2010d b➤ y V, Jetta 2005 ➤ , Jetta 2011 ➤ t gua
o o
ran
7-speed dual clutch gearbox 0AM - hEdition
or
ise
09.2011 tee
ut or
a ac
ss
– Please clean sealing surface of mechatronic unit.
ce
e
nl
pt
du
– Watch out for seal on mechatronic unit.
an
itte
y li
erm
ab
Seal must be pushed in all around.
ility
ot p
wit
– Look at gearbox input speed sender 3 -G641- . Clip must not
, is n
h re
be damaged.
hole
spec
– Put on mechatronic unit.
es, in part or in w
t to the co
– When gripping and putting on, make sure selector forks are
not inadvertently pressed out of their position.
rrectness of i
– Also observe engaging levers and plungers on mechatronic
unit.
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
– Screw in 7 new bolts and tighten until finger-tight. t. Cop py
rig
gh ht
yri
– Remove guide pins -T10406- again. p by
co Vo
by lksw
cted agen
Prote AG.
– Make sure that plungers meet up correctly in cups of engaging

levers.
– Pull out plungers by hand until they are seated in cups.
Plungers can be moved into position with a hook bent from a piece
of welding wire (local manufacture).
– Now check seat of plungers again.
Plungers that are not seated correctly will damage mechatronic

unit.
– Tighten mechatronic unit diagonally to 10 Nm.

– Turn assembly lever -T10407- clockwise and remove it.
AG. Volkswagen AG d
agen 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
– Install gearbox input speed sender 3 -G641- .
is n
h re
ole,
– Look at sender. Clip must not be damaged.
spec
• Sender lug must be fully and firmly in contact with gearbox
t to the co
housing. If sender is »loose« or clip is broken, renew mecha‐
tronic unit.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
– Remove plug and put breather cap -arrow- in place.
thi
te
sd
iva
o
pr
cum
r
Caution
fo
en
ng
t.
yi Co
op py
Risk of damaging gearbox components.
. C rig
ht ht
rig by
py
co Vo
by lksw
cted
agen
Prote AG.
unit.

– Put on connector of mechatronic unit.
– Attach all retainers and brackets to front of gearbox.


Now add gear oil ⇒ page 64 .
– Install starter ⇒ Rep. gr. 27 ; Removing and installing starter .
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
– Fit charge air or coolant hoses as necessary.
es, in part or in w
t to the co
– Install battery and battery tray ⇒ Rep. gr. 27 ; Battery; Re‐
rrectness of i
– Install complete air filter housing.
l purpos
♦ Vehicles with petrol engines ⇒ Rep. gr. 24 ; Removing and

nform
ercia
♦ Vehicles with diesel engines ⇒ Rep. gr. 23 ; Removing and

m
a
com
tion in
– If necessary, top up coolant ⇒ Rep. gr. 19 ; Draining and filling

r
te o
coolant .
thi
s
iva
do
r
– Install noise insulation⇒ Rep. gr. 50 ; Assembly overview -

rp
cum
fo
noise insulation .
en
ng
t.
yi Co
op
– Carrying out basic adjustment ⇒ page 11 . C py
t. rig
gh ht
yri by
Mechatronic unit remains filled with oil. cop Vo
by lksw
cted agen
Prote AG.
– Place plug on »removed« mechatronic unit if necessary.
This way, the mechatronic unit can be sent sealed in oil-tight con‐
dition.

. Volkswagen AG
gen AG does
swa
Golf Variant 2007 ➤ , Golf Variant y V 2010 ➤ , Jetta 2005 ➤ , Jetta
olk not 2011 ➤
gu
b ara
7-speedris dual clutch gearbox 0AM - Edition 09.2011
ed
nte
ho eo
aut ra
3.6 View of selector forks with mechatronic unit removed ss c
ce
le
un
pt
an
d
itte
y li
rm
N - Idling/gearbox neutral po‐
ab
pe
ility
sition »in the middle«
ot
wit
, is n
R - Reverse gear
h re
hole
spec
❑ If reverse gear is engag‐
es, in part or in w
ed, extended plunger of
t to the co
mechatronic unit catch‐
es behind gearbox
housing.
rrectness of i
– Therefore, move me‐
l purpos
chatronic unit into re‐
moval position by hand
⇒ page 104 .
nform
mercia
1 - gear
a
com
tion in
2 - gear
r
te o
thi
s
iva
3 - gear
do
r
rp
cum
fo
4 - gear
en
ng
t.
yi Co
op
5 - gear C py
ht. rig
rig ht
by
6 - gear copy Vo
by lksw
cted agen
Prote
7 - gear
AG.

4 Removing and installing gearbox,

Jetta 2005 ►, Golf Variant 2007 ►, AG. Volkswagen AG d
agen
Golf Variant 2010 ►
oes
olksw not
y V gu
b a d ran
se
Information about gearboxes with different output
ho
ri shafts tee
ut or
⇒ page 112 ss a ac
ce
le
Vehicles with petrol engines
un
pt
an
d
itte
y li
1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine rm
ab
⇒ page 113
pe
ility
ot
wit
1.6 l/75 kW MPI engine ⇒ page 122
, is n
h re
hole
Vehicles with diesel engine
spec
es, in part or in w
1.9 l/77 kW TDI PD engine ⇒ page 131
t to the co
1.6 l/77 kW TDI CR engine ⇒ page 138
rrectness of i
4.1 Information about gearboxes with differ‐
l purpos
ent output shafts

Gearbox with different output shafts.
nform
ercia
A - Stub shafts »to 11.2008«

m
a
com
tio
B - Flange shafts »from 12.2008«
n in
r
te o
thi
Vehicles with stub shafts on gearbox
s
iva
do
r
rp
c
To remove gearboxes with stub shafts, it is necessary to remove
um
fo
en
g
stub shafts. Only shafts with straight joints can be put back onto
n
t.
yi Co
the output shafts safely. Therefore, these drive shafts must be Cop py
t. rig
removed. opyri
gh by
Vo
ht
c lksw
Vehicles with flange shafts on gearbox
by
cted agen
Prote AG.
For gearboxes with flange shafts, the drive shafts must be unbol‐
ted from the gearbox. This way, the gearbox can be removed. In
individual cases, it is necessary to remove right-hand flange shaft
from gearbox. This gives you enough clearance for removing
gearbox.
Secure both drive shafts to suspension struts using tensioning

straps -T10038- .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
GolfutVariant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005
ho eo
r a ➤ , Jetta 2011 ➤
a
ss 7-speed dual clutch gearbox 0AM c - Edition 09.2011
ce
e
nl
pt
du
an
4.2 Removing gearbox, vehicles with 1.4 l/90 kW TFSI engine and 1.4 l/118 kW
itte
y li
erm
ab
TSI engine
ility
ot p
wit
, is n
h re
hole
spec
equipment required es, in part or in w
t to the co
♦ Support bracket -10 - 222
A-
rrectness of i
♦ Adjustment plate -3282/59-
l purpos
♦ Adapter -10 - 222 A /8-

♦ Socket -T10061-
nf
ercia
or
♦ Gearbox support -3282-
m
m
atio
m
♦ Insert tool, 18 mm -T10179-

o
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.
♦ Tensioning strap -T10038-
4. Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ►, Golf Variant 2010 ► 113
♦ Engine and gearbox jack -V.A.G 1383 A-
Brief description
The gearbox is removed downwards separately, without engine.
The battery, air filter and starter are removed »from above«.
Noise insulation beneath engine/gearbox, lower cover in front left
wheel housing and pendulum support are removed »from below«.
height.
n AG. Volkswagen AG
– Move selector leverolkto ge
swaposition »P« position.
does
no
V t gu
by ara
Only in vehiclesriswith
ed stub shafts nte
tho eo
s au ra
c
s
Note
ce
le
un
pt
an
d
itte
y li
After loosening centre bolt, do not lower vehicle to ground again.

rm
ab
pe
ility
ot
wit
, is n
– Step on the brake pedal while a 2nd mechanic loosens the two
h re
drive shaft bolts -arrow-.

hole
spec
es, in part or in w
– Remove both front wheels.

t to the co
Continuation for all vehicles

– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
rrectness of i
and installing air filter .

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.


– Remove starter ⇒ Rep. gr. 27 ; Removing and installing start‐
er .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
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Note

200- .
Cable may also be pushed slightly backwards out of cable support
bracket and removed later when gearbox is lowered. But then
observe cable when lowering gearbox.
Caution

unit.


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

used instead of an 18 mm socket.
– Remove front part of wheel housing ⇒ Rep. gr. 66 ; Assembly
overview - front wheel housing .
– Remove pendulum support.

Only in vehicles with stub shafts
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cable ties or a pair of tensioning straps -T10038- are therefore
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straps -T10038- .
– Remove right flange shaft of gearbox.

Bolt has a 6 mm hexagon socket. Bolt can also be removed and
installed with socket -V.A.G 1669- .
– Close opening in flange shaft using a suitable plug.
– Unbolt exhaust system bracket from subframe.
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es, in part or in w
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– If there are hose and cable connections in area of engine sup‐

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rrectness of i
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– Support engine and gearbox with support bracket -10-222 A-

but do not raise.
Remove all bolts -1- and -2- for bracket.

– Then lower engine and gearbox slightly using spindles of sup‐
port bracket -10 - 222 A- so that bracket can be removed.
At most, 5 turns are sufficient to remove bracket.
In many cases, the spindle does not need to be lowered further
for the later removal of the gearbox.
To remove gearbox 0AM, set up gearbox support -3282- with ad‐

justment plate -3282/59- and push onto engine and gearbox
support -V.A.G 1383 A- .
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t to the co
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– Place both remaining attachments onto gearbox as shown.

When doing this, place sheet metal of drift under gearbox
housing and not under mechatronic unit.
– Secure gearbox with tensioning strap -T10038- .
– Raise gearbox and engine support -V.A.G 1383 A- from below
to support gearbox.
The gearbox is separated from the engine in this position.
– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine, »observing selector lever cable«
and lower gearbox.
Note
♦ Distance between engine flange and gearbox flange should

be about 50 mm before gearbox is lowered. AG. Volkswagen AG d
agen oes
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♦ Be careful of all lines and coolant hoses when lowering gear‐
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h re
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If gearbox is to be sent:
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In some cases, there are retainers on the front of the gearbox.
nf
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om
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thi
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⇒ page 172 .
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AG. Volkswagen AG d
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4.3 Removing gearbox, vehicles with 1.6 l/75 kW MPI engine d by
Vol not
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Special tools and workshop ss c
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A-
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♦ Adapter -10 - 222 A /3-
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♦ Adapter -10 - 222 A /8-
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♦ Socket -T10061-
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♦ Retainer -T10346-
AG. Volkswagen AG d
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Brief description
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height.
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observe cable when lowering gearbox. Prote AG.
Caution

unit.


– Now remove all upper connecting bolts between engine and
gearbox.

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

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used instead of an 18 mm socket.

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t to the co
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mer
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c
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torque: ⇒ Rep. gr. 40 ; Repairing drive shafts .

iv
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– Disconnect left and right-hand drive shafts from flanges on

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

member. This will keep the shaft out of the way during further
work.
The surface protection of the shafts must not be damaged. Plastic
very good for this.


straps -T10038- .

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– Unbolt exhaust system bracket from subframe.
ab
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– Remove front exhaust pipe so that lower bolts can be removed
om
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or c
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– Bolt bracket -T10346- to rear of the 3 mounting holes for bat‐

tery tray.
– To do this, use a collar bolt M 6 or a securing bolt for battery
tray.
port eye for support bracket -10 - 222 A- , remove these now.
AG. Volkswagen AG d
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rig ht
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♦ Adapter -10 - 222 A /8-

♦ Adapter -10 - 222 A /3-
• Place adapters -10 - 222 A /8- on upper longitudinal carriers,
directly before the raised portion (-arrow 1-) next to bolt
(-arrow 2-).

– Connect left support eye on engine to support bracket .

– Connect bracket -T10346- to support bracket (⇒ previous il‐
lustration).
– Take up weight of engine/gearbox assembly and support
bracket on spindles.

– Align arms of gearbox support according to holes in adjust‐
ment plate -3282/59- .
– Screw in support elements as illustrated on adjustment plate
-3282/59- .
cle.
• Arrow on adjustment plate
agen-3282/59- points inoedirection of trav‐
AG. Volkswagen AG d
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– Align gearbox
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ce
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spec

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and lower gearbox.

ion
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be about 50 mm before gearbox is lowered.
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♦ Be careful of all lines and coolant hoses when lowering gear‐ co Vo
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box.
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in .
⇒ page 165 .
If gearbox is to be sent: agen
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– Install right flange shaft ⇒ page 172 .
hole
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Cop py
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4.4 Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine
Special tools and workshop agen

AG. Volkswagen AG d
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♦ Socket -T10061-
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Note
After loosening centre bolt, do not lower vehicle to ground again.
– Step on the brake pedal while a 2nd mechanic loosens the two
drive shaft bolts -arrow-.
– Remove both front wheels.

er .

Golf VariantA2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
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– Remove securing clip ho in -direction of arrow-.
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Securing clips for selector
ss lever cable must always be renewed. c
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Note
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– Remove cable from ball head e.g. using removal lever -80 - cop Vo
by lksw
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Caution

unit.


gearbox.
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Cop py
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– Remove both drive shafts ⇒ Rep. gr. 40 ; Removing and in‐
stalling drive shafts .
Only in vehicles with flange shafts
torque ⇒ Rep. gr. 40 ; Repairing drive shafts .

– Unscrew left suspension link from swivel joint.

work.
very good for this.

straps -T10038- .
AG. Volkswagen AG d
agen oes
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– Remove right flange shaft of gearbox. wit

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l purpos
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port eye for support bracket -10 - 222 A- , remove these now.
– Remove filler pieces from upper edges of both wings.

but do not raise.
AG. Volkswagen AG d
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Secure adapter -10 - 222 A /16- , hook -10 - 222 A /2- and shackle
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and lower gearbox. Prote
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agen
Note

box.

in .
⇒ page 165 .

⇒ page 172 .
4.5 Removing gearbox - vehicles with 1.6 l/77 kW TDI CR engine

equipment required
A-
♦ Adapter -10 - 222 A /3-
♦ Adapter -10 - 222 A /18-
♦ Socket -T10035-
♦ Socket -T10061-
AG. Volkswagen AG d
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– Remove filler pieces from upper edges of both wings.

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• Place adapters -10 - 222 A /8- on upper longitudinal carriers,

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box.


in .
⇒ page 165 .

⇒ page 172 .
4.6 Installing gearbox

– Please read these important work steps before installing gear‐
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– Securing clip for selector lever Bowden cable -arrow- must be

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A securing clip which has been removed is not allowed to be in‐
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– Therefore, when installing, always use a »new« securing clip.

stallation -arrow-.
If the sheet metal has been bent downwards when the gearbox
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the sheet metal.
installation.
– Always adjust selector lever cable ⇒ page 82 .
Torque settings for gearbox installation ⇒ page 148 .
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– The bracket can be moved within its seat with a screwdriver

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Nm + 90°.
Starter to gearbox ⇒ Rep. gr. 27 ; Removing and installing start‐
er .
Pendulum support to subframe and gearbox ⇒ Rep. gr. 40 ; As‐
sembly overview - subframe, anti-roll bar, suspension links .
Gearbox to engine:
♦ 1.4 l/90 kW TFSI engine ⇒ page 149
♦ 1.4 l/118 kW TSI engine ⇒ page 149
♦ 1.6 l/75 kW MPI engine ⇒ page 149
♦ 1.9 l/77 kW TDI PD engine ⇒ page 150
♦ 1.6 l/77 kW TDI CR engine ⇒ page 151

4.7.1 Engines: 1.4 l/90 kW TFSI, 1.4 l/118 kW TSI, 1.6 l/75 kW
M12 - 80 Nm
❑ If 18 mm insert -T10179-
is used: 65 Nm.
M10 - 40 Nm
- Arrows point towards dowel
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4.7.2 Engine: 1.9 l/77 kW TDI PD
M12 - 80 Nm
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M10 - 40 Nm
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4.7.3 Engine: 1.6 l/77 kW TDI common rail
M12 - 80 Nm
is used: 65 Nm.
M10 - 40 Nm
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4. Removing and installing gearbox, Jetta 2005 ►, Golf Variant 2007 ►, Golf Variant 2010 ►
Prote
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5 Removing and installing gearbox,

Jetta 2011 ►
Removing gearbox, Jetta 2011 with 1.6 l/77 kW TDI CR engine
⇒ page 152
Installing gearbox, Jetta 2011 with 1.6 l/77 kW TDI CR engine
⇒ page 160
Torque settings ⇒ page 163
5.1 Removing gearbox, Jetta 2011 with 1.6 l/77 kW TDI CR engine

equipment required
♦ Pin -3282/29-
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
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♦ Engine support basic set -T40091-
Brief description
Note
The battery earth must be disconnected for continued work.

Check whether a coded radio is fitted. Obtain anti-theft coding first
if necessary.
5. Removing and installing gearbox, Jetta 2011 ► 153

– With ignition switched off, disconnect battery earth strap ⇒

Electrical system; Rep. gr. 27 ; Disconnecting and connecting
battery .
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– Remove battery and battery tray ⇒ Electrical system; Rep.
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Note

200- .
Caution

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– Remove front left wheel.

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Assembly overview - noise insulation .
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Front wheel hous‐
ing liner .
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts


work.
very good for this.

straps -T10038- .
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– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
– Remove radiator grille ⇒ General body repairs, exterior; Rep.
gr. 50 ; Radiator grille; Removing and installing radiator grille .
– Set up support device -10 - 222 A- .

1- -10 - 222 A /31-2-
2- -10 - 222 A /11-
3- -T40091/3-
4- -10 - 222 A /3-
5- -10 - 222 A /10-
6- -10 - 222 A /31-1-
7- -10 - 222 A /31-3-
8- -10 - 222 A /31-4- agen
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Transporting gearbox and securing to assembly stand Prote AG.
⇒ page 165 .

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5.2 Installing gearbox, Jetta 2011 with 1.6 Vol
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spec
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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
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t.
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– If it has not already been done, renew needle bearing in crank‐
Co
Cop py
shaft -arrow- ⇒ Rep. gr. 13 ; Crankshaft, pulling needle
t. rig
gh ht
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bearing from crankshaft and driving in . p by
co Vo
by lksw
cted agen
– Check for proper seating of both dowel sleeves between en‐ Prote AG.
gine and gearbox.
– Check for proper seating of intermediate plate.
– Guide selector lever cable as soon as possible into its cable
support bracket.
Check Bowden cable as soon as gearbox is raised. Be sure to
insert it in cable support bracket »early«.
Bowden cable must not be greased.
It must be possible to guide the engine and gearbox together by
hand until the engine flange and gearbox flange make contact all
around.
If not, »something has gone wrong«!
– Readjust gearbox support until engine and gearbox are
»aligned with each other«.
– Turn crankshaft slightly if necessary.
– After fitting starter motor, check that both breather caps are in
place -arrows-!

– Securing clip for selector lever Bowden cable -arrow- must be

renewed.
A securing clip which has been removed is not allowed to be in‐
stalled again. The clip will have lost its internal tension and so it
might fall off.
– Therefore, when installing, always use a »new« securing clip.

stallation -arrow-.
If the sheet metal has been bent downwards when the gearbox
was removed, it may cause noises. The cable will vibrate against
the sheet metal.
installation.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter .
– Mount right flange shaft back on gearbox ⇒ page 172 .
AG. Volkswagen AG d
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ara
rise nte
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There is no need to renew oil seal for flange
s a shaft when doing
u ra
c
this. s
ce
le
un
pt
an
d
itte
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– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
erm
ab
ing; Rep. gr. 40 ; Removing and installing drive shafts .
ility
ot p
wit
– Install heat shield over right drive shaft ⇒ Running gear, axles,
is n
h re
steering; Rep. gr. 40 ; Repairing drive shafts; Drive shaft heat
ole,
spec
shield .
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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co lksw
by
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Prote AG.

– Attach pendulum support to gearbox with new bolts ⇒ Run‐

ning gear, axles, steering; Rep. gr. 40 ; Assembly overview -
Subframe .
– Assemble exhaust system and attach exhaust system bracket
to subframe ⇒ Engine; Rep. gr. 26 ; Removing and installing
parts of exhaust system .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
– Install radiator grille ⇒ General body repairs, exterior; Rep.
gr. 50 ; Radiator grille; Removing and installing
gen AG
. Volradiator
kswagen Agrille
G .
a does
lksw not
– Install battery tray and battery⇒ db
y VElectrical system; Rep. gr.
o gu
ara
27 ; Removing and installing
o
ir se battery . nte
h eo
ut ra
– Installing air filter ⇒ Rep.
ss
a gr. 23 ; Removing and installing air c
filter .
ce
le
un
pt
an
d
– Connect battery and follow procedure after connecting battery

itte
y li
⇒ Electrical system; Rep. gr. 27 ; Disconnecting and con‐
rm
ab
pe
ility
necting battery .
ot
wit
, is n
– Always adjust selector lever cable ⇒ page 82 .
h re
hole
spec
– Install engine cover ⇒ Engine; Rep. gr. 15 ; Removing and
es, in part or in w
installing engine cover .
t to the co
– Install front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Front wheel hous‐
rrectness of i
ing liner .
l purpos
– Install noise insulation ⇒ General body repairs, exterior; Rep.

gr. 50 ; Noise insulation .
nform
ercia
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;

Torque settings for mounting wheels .
m
a
com
tion in
r
5.3 Specified torques

te o
thi
s
iva
do
r
Left assembly mounting

rp
cum
fo
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ng
– Renew all bolts -1- and -2- of left assembly mounting.

t.
yi Co
Cop py
. rig
– First screw in all bolts by hand.
t
gh ht
pyri by
Vo
co lksw
– First attach console to gearbox with bolts -1-; specified torque:
by
cted agen
Prote
40 Nm + 90°.
AG.

AG. Volkswagen AG d
– The bracket can be moved within its seat with a screwdriver wage
n oes
olks not
when bolts -2- are tightened. Tightening torque ofd-bolts
by
V 2-: 60 gu
ara
Nm + 90°. or
ise nte
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ss
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erm
ab
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ot p
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ole,
spec
t to the co
5.3.1 Engine: 1.6 l/77 kW TDI common rail
rrectne
M12 - 80 Nm
ss o
cial p
f in
is used: 65 Nm.
form
mer
atio
M10 - 40 Nm
om
n
c
i
or
n thi
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sleeves
t
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6 Transporting gearbox and securing

to assembly stand lksw
agen
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Transporting gearbox. edb ran
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spec
es, in part or in w
t to the co
rrectness of i
– Pull off both breather caps -arrows- and close using suitable
plugs to achieve an oil-tight seal.
l purpos
nform
mercia
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com
tion in
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thi
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iva
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Secure gearbox on gearbox support -VW 353- .
lksw
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Prote AG.
6. Transporting gearbox and securing to assembly stand 165

Lift gearbox into assembly stand.

The gearbox is lifted »into assembly stand« together with gearbox
support -VW 353- .
AG. Volkswagen AG d
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un
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erm
ab
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ot p
wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
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Cop py
t. rig
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Prote AG.

35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
AG. Volkswagen AG d
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spec
es, in part or in w
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rrectness of i
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nform
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Cop py
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1. Currently, no repairs can be made to gears and shafts 167

39 – Final drive - front differential age n AG. Volkswagen AG do

ksw es n
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1 Oil seals
th or
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Gearbox with stub shafts -A-.
pt
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Right ⇒ page 168
erm
ab
ility
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Left ⇒ page 170
wit
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Gearbox with flange shafts -B-. hole
spec
Right ⇒ page 172
es, in part or in w
t to the co
Left ⇒ page 174
rrectness of i
l purpos
nf
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orm
m
atio
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1.1 Renewing oil seal for right stub shaft

t.
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Left-hand side ⇒ page 170
ht
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agen
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♦ Thrust piece -3305-
♦ Hexagon key -T10107 A- or socket and extended bit -V.A.G

1669-

168 Rep. gr.39 - Final drive - front differential

♦ Sealing grease -G 052 128 A1-

♦ Drip tray
Note
♦ Do not remove both drive shafts from gearbox at the same

time. If you do so, it will no longer be possible to hold the op‐
posite front wheel fixed for removing or installing the bolt of the
stub shaft.
♦ Do not remove both stub shafts from gearbox at the same time.
If the differential bevel gears turn, it is difficult to reinstall the AG. Volkswagen A
securing bolts for the stub shafts. lksw
agen G do
es n
o o t gu
yV
edb ara
ris nte
– Remove drive shaft ⇒ Rep. gr. 40 ; Removing ho and installing eo
drive shafts . aut ra
ss c
ce
e

nl
pt
du
an
itte
– Remove bolt -arrow- in stub shaft with socket -T10107 A- or
y li
erm
ab
socket -V.A.G 1669- .
ility
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wit
– Pull out stub shaft.
, is n
h re
hole
– Pry oil seal out using assembly lever.
spec
es, in part or in w
– Lightly oil outer circumference of new radial oil seal.
t to the co
rrectness of i
l purpos
nform
ercia
– Half fill space between sealing lip and dust lip with sealing
m
at
grease -G 052 128- -arrow-.
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Drive in new oil seal to stop, being careful not to cant oil seal.
If necessary, it is possible to press a new dust ring onto the stub
shaft using tube -2010- . Do not use a hammer.
– Insert stub shaft.
– Tighten new countersunk bolt for stub shaft to 30 Nm.
– Reinstall drive shaft ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
– Renew gear oil ⇒ page 64 .
– Install noise insulation; torque settings ⇒ Rep. gr. 50 ; As‐
sembly overview - noise insulation .
1. Oil seals 169

1.2 Renewing oil seal for left stub shaft

Right side ⇒ page 168 .
♦ Multipurpose tool -771-
AG. Volkswagen AG d
agen oes
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hole
spec
♦ Puller hooks -771/37-
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

um
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

1669-

AG. Volkswagen AG d
agen oes
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y V gu
Golf Variant 2007 ➤ , Golf Variant
rise
d b
2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ara ➤
nte
7-speed
autho
dual clutch gearbox 0AM - Edition 09.2011 eo
ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
♦ Drip tray
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
♦ Do not remove both drive shafts from gearbox at the same
rrectness of i
time. If you do so, it will no longer be possible to hold the op‐
posite front wheel fixed for removing or installing the bolt of the
l purpos
stub shaft.
♦ Do not remove both stub shafts from gearbox at the same time.
nf
ercia
o
If the differential bevel gears turn, it is difficult to reinstall the
rm
m
securing bolts for the stub shafts.
atio
om
n in
or c
– Remove drive shaft ⇒ Rep. gr. 40 ; Removing and installing
thi
te
sd
a
drive shafts .
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Remove bolt in stub shaft with socket -T10107 A- or socket - C py
t. rig
V.A.G 1669- .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Pull out stub shaft.
AG.
– Pull out stub shaft oil seal with multi-purpose tool -VW 771-
and puller hooks -VW 771/37-.
Oil seal can also be removed using extractor tool -T20143- .
– Half fill space between sealing lip and dust lip with sealing
grease -G 052 128- -arrow-.
1. Oil seals 171

– Drive in new oil seal to stop, being careful not to cant oil seal.
If necessary, it is possible to press a new dust ring onto the stub
shaft using drift sleeve -40 - 20- . Do not use a hammer.
– Insert stub shaft.
– Tighten new countersunk bolt for stub shaft to 30 Nm.
– Reinstall drive shaft ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
1.3 Renewing oil seal for right flange shaft

Left-hand side ⇒ page 174
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
♦ Tensioning strap -T10038- ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness

o
cial p
f i
1669-
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


♦ Drip tray
Note
♦ Do not remove both flange shafts from gearbox at the same

time. If the differential bevel gears turn, it is difficult to reinstall
the securing bolts for the flange shafts.
♦ Remove drive shaft from gearbox and lay to side. Drive shaft
is fixed onto suspension strut with tensioning belt -T10038- .
♦ You do not need to remove the centre bolt of the drive shaft.

– If heat shield for drive shaft is installed, remove it from engine

-arrows-.
Unbolt drive shaft from gearbox.
wage e
– Raise drive shaft as high as possible
Vol
ks and secure. Take care s not
gu
by
not to damage paint on drive
ise shaft in the process.
d ara
n r tee
ho
aut or
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
– Pull out flange shaft.

– Pry oil seal out using assembly lever.
rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
r
– Half-fill space between sealing lip and dust lip of new oil seal
o
his
te
with sealing grease -G 052 128- -arrow-.

a
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. Oil seals 173

– Drive in new radial oil seal to stop with thrust piece -3305- ,
being careful not to cant radial oil seal.
– Insert flange shaft.
– Tighten new countersunk bolt to 30 Nm. When doing this,
press flange shaft against gearbox so that bolt engages in
thread.
– Fit drive shaft back on ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
1.4 Renewing oil seal for left flange shaft

Right side ⇒ page 172
♦ Multipurpose tool -VW 771-
♦ Thrust piece -3305- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nform
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
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pyri by
Vo
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by c lksw
cted agen
Prote AG.


1669-

♦ Drip tray
Note
♦ Do not remove both securing bolts in left and right flange shafts
at the same time. If the differential bevel gears turn, it is difficult
to reinstall the bolts.
♦ Remove drive shaft from gearbox and lay to side. Drive shaft
is fixed onto suspension strut with tensioning belt -T10038- .
♦ You do not need to remove the centre bolt of the drive shaft.

– Remove left wheel housing liner⇒ Rep. gr. 66 ; Assembly AG. Volkswagen AG d
agen
overview - front wheel housing liner . Volksw
oes
not
by gu
d ara
ise nte
r
– If present, undo bolts securing front left vehicle levelutsender -
ho eo
ra
G78- and remove sender from suspension link. ss a c
ce
e
nl
Torque setting for removing and installing ⇒ Rep. gr. 40 ; front

pt
du
an
left vehicle level sender -G78- .
itte
y li
erm
ab
– Turn steering wheel to left lock and remove left drive shaft from
ility
ot p
flange shaft ⇒ Rep. gr. 40 ; Removing and installing drive

wit
, is n
shafts .
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
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rp
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f
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t.
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Cop py
t. rig
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Vo
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175
by c lksw
cted
1. Oil seals
agen
Prote AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ ,AJetta
G. Volk2005
swagen➤
AG, dJetta 2011 ➤
agen
7-speed dual clutch gearbox 0AM V-oEdition
lksw 09.2011 oes
not
y gu
db ara
ise nte
– Only unscrew left suspension linkthofrom swivel
r
joint. 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
rrectness of i
– Unscrew nut -1- from coupling rod -3- ⇒ Rep. gr. 40 ; As‐
l purpos
sembly overview - subframe, anti-roll bar, suspension links .

– Pull off coupling rod and turn anti-roll bar -2- upwards slightly.
nf
ercia
orm
– Swing left drive shaft into wheel housing.
m
atio
om
n in
– Raise drive shaft as high as possible and secure. Take care
or c
not to damage paint on drive shaft in the process.
thi
te
sd
iva
o
r

rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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by c lksw
cted agen
Prote
– Remove left flange shaft of gearbox.
AG.

– Pull out flange shaft.
– Remove flange shaft oil seal.


– Half-fill space between sealing lip and dust lip of new oil seal
with sealing grease -G 052 128- -arrow-.
– Drive in new radial oil seal to stop with thrust piece -3305- ,
being careful not to cant radial oil seal.
– Insert flange shaft.
– Tighten new countersunk bolt to 30 Nm. When doing this,
press flange shaft against gearbox so that bolt engages in
thread.
– Fit drive shaft back on ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
AG. Volkswagen AG d
agen oes
lksw n
– Fit suspension link and coupling y V rod back on ⇒ Rep. gr. 40 o; t gu
o
d b ara
Removing and installingordrive
ise shafts . nte
eo
th
u ra
– Renew gear oil ⇒ page
ss a 64 . c
ce
le

un
pt
an
d

itte
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rm
ab
pe
ility
ot
wit
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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
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s
iva
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1. Oil seals 177

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg MEX5R008520

1 Removing and installing dual clutch, gearboxes made up to 05.2011 . . . . . . . . . . . . . . . . 12

1.2 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1.1 Renewing oil seal for right stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

00 – Technical data n AG. Volkswagen AG do

The gearbox code also appears on the vehicle identification

2 Overview - power transmission

2 Rep. gr.00 - Technical data

3 Code, engine allocation

Allocation: gearbox codes for diesel engines

Capacities Hydraulic fluid part in mechatronic unit for

Risk of damage to gearbox.

J743- . Before repairs, the breather of the mechatronic unit

for dual clutch gearbox -J743- must be sealed so that no an

chatronic unit for dual clutch gearbox -J743- , it is not

possible to replenish it or check the level!

by changing the gear oil. It is not possible to check the oil

♦ If the level of oil/fluid is too high or too low in either of the

4 Rep. gr.00 - Technical data

To prevent personal injury and material damage to the vehicle,

while engine is running.

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

trical and electronic components, observe the following:

with the ignition switched off.

♦ Disconnect battery only after the ignition has been switch‐

– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .

5.2 During work on vehicles with start/stop

Injury hazard as a result of automatic engine start in vehicles

Danger of irreparable damage to gearbox.

6 Rep. gr.00 - Technical data

7 General repair notes

system. There is no clutch pedal.

The gearbox has an opening in the housing.

On some gearboxes, this opening is sealed with a cap.

-arrow-. Cover opening with a cloth.

7. General repair notes 7

Make sure that no dirt can enter an »open« gearbox.

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

do not run engine. Do not tow vehicle.

♦ Place removed parts on a clean surface. Cover parts to pre‐

8 Rep. gr.00 - Technical data

In some vehicles, a cover is fitted over the engaging levers.

Assembly overview of gearbox

4- Breather cap of mechatronic unit for dual clutch gearbox -

Use caution when handling oil. Dispose of used oil properly.

O-rings, radial oil seals, gaskets

7. General repair notes 9

♦ Threads of bolts secured with locking fluid must be cleaned

with a wire brush. Then insert bolts with locking fluid -

AMV 185 101 A1- .

with locking fluid are screwed, must be cleaned (e.g. with a yi

You have probably at some time received an electrical shock

7.3 Working with vehicle diagnostic testers

10 Rep. gr.00 - Technical data

means of signals on the data bus. Pressing the Adapt instal-

after the following activities:

♦ After work on the steering wheel paddle.