D4B804A300A-7-Speed Dual Clutch Gearbox 0DL

Service
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Workshop Manual
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7-speed dual clutch gearbox 0DL
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Edition 12.2019
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B804A300A

Arteon 2018 ➤ , Passat 2015 ➤ , Passat 2019 ➤ , Passat Variant 2015 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 12.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . .lk.sw. a. g.e.n A . . . . . . . . . . .AG. .do. e.s.n . . . . . . . . . 8
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4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . .ed. b.y.V. . . . . . . . . . . . . . . . . . . . . . . .t .gu.a.ra. . . . . 8
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5 Electrical components . . . . . . . . . . . . . .u.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r . 10
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5.1 Overview of fitting locations - electrical components ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c 10
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
spec
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1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.2 Removing and installing gearbox input speed sender G182 and oil temperature sender in
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multi-plate clutch G509 up to gearbox date 05/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.1 Distinguishing between different types of bevel boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 n

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

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3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Cop py
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3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 by c lksw
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3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.9 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

6 Transporting gearbox agen . . . . . . . . . . A. G
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7.1 Assembly oris overview - gearbox . . . . . . . . . . . . . .n.tee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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8 Securing
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9 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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9.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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9.2 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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10 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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10.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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10.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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2.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

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2.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

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2.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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3 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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3.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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3.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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3.3 Renewing needle bearing (polygon bearing) for stub shaft . . . . . . . . . . . . . . . . . . . . . . . .
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ii Contents
00 – Technical data
1 Safety information
(VRL013748; Edition 12.2019)
⇒ “1.1 General safety provisions”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Notes on tow-starting/towing”, page 2
⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
1.1 General safety provisions

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♦ Before working on vehicle with engine running, move se‐
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lector lever into position “P” and apply handbrake.
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To prevent personal injury and damage to or destruction of elec‐
trical and electronic components, observe the following:
♦ Connect and disconnect measuring and testing devices only
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with the ignition switched off.
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♦ Disconnect battery only after the ignition has been switch‐

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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Prote
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Disconnecting and reconnecting battery .
1. Safety information 1
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1.2 Safety measures when working on ve‐
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hicles with a start/stop system
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Observe the following when working on vehicles with a start/stop
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WARNING
Injury hazard as a result of automatic engine start in vehicles
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with start/stop system.
♦ In vehicles with the start/stop system activated (identifia‐
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can start automatically if required.
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♦ When working on the vehicle, always make sure that the
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start-stop system is deactivated (switch off the ignition;

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1.3 Notes on tow-starting/towing
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Danger of irreparable damage to gearbox.
♦ If the vehicle must be towed, the selector lever must be in
the “N” position, and the vehicle must be towed at a speed
no greater than 50 km/h and for a distance not exceeding
50 km.
Note
It is not possible to tow-start the engine, e.g. if the battery is too

flat or the starter is not functioning.
1.4 Safety precautions when using testers

and measuring instruments during a
road test
Observe the following if test and measuring equipment is required
during a road test:
WARNING
Risk of accident due to distraction and inadequate securing of

test and measuring equipment.
Danger as a result of activation of front passenger airbag in
event of an accident.
• Operation of test and measuring equipment while driving
results in distraction.
• Increased risk of injury as a result of unsecured test and
measuring instruments.
♦ Always strap in place test and measuring equipment on
rear seat and have a 2nd person sitting on the rear seat
to operate them.
2 Rep. gr.00 - Technical data

Please note the following to avoid personal injury and damage to,
or destruction of, electrical and electronic components:
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Risk of irreparable damage to electronic components when
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disconnecting battery.
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♦ Disconnect battery only after the ignition has been switch‐ es, in part or in w
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
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1. Safety information 3
2 Identification
2.1 Gearbox identification

The gearbox code can be found on top of the gearbox, near the
starter.
1 - Gearbox code
2 - Day of production
3 - Month of production
4 - Year of production
5 - Serial number
6 - Minute of production
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7 - Hour of production kswagen AG does
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Note
The gearbox code is also indicated on the vehicle data stickers.

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3 Repair instructions
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⇒ “3.1 General information”, page 5
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⇒ “3.2 Rules for cleanliness”, page 5
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⇒ “3.3 General repair instructions”, page 6
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⇒ “3.4 Gaskets and seals”, page 7
⇒ “3.5 Nuts and bolts”, page 7
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3.1 General information
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Gearbox
♦ The torque of the engine is transmitted via the flywheel to the
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dual clutch gearbox. The flywheel and the dual clutch are
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♦ The gearbox is structured like a manual gearbox. Through op‐
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an automatic gearbox. In other words, the gears are engaged
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automatically or manually via the Tiptronic system. There is no

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The feedback for the gearbox concerning the selector lever po‐
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sition is not transferred by mechanical means via the selector

lever cable and the multifunction switch (gear sensor) any more,
as is the case for the automatic gearbox. The information con‐
cerning selector lever positions or shifting operations are trans‐
ferred to the gearbox control unit via a separate control unit in the
selector mechanism and the CAN data bus. That is, gears are
shifted without any mechanical cables being involved. Only for
selector lever position “P” the parking lock is engaged mechani‐
cally via the selector lever cable.
Gear change point variations for gradients
An additional gear change map automatically selects gear
changes for gradients dependent upon accelerator pedal position
and driving speed.
• Gear change map for extreme uphill stretches is matched to
engine output.
• Gear change map for extreme downhill gradients is matched
to the braking efficiency of the engine.
• If a gear is selected directly via the Tiptronic system, it is also
possible to use the braking effect of the engine in a specific
gear, e.g. when driving down a slope with a trailer attached.
3.2 Rules for cleanliness

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

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

To ensure flawless and successful gearbox grepairs, AG. Vothe
lkswgreatest
agen AG
a en do
care and cleanliness as well as the use Volof
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are essential. Also note the basic rules
d b on safety when performing
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repair procedures. thori
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A number of general notes son
s the individual repair procedures, c
ce
e
which can otherwise be found in the relevant sections of the man‐

nl
pt
du
ual, are summarised here. They apply for this particular workshop
an
itte
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manual.
erm
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Guided Fault Finding, vehicle self-diagnosis and test instruments
wit
, is n
h re
♦ Before performing repairs to the gearbox, determine the cause
hole
spec
of the fault as accurately as possible ⇒ Vehicle diagnostic
es, in part or in w
tester, Guided Fault Finding , Vehicle Self-Diagnosis
t to the co
or Test Instruments .
Special tool
rrectness of i
For a complete list of special tools used in this workshop manual,
l purpos
see ⇒ "Workshop equipment and special tools" .

Gearbox
nf
ercia
o
Always make sure that no dirt can enter an »open« gearbox. In
rm
m
atio
particular, dirt entering an »exposed« mechatronic unit for dual
om
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
n in
or c
thi
e
♦ If gearbox covers have been unbolted or gearbox has no fluid,

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do not run engine or tow vehicle.

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♦ First thoroughly clean connecting points and surrounding

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areas and then loosen bolts. Cop py
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♦ When installing the gearbox, ensure that dowel sleeves be‐ p by
o Vo
by c lksw
tween the engine and gearbox are correctly located. Prote
cted AG.
agen
Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
Dual clutch gearbox oil
The oil quality is of critical importance for the function of the gear‐
box.
Shake oil bottle before opening.
Do not mix additives in oil. Do not fill any other oil.
Oil which has been drained out cannot be filled again.

Oil drain and inspection plug

en AGhexagon socket . Volkswage
A plastic overflow pipe (with
ksw
8gmm
a
n AG d
oehead)
s no is lo‐
l
cated behind this plugby-arrow-.
Vo Its length determines the t guoil level
ara
in the gearbox. rise d
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3.4 Gaskets and seals
♦ Renew O-rings, seals and gaskets.
rrectness of i
♦ After removing gaskets and seals, always inspect contact sur‐
l purpos
face of housing or shaft for burrs resulting from removal or for

other signs of damage.
nform
ercia
♦ Before installing seals, lightly oil outer diameter and half-fill

space between sealing lips -arrow- with sealing grease -
m
a
G 052 128 A1- .
com
tion in
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♦ The open side of the oil seals faces toward the side with fluid
te o
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filling.
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♦ Only use dual clutch gearbox oil. Other lubricants will cause
fo
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problems in function.
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♦ Coat O-rings with dual clutch gearbox oil to prevent pinching
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♦ After renewing gaskets, O-rings and seals, check oil level in
AG.
gearbox and top up if necessary ⇒ page 164 .
3.5 Nuts and bolts

♦ Loosen and tighten securing bolts and securing nut for covers
and housings diagonally.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
♦ Always renew self-locking bolts and nuts.
3. Repair instructions 7
4 Technical data
4.1 Allocation gearbox - engine
4.1.1 Passat 2015 ►, Passat Estate 2015 ► olkswagen AG

en AG. V ag does
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Take account of the gearbox code if spare partsbyare gu
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Dual clutch gearbox 0DL, all-wheel
ss
a
drive c
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Codes QAX, RCG, SDR, QBB, SDM

un
pt
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TJG, TJM
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Engine 2.0 l - 176 kW TDI 2.0 l - 162 kW TSI
ility
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4.1.2 Tiguan 2016 ►
h re
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spec
Take account of the gearbox code if spare parts are required for
t to the co
a repair.
Dual clutch gearbox 0DL, all-wheel drive
rrectne
Codes QAY, QAY, QBB, TAH, QBA,
RPN, SDK, RPL, TFQ, RPM,
s
SDK, RPN, RPP, TNZ, SDL,
s o
TFR TFR, SDN, TUS TFS,
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TNY TAH, TJL
form
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TFQ,
atio
TUR
om
n
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Engine 2.0 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l -
or
n thi
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105, 110 130, 132, 169 kW 176 kW

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kW TDI 140 162 kW TSI TDI

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Dual clutch gearbox 0DL, front-wheel drive
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Codes QAZ, RPK, SDS, cop Vo
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Engine 2.0 l - 110 kW TDI
4.1.3 Arteon 2018 ►

a repair.
Codes RWU, TFT, TJM
Engine 2.0 l - 176 kW TDI
4.1.4 Passat 2019 ►, Passat estate 2019 ►

a repair.
Codes TJM SDM
Engine 2.0 l - 176 kW TDI 2.0 l - 162 kW TSI
4.2 Capacities
Capacity Dual clutch gearbox 0DL
Initial filling 7.0 l ± 0.1 l

Capacity Dual clutch gearbox 0DL

Changing approx. 5.5 litres
♦ Change interval: ⇒ Maintenance manual and/
or ⇒ service tables “ELSA”
Lubricant Dual clutch gearbox oil

The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
Capacity Front bevel box

Capacity of bevel box 0A6 0.9 l
⇒ page 34
Capacity of bevel box 0CP 0.75 l
⇒ page 34
Changing Filled for life, no change
Lubricant Gear oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
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4. Technical data 9
5 Electrical components
5.1 Overview of fitting locations - electrical components
1 - Mechatronic unit for dual

clutch gearbox - J743-
❑ Removing and installing
⇒ page 26
2 - Gearbox input speed send‐
er - G182- and oil temperature
sender in multi-plate clutch -
G509-
❑ Both senders are com‐
bined in one component
and can be renewed to‐ AG. Volkswagen AG d
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❑ Removing and installing rise nte
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⇒ page 32 aut ra
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❑ Before removal of the
ce
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un
sender, the mechatronic
pt
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unit for dual clutch gear‐
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box - J743- must be re‐
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moved ⇒ page 26 .
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❑ Discontinued as of gear‐
h re
ole,
box date 06/15
spec
3 - Selector lever - E313-
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❑ With selector lever sen‐
sors control unit - J587- ,
selector lever lock sole‐
rrectne
noid - N110- and selec‐
tor lever locked in posi‐
tion P switch - F319- ss o
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❑ The components are in‐

nform
tegrated into the printed

mer
atio
circuit of the selector

om
mechanism and cannot

n
c
i
or
be renewed separately
thi
te
sd
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❑ Checking ⇒ vehicle di‐

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agnostic tester
um
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fo
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selector mechanism ⇒ page 72
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30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 11
⇒ “1.2 Removing and installing clutch end cover”, page 12
⇒ “1.3 Removing dual clutch”, page 15
⇒ “1.4 Installing dual clutch”, page 18
1.1 Assembly overview - dual clutch

Replacement parts
1 - Retaining ring for dual

clutch end cover
❑ Renew after removal
2 - Retaining ring for dual
clutch
AG. Volkswagen AG d
3 - Retaining ring for drive plate ksw
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4 - Dual clutch ised ara
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The
♦ drive plate has to re‐
an
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the teeth of the outer
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plate carrier.
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If♦the drive plate de‐
ole,
spec
taches, the plates in the
dual clutch can shift. It
t to the co
may then not be possible
to adjust the clutch cor‐
rectly when it is installed.
rrectne
5 - Shims
ss o
❑ 10 spacer rings which
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have different »thick‐
form
mer
nesses«. They are sized

atio
in 0.05 mm increments.
om
n
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❑ Thickness of spacer ring

i
or
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e
must be determined
t
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when installing dual

i
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clutch.
fo
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6 - Dual clutch end cover t. Cop py
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1. Clutch 11
Caution
♦ This figure is intended only to provide an overview of the

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

er
Special tools and workshop equipment required
♦ Clean assembly sleeve - T10459- before using. Do not use a
scratched sleeve.
Brief description
AG. Volkswagen AG d
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The cover is held in its seat by a retaining ring. After the retaining olks
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ring has been removed, the cover can be levered out of itsseseat. db ara
nte
Cover and retaining ring must always be renewed. Never ho install
ri eo
a new cover with a hammer and never oil the centre seal aut or touch ra
ss c
it with a hand! However, if this should happen, the cover is certain
ce
e
nl
to leak!
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Removing y li
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The gearbox must be removed for work on cover. wit

, is n
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– Drain gear oil ⇒ page 166 .
hole
spec
– Remove gearbox ⇒ page 90 .

es, in part or in w
t to the co
– Secure gearbox to assembly stand ⇒ page 159 .

Often, doubts arise as to whether the filter must be renewed or
rrectness of i
not.
l purpos
Note
nf
ercia
orm
It is not always necessary to change the oil filter ⇒ page 161 .

m
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om
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12 Rep. gr.30 - Clutch

– Remove filter if necessary ⇒ page 161 .
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
Cover can be levered out with a screwdriver.
Note
The removed cover and retaining may not be installed again.
Install only a »new« cover.
AG. Volkswagen AG d
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Installing
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Caution
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Cover and retaining ring must always be renewed.

hole
spec
Never grasp a new cover in centre seal. The centre hole of the
es, in part or in w
t to the co
cover must not be touched, oiled or brought into contact with

other materials. Leaks will result.
Never install new covers with a hammer!
rrectness of i
l purpos
nf
ercia
orm
m
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om
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13
by c lksw
cted
1. Clutch
agen
Prote AG.
7-speed dual clutch gearbox 0DLg-enEdition
AG. Volk12.2019
swagen AG
d wa oes
olks not
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– Only handle cover as shownise-in
d this picture-.
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Note
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There must be no stickers on the inside of the cover. If stickers
rm
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are present, remove them carefully.
pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– The running surface on the end of the shaft of the clutch
-arrow- must be free of oil and dry.
l purpos
– If necessary, thoroughly clean running surface.
nform
ercia
WARNING
m
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com
tion in
The centre seal of the new cover must be »preformed« before
r
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installing:
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Cop py
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– Clean assembly sleeve - T10459- “before using”. Do not use
by lksw
cted agen
Prote
a scratched sleeve.
AG.
– Set sleeve on a flat surface.
– Guide cover horizontally and evenly over entire sleeve

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

– Guide cover horizontally over sleeve and press evenly onto its
seat.
Caution
Work carefully. Any sort of blow to the cover is certain to cause

AG. Volkswagen AG d
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It is possible to lever cover carefully into its seat with a
ility
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-screwdriver- until »new« retaining ring can be installed.
wit
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– Install new retaining ring.
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
m
– Do not remove bush until retaining ring is installed.

o
n in
or c
– Installing gearbox ⇒ page 148

thi
te
sd
iva
– Top up gear oil ⇒ page 166 .

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WARNING C py
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Do not start engine if there is no oil in gearbox. by c lksw
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Prote AG.
1.3 Removing dual clutch

♦ Hooks - 3438- , qty. 2
1. Clutch 15
♦ Puller - T10055-
♦ Puller - T10525-
Brief description
• The axial play of the clutch is readjusted during installation
procedure.
• To remove or install clutch, gearbox must Abe securely
G. Volkswagenattached
AG do
agen
to an assembly stand in verticalVoposition
lksw ⇒ page 159 . Only es n
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this way is it possible later etod adjust axial play of the clutch
by ua
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Removing ss c
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un
pt
– Remove clutch end cover ⇒ page 12 .

an
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Important! Installation location of drive plate

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

h re
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spec
If there is no marking:
t to the co
– Mark installation position of drive plate relative to periphery of

outer plate carrier with permanent marker, as shown in illus‐
tration.
rrectne
• During installation, drive plate must always be repositioned at

marked position.
ss o
cial p
f inform
Note
mer
atio
om
The retaining ring is renewed together with the clutch. If the clutch
c
i
or
which is removed is reinstalled, the securing ring is to be used

thi
te
sd
a
again as well.
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Cop py
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Arteon 2018 ➤ , Passat 2015orise ➤ , Passat 2019 ➤ , Passat Variant 2015 nte ➤ , ...
eo
h
a 7-speed dual clutch gearbox 0DL - Edition 12.2019
ut ra
ss c
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un
– Lever out retaining ring -2- of drive plate using screwdriver
pt
an
d
-1- -arrow-.
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– Apply puller - T10525- together with puller - T10055- on

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splines and carefully pull drive plate off its seat -arrows-.
C py
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Prote AG.
– Remove retaining ring -arrow- and save it for now.
Note
Do not dispose of the retaining ring yet because it will be needed

to measure axial clearance.
1. Clutch 17
– Remove shim -arrow-.
Caution
Carefully remove the dual clutch. Take care that no parts fall
out. Therefore, do not turn the clutch over!
lk swage es n
Vo ot g
– Engage 2 hooks - 3438- on opposite esidesd by of clutch -arrow-. ua
ran
ir s tee
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t to the co
rrectne
– Remove dual clutch using hooks - 3438- .
ss o
cial p
f inform
mer
atio
om
n
c
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or
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1.4 Installing dual clutch
c by lksw
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Prote AG.

♦ Universal dial gauge holder - VW 387-

♦ Dial gauge - VAS 6079-
♦ Retaining pins - T10524-

AG. Volkswagen AG d
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♦ Drift sleeve - 40-21-

rrectness of i
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ercia
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Caution
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Prote
♦ The drive plate has to remain engaged between the teeth
AG.
of the outer plate carrier.

♦ If the drive plate detaches, the plates in the dual clutch can
shift. It may then not be possible to adjust the clutch cor‐
rectly when it is installed.
♦ Do not lift (not even slightly) or remove plate carrier! The
plates could turn.
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
1. Clutch 19
Installing
olkswagen AG
en AG. V
– Take great care when
olks removing the dual clutch
wag does from its pack‐
not
age. ed
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– Turn piston
au
tho rings by hand. They must move freely and emust
or
ac
not bind.
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itte
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ility
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hole
spec
es, in part or in w
t to the co
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rrectness of i
rectly. The ring butts -arrows- of piston rings -1- and -3- should
align.
l purpos
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Important! Position of drive plate rig ht
py by
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by lksw
– Before installing, check if there is a marking -arrow- on dual cted agen
Prote AG.
clutch.
– If there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the outer plate carrier.
– Insert retaining pin - T10524- .

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

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

– If necessary, insert clutch by turning slightly.
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The dual clutch is properly fitted if there is almost no play in the s
ce
le
retaining pin - T10524- .

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Note
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♦ The retaining pin remains inserted until the clutch end cover
spec
is installed.
t to the co
♦ The dual clutch must now not be rotated any more, as this can
shift the position of the retaining pin - T10524- .
rrectness
– Lever out retaining ring -2- of drive plate using screwdriver
o
cial p
f i
-1- -arrow-.
nform
mer
atio
om
Note
n
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This retaining ring will be used again. Do not dispose of it.

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

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

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

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

AG. Volkswagen AG d
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– Temporarily install “old” retaining ring -arrow-. hor eo
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Before this ring is finally disposed of, 3 measurements must be s
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made.
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First measurement (axial play of shaft)
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– Screw universal dial gauge - VW 387- to gearbox flange.
wit
is n
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ole,
spec
t to the co
rrectne
– Set -tip of dial gauge- on input shaft.
ss
– Set -dial gauge- to 0 with preload.
o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
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– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.
Note
This value will be needed later for the check measurement so

save value “A” until the last measurement has been performed.
Second measurement
• The retaining pin - T10524- remains installed!
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Tip must not sit on retaining ring.
– Set -dial gauge- to 0 with preload again.

– Lift dual clutch with force to stop and note measurement.
– Call this value “B”.
Now calculate which shim must be fitted:
AG. Volkswagen AG d
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– Use this formula: y Volksw not
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Value “B” minus value rise minus 0.11 = thickness of shim to
“A” nte
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be fitted. s aut ra
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– Note result.
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The shims are sized in 0.05 mm increments.

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– Measure the shims and determine which one is closest to the

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result.
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spec
WARNING
t to the co
Always use the next-largest shim, never the next-smallest.

rrectne
Example:
ss
Calculated dimension for shim New shim

o
cial p
f inform
1.28 mm 1.3 mm
mer
atio
1.26 mm 1.3 mm
om
n
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or
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– Remove old retaining ring -arrow-.

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Do not dispose of ring yet; it will be needed once more. p by
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1. Clutch 23
AG. Volkswagen AG d
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Arteon 2018 ➤ , Passath2015oris ➤ , Passat 2019 ➤ , Passat Variant 2015 nte
eo ➤ , ...
t
s au 0DL - Edition 12.2019 ra
c
s
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nl
pt
– Fit calculated shim.
du
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itte
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Third measurement (check measurement)
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To make sure that the shim is correct, a test measurement must
wit
still be carried out. Proceed as follows: , is n
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hole
spec
• The retaining pin - T10524- remains installed!
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Install old retaining ring -arrow- once more.

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Prote AG.
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Set the tip of the dial gauge on the shim -1-.
– Set -dial gauge- to 0 with preload again.

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

– Fit drive plate into dual clutch.

• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier -arrows-. If the markings were
subsequently make, align these.
– A second mechanic must hold retaining pin - T10524- in its
place and press outwards slightly.
– Carefully drive the drive plate onto its seat using press tool -
40-21- and a plastic hammer.
– Install drive plate retaining ring.
– Starting at the opening, press retaining ring in clockwise di‐
rection into its fitting position.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
and housing.
– Install clutch end cover ⇒ page 12 .
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mer
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Prote AG.
1. Clutch
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox installed)”, page 26
⇒ “1.2 Removing and installing gearbox input speed sender G182
and oil temperature sender in multi-plate clutch G509 up to gear‐
box date 05/15”, page 32
1.1 Removing and installing mechatronic

unit for dual clutch gearbox - J743-
(gearbox installed)
♦ Up to gearbox date 05/15 release tool - T10465-
AG. Volkswagen AG d
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d by ara
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nl
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du
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♦ Torque wrench - V.A.G 1331-

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es, in part or in w
t to the co
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nform
mercia
at
Always make sure that no dirt can enter an »open« gearbox.

om
ion
c
in t
In particular, dirt entering an »exposed« mechatronic unit for dual

or
his
e
clutch gearbox - J743- can lead to gearbox failure.

at
do
priv
Please also refer to the notes on the oil filter change regarding
um
for
en
g
»dirty oil« ⇒ page 161 .

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t.
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Remove mechatronic unit.
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– Move selector lever to position “P”. by c lksw
cted agen
Prote AG.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
26 Rep. gr.34 - Controls, housing

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

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

– Remove connecting hose between charge air cooler and
charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
overview - charge air system .
Continued for all vehicles
– Remove electrical wiring and retainer from front of sump

-arrows- (2 x M6 nuts).
– Raise wiring in area of sump and secure it.
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– Place used oil collection and extraction unit - V.A.G 1782-
yV
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low gearbox. ise
d b ua
ran
r tee
ho
– Drain oil ⇒ page 166 . aut or
ac
ss
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nl
pt
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ility
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wit
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hole
– Remove securing clip -3-.
spec
es, in part or in w
– Unscrew bolts -1- diagonally and remove.
t to the co
– Remove cover -2- with seal.
Note rrectness of i
l purpos
Always renew bolts, securing clips and the cover with seal.
nf
ercia
orm
m
atio
om
n in
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Prote AG.
1. Mechatronic unit 27
Before touching mechatronic unit, touch an earthed object again.
To gearbox date 05/15

– Release connector -1- of gearbox input speed sender - G182-
and oil temperature sender in multi-plate clutch - G509- using
release tool - T10465- .
Continued for all:
AG. Volkswagen AG d
agen oes
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au ra
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un
pt
an
d
itte
– Remove bolts -arrows- diagonally.

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ab
pe
All 9 bolts have same length and are not allowed to be reused. ility
ot
wit
, is n
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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
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com
tion in
r
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thi
s
iva
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fo
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Cop py
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– Remove mechatronic unit -1- carefully.
Caution
• Lift or put down mechatronic unit only on housing and on

solenoid valves.
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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ility
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Lay mechatronic unit to side properly.
h re
hole
– Put down mechatronic unit so that sensors -arrows- are point‐
spec
es, in part or in w
ing upwards.
t to the co
Install mechatronic unit.
Install in reverse order of removal. During this procedure, observe
rrectness of i
the following:
l purpos
WARNING
nform
ercia
Before installing the mechatronic unit, clean the sealing sur‐

m
face on the gearbox housing thoroughly without using cleaning

com
tion in
agents. Always make sure that no dirt can get into the inside.
r
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– Before installation, check that »sender« -1- is installed
t. C rig
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⇒ page 32 . yri
p by
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by c lksw
cted
Continued for all:
agen
Prote AG.
Before touching mechatronic unit, touch an earthed object again.
Caution
• Lift or put down mechatronic unit only on housing and on

solenoid valves.
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ility
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– Carefully insert mechatronic unit -1- into gearbox.
wit
, is n
h re
– Screw in new bolts -arrows- diagonally until finger-tight.
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
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ate
do
priv
cum
for
en
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t.
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by
– Tighten bolts in specified sequence to 8 Nm + 45°. cted agen
Prote AG.


– Push on connector -1- and engage.
– After this, check that fastener -2- is not damaged.
Caution
• Work with great care. The fastener of the connector -2-

can break. If this has happened, the connector will no
longer hold and the damaged part, e.g. mechatronic unit
for dual clutch gearbox - J743- must be renewed.
AG. Volkswagen AG d
agen oes
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Continued for all: ise d b ara
nte
or eo
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aut ra
ss c
ce
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un
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d
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rm
ab
pe
ility
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wit
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– Check seal -arrow- for damage. Renew seal if defective.
h re
hole
spec
A new mechatronic unit already has a new oil seal.
es, in part or in w
t to the co
– Moisten seal with oil.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
– Set new cover with seal -2- in place and tighten with new bolts
thi
s
iva
-1- diagonally in several stages to 10 Nm + 45°.

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fo
– Install new securing clip -3-.

en
ng
t.
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op
– Attach wire retainer to cover and tighten nuts to 10 Nm. C py
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yri by
– Push on connector for mechatronic unit for dual clutch gearbox op Vo
by c lksw
- J743- and engage lock by turning. cted agen
Prote AG.
– Do not start engine!

– Fill with oil ⇒ page 166 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
– Conduct basic adjustment of mechatronic unit for dual clutch
gearbox - J743- .
1.2 Removing and installing gearbox input

speed sender - G182- and oil tempera‐
ture sender in multi-plate clutch - G509-
up to gearbox date 05/15
Note
AG. Volkswagen AG d
agen oes
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♦ As of gearbox date 06/15, the gearbox input speed sender e-d by V gu
ara
G182- and the oil temperature sender in multi-plate clutch oris- nte
eo
G509- have been discontinued.
h
aut ra
ss c
♦ If a sender is fitted, a sender must be reinstalled after it has
ce
le
un
pt
been removed.
an
d
itte
y li
rm
♦ The following procedure applies only to gearboxes in which a
ab
pe
ility
sender is fitted.
ot
wit
, is n
h re
hole
Brief description
spec
es, in part or in w
Both senders are combined in one component and can be re‐
t to the co
newed together only. They are in the gearbox near the multi-
clutch. Before removal, the mechatronic unit for dual clutch
gearbox - J743- must be removed. rrectness of i
Removing
l purpos
– Remove mechatronic unit for dual clutch gearbox - J743-

⇒ page 26 .
nform
ercia
Do not pull on line!

m
a
com
tio
– Unscrew and remove bolt -2- and pull out sender -1-.
n in
r
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Installing
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fo
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the following:
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Reinstall »old« sender only if: ht. rig
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• The sender has no defect by c lksw
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Prote AG.
• The cable was not pulled on when it was removed
– Moisten sender with dual clutch gearbox oil and install.

– Tighten bolt -2- to 10 Nm.

– Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
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
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
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or
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ate
do
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cum
for
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ng
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2 Bevel box
⇒ “2.1 Distinguishing between different types of bevel boxes”,
page 34
⇒ “2.2 Removing and installing bevel box”, page 35
⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
page 57
2.1 Distinguishing between different types

of bevel boxes
The bevel box installed in the vehicle could be “0A6” or “0CP”.
Bevel boxes can be identified by means of the following:
Distinguishing feature with bevel box installed:
Determine version of bevel box by recess -arrow- in right area of
subframe.
Remove following components if necessary:
– Noise insulation ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation . en AG. V
olkswagen AG
ag does
ol ksw not
– Centre underbody cladding ⇒ General body repairs,
yV exterior; gu
db ara
Rep. gr. 66 ; Underbody cladding; Removing
ris and installing
e nte
underbody cladding . au
tho eo
ra
ss c
ce
le
un
pt
an
d
itte
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Area denoted by -arrow- is marked with “0A6” or “0CP”.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Additional distinguishing feature with bevel box removed:

m
a
com
tion in
Output flange on bevel box “0A6” is secured with a nut -A- ⇒ As‐
r
te o
sembly overview - bevel box, “0A6” ⇒ page 189 .

thi
s
iva
do
r
Disregard -B- and -arrows-.

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Cop py
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Prote AG.

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

-A- ⇒ Assembly overview - bevel box, “0CP” ⇒ page 191 .
Located behind retaining ring -A- is a washer -B-.
2.2 Removing and installing bevel box

⇒ “2.2.1 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat estate 2015 ►, Tiguan 2016 ►, Arteon 2018 ►, Passat 2019 ►,
Passat estate 2019 ►, vehicles with 2.0 l - 176 kW TDI with bitur‐
bo”, page 35
⇒ “2.2.2 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat estate 2015 ►, Passat estate 2019 ►, vehicles with petrol
engine”, page 40
⇒ “2.2.3 Removing and installing bevel box, Tiguan 2016 ►”, page
48
2.2.1 Removing and installing bevel box,

wage
n AG. VPassat
olkswagen A2015
G do
es n
►, Passat estate 2015 ►,
Tiguan 2016 ►, Arteon d2018 ►, Passat 2019 ►, Passat estate 2019 ►, ve‐
olks ot g
V
by ua
ran
hicles with 2.0 l - 176 riskW TDI with biturbo
e
o tee
h
ut o
a ra
ss c
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e
nl
pt
du
an
itte
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erm
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
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om
n in
or c
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2. Bevel box 35
Special tools and workshop

equipment required
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spec
♦ Multi-purpose tool - VW 771-
t to the co
♦ Hexagon key extension, 8 mm - 3247-
♦ Supplementary set for engine and gearbox support - VW 540/1
rrectne
B-
♦ Puller - T 10472-
ss o
Removing
cial p
f inform
– Raise vehicle. All 4 supports of lifting platform must be at same

mer
atio
height.
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
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fo
en
ng
After loosening centre bolt, do not lower vehicle to ground again.

t.
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Cop py
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cted agen
Prote AG.

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

– Do not loosen the front flange bolt -arrow- more than 90° while
the vehicle is still standing on its wheels, or the wheel bearing
will be damaged. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
lkswage es n
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Note d b ua
ran
ir se tee
tho
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So that the propshaft
ss
a can be turned later in order to loosen it: ac
ce
e
nl
pt
du
– Move selector lever to »N« position.
an
itte
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erm
ab
– Remove exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
ility
ot p
haust gas recirculation; Removing and installing exhaust gas
wit
, is n
recirculation cooler .
h re
hole
spec
The engine support - T10533- -A- remains in the forward position
es, in part or in w
t to the co
after the cooler has been removed. This makes it easier to remove
the bevel box later.
– Remove right drive shaft ⇒ Running gear, axles, steering;
rrectness of i
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
f
en
ng
bevel box.
t.
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– Remove upper securing bolts -arrows- securing bevel box to

gearbox.
2. Bevel box 37
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Arteon 2018 ➤ , Passat 2015 ➤ , Passatau 2019 ➤ , Passat Variant 2015 ➤ , ...
th or
ac
7-speed dual clutch gearbox 0DL - Edition 12.2019 ss
ce
le
un
pt
an
d
– Loosen lower securing bolts securing bevel box to gearbox
itte
y li
and unscrew only as far as dimension -a-.
erm
ab
ility
ot p
Dimension -a- = 15 mm.
wit
is n
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ole,
This prevents the bevel box from falling down immediately when
spec
loosened using multi-purpose tool - VW 771- .
t to the co
rrectness o
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– Prepare multi-purpose tool - VW 771- with a washer -a- and 2

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

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

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

splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
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2. Bevel box 39
– Unbolt gearbox carrier for bevel box. Observe installation lo‐

cation and tightening sequence of bolts ⇒ page 89 .
– Install exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
haust gas recirculation system; Removing and installing ex‐
haust gas recirculation cooler .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Check gear oil in bevel box ⇒ page 172 .
– Following installation, check oil level in gearbox
⇒ page 164 .
gr. 66 ; Noise insulation .
Specified torques: ⇒ page 89
2.2.2 Removing and installing bevel box, Passat 2015 ►, Passat estate 2015 ►,
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sender - G266- .
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(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
Caution
Risk of damage to flexible joint.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
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– If necessary, counterhold at rear final drive when loosening or

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wheels at same time.
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• -A- thin end
• -B- thick end
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hole for noise insulation.
It may be necessary to push the gearbox forwards slightly in order
to attach the engine support - T10533- .
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spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
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2. Bevel box 45

Installing

splines - G 000 100- .
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot

be pressed to stop against gearbox).
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– Mount drive shaft heat shield -1-, if present, on bevel box

shaft .
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Note
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rrectne
Removing and installing propshaft .

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2. Bevel box 47
Version 1:
Version 2:
– Secure pendulum support to gearbox using new bolts -1-.

Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
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The following procedure does not apply to vehicles with bitur‐
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Removing and installing bevel box - vehicles with 2.0 l - 176 kW

TDI engine and bi-turbocharger ⇒ page 35
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equipment required
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B-
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2. Bevel box 49
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eral body repairs, exterior; Rep. gr. 66 ; Noise insulation

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– Separate connector -1-.

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to right side. Do not disconnect any lines ⇒ Rep. gr. 19 ;
Coolant pump, regulation of cooling system; Assembly over‐
view - electric coolant pump .
Continued for all vehicles:

sender - G266- .
shaft .
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Note
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– Unscrew pendulum support bolts -1- from gearbox.

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shaft when it is placed on subframe.

– Push font propshaft back to stop. Make sure not to damage

seal -arrow- in centring bush.
– Place front propshaft on heat shield or on subframe as appro‐
priate.
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– Unbolt gearbox carrier for bevel box.

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Continued for all:
2. Bevel box 53

gearbox.

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bevel box will slide to stop against gearbox.
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2. Bevel box 55

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port - T10533- . Take note of seal in propshaft flange when
doing this.
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Removing and installing propshaft .
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– Secure pendulum support to gearbox using new o
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2.3 Detaching bevel box from gearbox -

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2. Bevel box 57
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♦ Puller - T 10472-
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Removing
– Remove gearbox with bevel box ⇒ page 90 .
– Secure gearbox with bevel box to assembly stand
⇒ page 159 .
In the following illustrations the bevel box is shown in installed
condition.
gearbox.


– Bolt multi-purpose tool - VW 771- onto puller T10472 and

AG. Volkswagen AG d
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Installing
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agen 2. Bevel box

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


bevel box will slide against contact surface on gearbox.
Caution
Retaining ring on stub shaft must engage correctly in differen‐

tial bevel gear. If retaining ring is not engaged, there is a risk
that stub shaft might move outwards.
Also, bevel box is not allowed to be bolted onto gearbox force‐
fully. Damage to gearbox or bevel box could result in both
cases.
– To ensure that the retaining ring engages properly in the dif‐

ferential bevel gear, strike the face of the spline stub several
times with a plastic hammer (weight 1000 - 2000 g).

AG. Volkswagen AG d
then tighten. Specified torque: ⇒ page 89 . agen oes
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db ara
– Installing gearbox ⇒ page 148 rise nte
tho eo
– After installing gearbox, check oil level sand
s top up au ra
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⇒ page 164 .
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3 Selector mechanism
⇒ “3.1 Assembly overview - selector mechanism”, page 61
⇒ “3.2 Emergency release from position P”, page 64
⇒ “3.3 Removing and installing selector lever handle”,
page 65
⇒ “3.4 Moving push-button in the handle to installation position”,
page 70
⇒ “3.5 Removing and installing selector mechanism”, page 72
⇒ “3.6 Removing and installing gear selector cable”, page 79
⇒ “3.7 Checking selector mechanism”, page 84
⇒ “3.8 Checking and adjusting selector lever cable”, page 84
⇒ “3.9 Renewing selector shaft seal”, page 86
3.1 Assembly overview - selector mecha‐

nism
⇒ “3.1.1 Assembly overview – selector mechanism, Passat
2015 ►, Passat estate 2015 ►, Arteon 2018 ►, Passat 2019 ►,
Passat estate 2019 ►”, page 61 wage
es ks not
Vol gu
⇒ “3.1.2 Assembly overview- selectored mechanism, Tiguan 2016
by ara
nte
►”, page 63 thoris eo
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sa
3.1.1 Assembly overview – selector mechanism, Passat 2015 ►, Passat estate
s c
ce
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un
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2015 ►, Arteon 2018 ►, Passat 2019 ►, Passat estate 2019 ►
an
d
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mer
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3. Selector mechanism 61
1 - Handle with selector cover

❑ Do not remove handle n AG. Volkswagen AG do
without reason. For lkswage es n
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emergency release, on‐ byV ua
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or
unclipped ⇒ page 64 . au ac
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⇒ page 65
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2 - Bolt
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❑ Qty. 4
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❑ 8 Nm ole,
spec
3 - Selector mechanism
t to the co
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
rrectne
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
ss
in P - F319- and selector
o
cial p
f i
lever lock solenoid -
nform
N110-
mer
atio
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n
⇒ page 72
c
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4 - Selector lever cable
iva
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❑ Selector lever cable is
um
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not greased
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⇒ page 79
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❑ Checking ⇒ page 84 Prote
cted AG.
agen
❑ Adjusting ⇒ page 84
5 - Securing clip
6 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
7 - Selector housing
8 - Cover
9 - Bolt
❑ For selector cable support bracket to gearbox
❑ Qty. 2
❑ 20 Nm +90°
10 - Gearbox
11 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm

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

⇒ page 65
2 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid -
N110-
⇒ page 72
3 - Bolt
❑ Qty. 4
❑ 8 Nm
4 - Plug
5 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
6 - Selector housing
7 - Gearbox agen
AG. Volkswagen AG d
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8 - Bolt d by ara
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❑ Always renew after re‐ utho eo
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❑ For selector cable sup‐

nl
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port bracket to gearbox
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9 - Bolt h re
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spec
❑ Adjuster screw for selector lever cable
es, in part or in w
t to the co
❑ 13 Nm
10 - Securing clip
rrectness of i
❑ Always renew after removing.

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

11 - Selector lever cable
nf
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❑ Selector lever cable is not greased

orm
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❑ Removing and installing ⇒ page 81

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c
❑ Checking and adjusting ⇒ page 84

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3.2 Emergency release from position P

⇒ “3.2.1 Manual release mechanism from position P, Passat 2015
►, Passat estate 2015 ►, Arteon 2018 ►, Passat 2019 ►, Passat
estate 2019 ►”, page 64
⇒ “3.2.2 Emergency release from position P, Tiguan 2016 ►”,
page 64
3.2.1 Manual release mechanism from posi‐

tion P, Passat 2015 ►, Passat estate
2015 ►, Arteon 2018 ►, Passat 2019 ►,
Passat estate 2019 ►
Do not remove handle
– Depress brake pedal or set handbrake.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Push selector cover to one side. AG. Volkswagen AG d
agen oes
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– Using a screw driver, from right side, press yellow plastic part
es, in part or in w
and hold in this position.
t to the co
Selector lever can now be moved from position »P«.
rrectness of i
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3.2.2 Emergency release from position P, Ti‐

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♦ -T10383/2-
Do not remove handle

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

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

wit
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handle
h re
hole
spec
⇒ “3.3.1 Removing and installing selector lever handle, Passat

es, in part or in w
t to the co
2015 ►, Passat estate 2015 ►, Arteon 2018 ►, Passat 2019 ►,

Passat estate 2019 ►”, page 65
⇒ “3.3.2 Removing and installing selector lever handle, Tiguan
rrectness of i
2016 ►”, page 68

l purpos
3.3.1 Removing and installing selector lever

handle, Passat 2015 ►, Passat estate
nf
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or
2015 ►, Arteon 2018 ►, Passat 2019 ►,

m
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Passat estate 2019 ►

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Prote
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agen 3. Selector mechanism
♦ Hose clip pliers - V.A.G 1275-
Brief description
Handle is removed together with selector cover.
Removing
– Shift selector lever to position “D”. AG. Volkswagen AG d
agen oes
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The push button -arrow- does not need to be pulled out bby y V hand.
o l not
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Push button engages automatically in installation position
rised when ara
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handle is pulled off. ut
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– Open lid of storage compartment. s
ce
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ab
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ot p
wit
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spec
t to the co
– Grasp under selector lever cover with one hand, and unclip
rrectne
cover by pulling it upwards.
– Separate electrical connector.
ss o
cial p
f inform
mer
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– Cut open clamp -arrow- under boot using side cutters.

– Pull handle upwards off selector lever without pressing push
button.
Note
Do not press button again after removal as it will no longer be

possible to install the handle.
Installing
Install in reverse order of removal, observing the following:
• Selector lever is in position “D”.
AG. Volkswagen AG d
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Note
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♦ There is a danger of the button being pressed into the handle.

h re
Never install a handle with the button pressed in.

ole,
spec
♦ Move push-button to installation position ⇒ page 70 .

t to the co
♦ New handle is supplied with installation guard. Do not remove

guard until just before installing. To remove, pull out
-in direction of arrow-.
rrectness o
cial p
f inform
mer
atio
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cted agen
Prote
3. Selector mechanism
AG.
– Push on handle with new clamp -arrow- to stop. Do not tighten

clamp yet.
– Press push button after installation.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 70 . Then
fit the handle again.
– If the push button returns to its start position when released,

the clamp can be tightened using the hose clip pliers - V.A.G
1275- .
– Connect electrical connector.
– Clip cover in position.

handle, Tiguan 2016 ►
♦ Hose clip pliers - V.A.G 1275- agen
AG. Volkswagen AG d
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♦ -T10383/2-
rrectness of i
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nform
mercia
at
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ion
c
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do
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for
en
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t.
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Cop py
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Brief description pyri by
Vo
co lksw
by
cted agen
Handle is removed together with selector cover. Prote AG.
Removing
– Shift selector lever to position “D”.

The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
– Fit wedge - T10383/2- at front between centre console and

selector cover, and lever selector cover off centre console by
carefully pushing wedge downwards.
– Separate electrical connector.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
– Cut open clampaut -arrow- under boot using side cutters.
h eo
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– Pull handle upwards off selector lever without pressing push
ce
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nl
pt
button.
du
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Note
wit
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hole
Do not press button again after removal as it will no longer be

spec
possible to install the handle.

es, in part or in w
t to the co
Installing
rrectness of i

• Selector lever is in position “D”.
l purpos
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AG. Volkswagen AG d
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ab
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spec
es, in part or in w
t to the co
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nform
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c
Note
in t
or
his
ate
do
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♦ There is a danger of the button being pressed into the handle.

p
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or
Never install a handle with the button pressed in.

f
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t.
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♦ Move push-button to installation position ⇒ page 70 . Cop py
t. rig
gh ht
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♦ New handle is supplied with installation guard. Do not remove p by
o Vo
by c
guard until just before installing. To remove, pull out
lksw
cted agen
Prote
-in direction of arrow-.
AG.
– Push on handle with new clamp -arrow- to stop. Do not tighten

clamp yet.
– Press push button after installation.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 70 . Then
fit the handle again.
– If the push button returns to its start position when released,

the clamp can be tightened using the hose clip pliers - V.A.G
1275- .
– Connect electrical connector.
– Clip cover in position.
3.4 Moving push-button in the handle to in‐

stallation position
If the button was pressed by mistake, the installation position can
be restored.
There are 2 ways of moving the push-button into the installation
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.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
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nl
pt
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– Holding down push button, completely push in installation
wit
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guard with eyelet -arrow- until installation guard engages, then
h re
release push button. When the installation guard is pulled out,
hole
spec
the push-button engages in the installation position.
es, in part or in w
t to the co
Place handle »without« installation guard in installation position:
rrectness of i
l purpos
nform
mercia
at
om
ion
– Carefully unclip handle trim -A- upwards.
c
in t
or
his
ate
do
priv
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for
en
ng
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Cop py
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Prote AG.
– Using e.g. a screwdriver press small lever -1- for pull rod into
groove -2-. This action presses the push button -3- back into
installation position.
-I- Button pressed in
-I- Button in installation position
AG. Volkswagen AG d
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Note ise
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♦ Press the lever only into the groove and no further.
s a c
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nl
♦ Do not clip the handle trim onto selector mechanism until the
pt
du
an
handle has been fitted. This makes it possible to check wheth‐
itte
y li
erm
er the small lever engages in the pull rod when the button is
ab
ility
pressed.
ot p
wit
, is n
h re
hole
spec
3.5 Removing and installing selector mech‐
es, in part or in w
t to the co
anism
⇒ “3.5.1 Removing and installing selector mechanism with selec‐
rrectness of i
tor lever cable”, page 72
l purpos
⇒ “3.5.2 Removing and installing selector mechanism without se‐

lector lever cable, Passat 2015 ►, Passat Estate 2015 ►, Arteon
2018 ►”, page 74
nf
ercia
or
⇒ “3.5.3 Removing and installing selector mechanism without se‐
m
m
atio
m
lector lever cable, Tiguan 2016 ►”, page 76

o
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3.5.1 Removing and installing selector mech‐ thi

te
sd
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anism with selector lever cable

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Brief description
t.
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Cop py
t. rig
In the interior, the centre console must be removed. opyri
gh by
Vo
ht
c lksw
The heat shield beneath the vehicle must be removed.
by
cted agen
Prote AG.
Removing
– Remove selector lever handle ⇒ page 65 .
– Remove centre console with securing bracket ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Remove footwell air duct ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview - air routing and air distribu‐
tion in passenger compartment .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove air filter housing.
Passat, Tiguan with diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing
Tiguan with petrol engine
housing

Continued for all:

– Pry selector lever cable -arrow- off lever using an open-ended
spanner.
Caution
Locks on selector lever cable break off very easily. If a locking

lug has broken off, complete selector mechanism with selector
lever cable must be renewed.
– Carefully push locking mechanisms of selector olkslever

wagencable
AG do to‐
en AG. V
gether -arrows- and remove selector
olkswaglever cable upwards eout
s no
of cable support bracket. d by V t gu
ara
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ris
– Do not bend or kink cable.
au
tho eo
ra
ss c
– Remove propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
ce
le
un
Propshaft; Removing and installing propshaft .
pt
an
d
itte
y li
– Install centre tunnel heat shield below selector mechanism ⇒
erm
ab
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
ility
ot p
extensions; Removing and installing floor heat shield .
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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Prote AG.
– If fitted, remove bracket -A-.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards.
Installing
the following:
Note
♦ Do not bend or kink gear selector cable.

♦ Do not grease selector lever cable.
♦ Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
– Install heat shield below selector mechanism ⇒ General body

repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– Install propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
– Install footwell air duct ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview - air routing and air distribu‐
tion in passenger compartment .
– Install centre console securing bracket and centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console;
Assembly overview - centre console .
AG. Volkswagen AG d
– Install selector lever handle ⇒ page 65 . agen oes
olksw not
byV gu
ara
– Adjust selector lever cable ⇒ page 84ris. ed
nte
ho eo
ut
– Check selector mechanism ⇒ page ss a 84 . ra
c
ce
le
– Install air filter housing.

un
pt
an
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Passat, Tiguan with diesel engine

erm
ab
ility
ot p

wit
housing
is n
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spec

t to the co
housing
Specified torques
rrectne
♦ Selector housing to body

⇒ “3.1 Assembly overview - selector mechanism”, page 61
ss o
cial p
f in
3.5.2 Removing and installing selector mech‐

form
mer
anism without selector lever cable, Pas‐

atio
om
n
c
sat 2015 ►, Passat Estate 2015 ►,

i
or
n thi
te
Arteon 2018 ►
sd
iva
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pr
cum
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fo
Brief description
en
ng
t.
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op
In the interior, the centre console must be removed.
C py
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rig ht
py by
The heat shield beneath the vehicle must be removed. co Vo
by lksw
cted agen
Prote AG.

Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove centre console vent ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Remove mounting bracket for centre console ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Removing and
installing centre console .
– Separate electrical connector from selector mechanism to ve‐
– Shift selector lever on selector mechanism to position “N”.
– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐

moving.
olkswagen AG
en AG. V
– Release the cable ksas
wagshown with a screwdriver,
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– Remove securing clip -arrow-.

rrectne
Always renew securing clip.

s
– Pull selector lever cable out of selector mechanism.

s o
cial p
f inform
mer
atio
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n
c
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– Remove nuts -arrows- inside vehicle. Volksw
oes
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– Remove selector mechanism -B- together
orise with selector hous‐ nte
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rm
the following:
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Note
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• Selector lever on selector mechanism must be set to position
nform
ercia
“N”.
m
– Insert cable into selector mechanism, attach to selector lever
a
com
tio
and fit new securing clip.
n in
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– Install mounting bracket ⇒ General body repairs, interior; Rep. t. Cop py
rig
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yri by
sole . cop Vo
by lksw
cted agen
Prote
– Install centre console vent ⇒ Heating, air conditioning; Rep.
AG.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
– Install selector lever handle ⇒ page 65 .
– Adjust selector lever cable ⇒ page 84 .
– Check selector mechanism ⇒ page 84 .
Specified torques
♦ Selector housing to body ⇒ page 61
3.5.3 Removing and installing selector mech‐

anism without selector lever cable, Ti‐
guan 2016 ►
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
sole .

– If fitted, remove footwell air duct ⇒ Heating, air conditioning;

Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– If fitted, remove mounting bracket gen-2-.
AG. VTo
olksdo
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bolts -1- on right and left.Volkswa not
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– Separate electrical oconnector
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– Shift selector lever on selector mechanism to position “N”. On‐
ce
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pt
ly in this position the selector lever cable can be released.
an
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– Remove plug and securing clip -arrow-.
rrectne
ss o
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mer
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n
c
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pr
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op py
– Fit a large screwdriver in grooves of locking element and turn
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– Pull selector lever cable out of selector mechanism. Prote AG.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
the following:
Note


“N”. Only in this position the selector lever cable can be en‐
gaged.
– Insert selector lever cable into selector mechanism until it is

visible in locking mechanism -arrow-.
AG. Volkswagen AG d
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it 90° in direction of arrow.

rm
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es, in part or in w
t to the co
rrectness of i
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nform
ercia
– The selector lever cable is properly engaged when the

grooves in the locking element are at right angles to the se‐
m
a
com
ti
lector lever cable.

on in
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thi
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– Install new securing clip -arrow- and insert plug.

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– If previously removed, install mounting bracket -2- ⇒ General

nl
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body repairs, interior; Rep. gr. 68 ; Centre console; Removing
an
itte
y li
and installing centre console .
erm
ab
ility
ot p
– If featured, install footwell air duct ⇒ Heating, air conditioning;
wit
, is n
Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
h re
distribution in passenger compartment .
hole
spec
es, in part or in w
– Install centre console ⇒ General body repairs, interior; Rep.
t to the co
sole .
rrectness of i
– Install selector lever handle ⇒ page 65 .
l purpos

– Check selector mechanism ⇒ page 84 . nform
ercia
Specified torques
m
at
om
♦ Selector housing to body ⇒ page 63

on
c
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3.6 Removing and installing gear selector

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⇒ “3.6.1 Removing and installing selector lever cable, Passat C py
t. rig
gh
2015 ►, Passat Estate 2015 ►, Arteon 2018 ►”, page 79
ht
pyri by
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⇒ “3.6.2 Removing and installing selector lever cable, Tiguan
cted agen
Prote AG.
2016 ►”, page 81

cable, Passat 2015 ►, Passat Estate
2015 ►, Arteon 2018 ►
Removing
Diesel engine
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing
Continued for all:

spanner.
Caution

AG. Volkswagen AG d
agen oes
olksw not
byV gu
– Carefully push locking mechanisms of riseselector
d lever cable to‐ ara
nte
gether -arrows- and remove selector
ut lever cable upwards out
ho eo
ra
of cable support bracket. ss a c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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– Remove parts of ⇒ exhaust system; Rep. gr. 26 .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
e
It is not permissible to reuse the cover. Always renew after re‐

t
sd
iva
moving.
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.
– Release the cable as shown with a screwdriver, and pull off

from the selector lever -arrows-.

– Remove securing clip -arrow-.

– Pull cable out of selector mechanism and remove. AG. Volkswagen AG d
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Installing byV
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Install in reverse order of removal. During this procedure,
hor observe eo
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the following: ss a ra
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nl
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an
itte
Note
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erm
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ility
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spec
♦ Following installation, selector lever cable must be checked
es, in part or in w
t to the co
for ease of movement and be adjusted.
rrectness of i
“N”.
l purpos

nf
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m
atio
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o
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or c
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– Check and adjust selector lever cable ⇒ page 84 .
te
sd
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Diesel engine:
t.
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Cop py
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– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing py
rig by
ht
and installing air filter housing . co Vo
by lksw
cted agen
Prote
AG.

cable, Tiguan 2016 ►
Removing
Diesel engine
housing
housing
Continued for all:

wage e
– Pry selector lever cableyV
olks -arrow- off lever using ans nopen-ended
ot g
ua
spanner. ed b ran
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au ac
s
Caution
s
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le
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pt
an
d

itte
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ab
pe
ility
ot
wit
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hole
spec
– Carefully push locking mechanisms of selector lever cable to‐
es, in part or in w
gether -arrows- and remove selector lever cable upwards out
t to the co
of cable support bracket.
rrectness of i
l purpos

nform
ercia

m
a
com
t
ion in
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te o
– Remove plug and securing clip -arrow-. thi

s
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do
r
rp
cum

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

– Pull cable out of selector mechanism and remove.
Installing
Note

♦ Ensure that selector lever cable moves freely after installing.

“N”. Only in this position the selector lever cable can be en‐
gaged.

– Insert selector lever cable into selector mechanism until it is

visible in locking mechanism -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
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wit
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hole
spec
– The selector lever cable is properly engaged when the
es, in part or in w
t to the co
grooves in the locking element are at right angles to the se‐
lector lever cable.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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– Install new securing clip -arrow- and insert plug.

m
f
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ng
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– Install heat shield below selector mechanism ⇒ General body Cop py
t. rig
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions; yri
gh by
ht
Removing and installing floor heat shield . cop Vo
by lksw
cted agen
Prote
AG.

– Check and adjust selector lever cable ⇒ page 84 .
Diesel engine
housing
housing
3.7 Checking selector mechanism

The starter must not operate in the selector lever positions “R”,
“D” and “S” and in the Tiptronic position. gen AG
. Volkswagen AG
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lksw not
On right-hand drive vehicles, the starterdb
y Vmust operate in selector
o gu
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lever positions “P” and “N” only whenris the push-button in the se‐
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lector lever handle is not pressed. eo
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ss
Above 5 km/h:
ce
e
nl
pt
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an
When the selector lever is shifted to “N”, the selector lever lock
itte
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solenoid must not lock the selector lever. Selector lever can be
erm
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ility
shifted back into a driving range.
ot p
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Below 5 km/h:
h re
hole
spec
When the selector lever is shifted to “N”, the selector lever lock
es, in part or in w
solenoid must lock the selector lever only after approx. 1 second.
t to the co
Selector lever cannot be shifted out of “N” position until brake
pedal is depressed.
rrectness of i
Selector lever in “P” position and ignition switched on
l purpos
• Brake pedal not depressed:
nform
ercia
Selector lever is locked and cannot be shifted out of “P” position

when the push-button is pressed. Solenoid for selector lever lock
m
at
blocks selector lever.
om
ion
c
in t
r
• Brake pedal is depressed:

o
his
ate
do
riv
Solenoid for selector lever lock releases selector lever. It is pos‐

p
cum
sible to shift into a driving gear. Slowly shift selector lever from
for
en
g
“P” through to “S”, checking whether selector lever position in

n
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yi Co
op
dash panel insert corresponds to selector lever position. C py
ht. rig
rig ht
Selector lever in “N” position and ignition switched on
py by
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• Brake pedal not depressed:
Prote AG.
Selector lever is locked and cannot be shifted out of “N” position

with the push-button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
Selector lever in position “Tiptronic”
• Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
When the selector lever is shifted into the Tiptronic gate, the se‐
lector lever position display in the dash panel insert must change
from “P R N D S” to “6 5 4 3 2 1”.
Ignition and light switched on
The respective symbol in the shift mechanism cover lights up.
Selector lever position indicator
Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
3.8 Checking and adjusting selector lever

cable

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.
Do not grease connections of cable!
Always adjust selector lever cable if the following applies:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been
agen
AG. Vremoved
olkswagen Aand
G doinstalled.
w es n
olks o
♦ Parts of the assemblyd mounting
by
V have been removed and in‐
t gu
ara
stalled. orise nte
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ac
♦ The cable itselfss aor the selector mechanism has been removed
and installed.
ce
e
nl
pt
du
an
itte
♦ The position of the engine and gearbox is shifted, for example

y li
erm
ab
to install it free of tension.

ility
ot p
Check
wit
, is n
h re
hole
– Switch selector lever to »P« position.

spec
es, in part or in w
– Remove air filter housing.

t to the co
Diesel engine
rrectness of i
housing
l purpos

nf
ercia
housing
rm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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.
Continued for all:

spanner.
Caution


– Shift selector lever several times from position »P« to »S« and
back to »P«.
• Selector lever must move easily.
– Reinstall cable.
– Then adjust selector lever cable.
Adjusting
– Move selector lever in vehicle to “P” position. olkswage es n
ot g
byV ua
– Selector shaft on gearbox is also in position “P”. rToise check,
d ran
tee
push lever opposite to driving direction to rearautstop.
ho
or
ac
ss
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un
pt
Note
an
d
itte
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rm
ab
pe
Raise vehicle, to be sure that the gearbox is in “P” (parking lock
ility
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engaged). It should not be possible to turn both front wheels to‐
wit
, is n
gether in the same direction.
h re
hole
spec
es, in part or in w
t to the co
– Loosen bolt -2- of the Bowden cable -1-.
– Gently push knob of selector lever forwards and backwards
but under no circumstances must you shift out of “P”. rrectness of i
– Tighten bolt -2- to 15 Nm.

l purpos
This completes the adjustment.

nform
ercia

m
a
com
Diesel engine
ion in
r
te o

thi
s
iva
housing
do
r
rp
cum
fo

en
ng
t.
yi Co
op
– ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter C py
t. rig
housing gh ht
pyri by
Vo
co lksw
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cted agen
Prote
3.9 Renewing selector shaft seal
AG.
Brief description
The seal can be renewed only with the gearbox removed.

♦ Tube - VW 423-
AG. Volkswagen AG d
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olksw not
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wit
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♦ Extractor hook - T20143-
h re
ole,
spec
t to the co
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cial p
f inform
mer
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om
n
c
i
or
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te
sd
♦ Not illustrated: Torque wrench - V.A.G 1331-
iva
o
pr
cum
r
fo
– Remove gearbox ⇒ page 90 .
en
ng
t.
yi Co
– Remove selector lever cable from gearbox ⇒ page 72 . Cop py
t. rig
gh ht
yri
– Unscrew securing nut -arrow- and carefully pull gearbox se‐ p by
o Vo
by c lksw
lector lever -A- off selector shaft. Prote
cted AG.
agen
– Pry seal out -in direction of arrow-.

– Lightly oil outer circumference of new oil seal.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
AG. Volkswagen AG d
agen oes
olksw not
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un
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erm
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ility
– Drive new seal in onto limit stop. Do not cant oil seal in the ot p
wit
is n
process.
h re
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spec
• Closed side of oil seal -arrow- points towards tube - VW 423- .
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– Install gearbox selector lever -A-, and tighten new nut
i
or
n thi
e
-arrow-. Specified torque: ⇒ Item 21 (page 155) .

t
sd
iva
o
pr
c
Gearbox selector lever fits on splines in only one position
um
r
fo
en
ng
t.
yi
– Install gearbox ⇒ page 148 .
Co
Cop py
t. rig
– Install and adjust selector lever cable on gearbox ⇒ page 84 .
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4 Removing and installing gearbox

⇒ “4.1 Specified torques for gearbox”, page 89
⇒ “4.2 Removing gearbox”, page 90
⇒ “4.3 Installing gearbox”, page 148
⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
page 57
4.1 Specified torques for gearbox

⇒ “4.1.1 Gearbox carrier to engine and bevel box”, page 89
Item Bolt Nm
wage es n
1, 2, 3 M12x55 80 y Volks ot g
• Withisinsert
ed
b tool ua
ran
tT10179
ho r
or tee
or
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au
T10509: ac
»65 Nm«
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pt
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4 M12×65 80
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5, 6, 7 M10x50 40
ility
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8 M12×70 80
h re
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A Dowel sleeves for centring
spec
es, in part or in w
t to the co
Component Nm
Assembly mountings to gearbox (renew bolts after 60 Nm + turn 90° further
rrectness of i
each removal)
l purpos
Earth strap to assembly mounting 25

Heat shield for right drive shaft to bevel box 20
nf
ercia
Propshaft to bevel box ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - prop‐
orm
shaft
m
atio
om
n in
or c
thi
te
sd
iva
Bevel box to gearbox 40 Nm + turn 90° further

o
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rp
♦ Renew bolts after re‐ cu

o
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f
en
ng
moving.
t.
yi Co
Cop py
t. rig
gh ht
yri by
4.1.1 Gearbox carrier to engine and bevel box
cop Vo
by lksw
cted agen
Prote AG.
Installation location and tightening sequence:
Diesel engine
Item Bolt
A M10 x 21
B M10 x 45
Sequence Bolts Specified torque

1 -A- and -B- Screw in to contact by hand
2 Tighten -A- 40 Nm
3 Tighten -B- 40 Nm
Petrol engine
4. Removing and installing gearbox 89

Installation location and tightening sequence:

Item Bolt
1 M10 x 45
2 M10 x 21
Sequence Bolts Specified torque

1 -1- and -2- Screw in to contact by hand
2 Tighten -2- 40 Nm
3 Tighten -1- 40 Nm
Heat shield for propshaft

♦ Bolt -A-: 20 Nm n AG. Volkswagen AG do
lkswage es n
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♦ Bolt -B-: 40 Nm d byV ua
ran
ir se tee
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pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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4.2 Removing gearbox t to the co

⇒ “4.2.1 Removing gearbox, Passat 2015 ►, Passat estate 2015
►, Arteon 2018 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles
rrectness of i
with 2.0 l - 176 kW TDI with biturbo”, page 90

l purpos
⇒ “4.2.2 Removing gearbox, Passat 2015 ►, Passat estate 2015

►, Passat estate 2019 ► vehicles with petrol engine”, page 101
nform
ercia
⇒ “4.2.3 Removing gearbox, Tiguan 2016 ► vehicles with 2.0 l -

m
105 kW, 110 kW, 130 kW, 140 kW diesel engine, all-wheel drive”,
at
om
io
page 112
n
c
in t
or
his
e
⇒ “4.2.4 Removing gearbox, Tiguan 2016 ►, vehicles with petrol

at
do
riv
engine, all-wheel drive”, page 121

p
cum
for
⇒ “4.2.5 Removing gearbox, Tiguan 2016 ►, vehicles with diesel

en
ng
t.
yi Co
engine, front-wheel drive”, page 131 t. Cop py
rig
gh ht
⇒ “4.2.6 Removing gearbox, Tiguan 2016 ►, vehicles with 2.0 l - pyri by
Vo
co
176 kW TDI”, page 139
by lksw
cted agen
Prote AG.
4.2.1 Removing gearbox, Passat 2015 ►,

Passat estate 2015 ►, Arteon 2018 ►,
Passat 2019 ►, Passat estate 2019 ►,
vehicles with 2.0 l - 176 kW TDI with bi‐
turbo
Brief description
The gearbox is removed downwards together with the bevel box.
»From above«:
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Support engine and gearbox before left
subframe mounting is unbolted.
»From below«:

The -subframe- is removed together with -pendulum support- and

-both suspension links-.
Both drive shafts are disconnected from gearbox and left installed
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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♦ Support - 10-222A-
♦ Shackle - 10 - 222 A /12-
♦ Support - 10 - 222 A /31-
♦ Engine support basic set - T40091-
♦ Engine support supplement set - T40093-
♦ Gearbox support - 3282-

♦ Engine and gearbox

jack - V.A.G 1383 A-
or engine and gear‐
box jack - VAS 6931-
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♦ Adjustment plate -
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3282/42 A-
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♦ Hose clamps to 25
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mm - 3094-
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♦ Tensioning strap -
ole,
T10038-
spec
t to the co
♦ Engine bung set -
VAS 6122-
♦ Insert tool, 18 mm -
rrectne
T10179-
♦ Insert tool, 18 mm -
ss o
T10509-
cial p
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mer
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♦ Socket, multi-point bit

- T10061-

♦ Counter-hold tool -
T10172A-
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♦ Support bridge - yV
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T10323- ir se
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♦ Adapter -
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T40093/3-6- , qty. 2
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(check and modify as

necessary
⇒ page 93 )
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T40093/3-6A- : qty. 2
AG.
Check adapters -
T40093/3-6- and modify
as necessary
– If necessary, cut off
the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as -
T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be fitted onto longitudinal
members with adapters -
T40093/3-6A- .

• To prevent damage
to the longitudinal
members, wrap the
front section of the
adapters -
T40093/3-6A- with
textile-reinforced ad‐
hesive tape ⇒ Elec‐
tronic parts catalogue
(ETKA chemical sub‐
stances) .
Removing:
– Raise vehicle. All 4
supports of lifting
platform must be at
same height.
Note
So that the propshaft can

be turned later in order to agen
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– Move selector lever aut
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un
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– Remove complete air
an
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filter housing ⇒ Rep.
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gr. 23 ; Air filter; Re‐
pe
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moving and installing
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air filter housing .
h re
hole
spec
Battery in engine com‐
es, in part or in w
partment
t to the co
– Remove battery and
battery tray ⇒ Electri‐
rrectness of i
cal system; Rep. gr.
27 ; Battery; Remov‐
l purpos
ing and installing bat‐

tery tray . nform
ercia
Battery in luggage com‐

partment
m
a
com
tion in
r
– Remove air filter housing bracket ⇒ Rep. gr. 23 ; Air filter;

te o
thi
Removing and installing air filter housing .

s
iva
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The bracket is similar to the one shown.

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– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Cop py
Removing and installing starter . ht. rig
rig ht
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Prote AG.

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


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

or hose clamps to 25 mm - 3094- and remove.
– Seal connecting necks of gear oil cooler using suitable plugs
from engine bung set - VAS 6122- .
– Disconnect connector -1- for mechatronic unit for dual clutch

gearbox - J743- . To do this, turn rotary locking mechanism
anti-clockwise -arrow-.
– Remove air intake pipe ⇒ Rep. gr. 21 ; Charge air system;
Removing and installing air intake pipe .
lkswage es n
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– Unscrew upper engine/gearbox connecting bolts using insert

ot p
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tool 18 mm - T10179- or insert tool 18 mm - T10509- .

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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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Prote AG.
4. Removing and installing gearbox
A bolt is located in the starter motor hole -arrow-. This bolt can be
removed using socket - T10061- .
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222A- , remove these now.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
AG. Volkswagen
– Remove plenum chamber cover ⇒ lkGeneral swa
gen body repairs, ex‐es n
AG do
terior; Rep. gr. 50 ; Plenum chamber
d by
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cover; Removing and ot g
ua
installing plenum chamber ocover
rise . ran
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– If there are hose and cable
ss
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pt
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– Install support bracket - 10-222 A- as follows:
erm
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ility
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Required material:
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♦ Adapter - 10 - 222 A /31-1-
hole
spec
♦ Adapter - 10 - 222 A /31-2-
es, in part or in w
t to the co
♦ Connector - T40091/3-
♦ Square tube - T40091/1-
rrectness of i
♦ Spindle from engine support supplement set - T40093 /3-
l purpos
♦ Adapter - T40093/3-6- , qty. 2 (check and modify as necessary

⇒ page 93 )
nform
ercia
♦ or adapter - T40093/3-6A- : qty. 2

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– Detach cover caps on bolted connections for suspension
n
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struts (front).
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– Fit adapter - 10 - 222 A /31-1- and adapter - 10 - 222 A /31-2-

p
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-A- onto suspension strut mountings.

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The webs -arrow- must face towards front end. t. Cop py
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– Bolt support bracket - 10-222 A- to adapter - 10 - 222 A /31-1-

and to adapter - 10 - 222 A /31-2- .
-A- = adapter - T40093/3-6A- (⇒ next figure)

– Remove fuel filter and lay to side. Do not open pipe/hose sys‐
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
– Position adapter - T40093/3-6A- on left longitudinal member

directly behind filler pipe for washer fluid reservoir.
• Each of the adapters - T40093/3-6A- locks with pin -A- behind
the web of the longitudinal member -arrow-.
– Screw on spindle from engine support supplement set -
T40093 /3- , connect it via square tube - T40091/1- to engine
support bracket - 10-222 A- and fasten connection (⇒ previous
fig.).
• The square tube - T40091/1- must be flush with the connecting
piece - T40091/3- and the engine support supplement set -
T40093 /3- (⇒ previous figure).
– Then attach spindles to engine support eyes.
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– Take up weight of engine/gearbox assemblyolksand support
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– Remove noise insulation ⇒ Generalaut
h body repairs, exterior; eo
ra
Rep. gr. 66 ; Noise insulation; sAssembly overview - noise in‐
s c
sulation .
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– Remove lower part of front left wheel housing liner ⇒ General

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body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐

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sembly overview - front wheel housing liner .

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– Remove electrical wiring and retainers from sump at front

spec
-arrows-.
es, in part or in w
t to the co

rrectness of i
l purpos
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mercia
at
om
ion
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ate
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for
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Cop py
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rig ht
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Prote AG.


sender - G266- .
Remove subframe. ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe
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– Remove drive shaft heat shield -1-, if present, fromhobevel box
ris nte
eo
(-arrows-) ⇒ Running gear, axles, steering; Rep.s gr.
au 40 ; Drive
t ra
c
shaft . s
ce
e
nl
pt
du
– Disconnect both drive shafts from gearbox ⇒ Running gear,
an
itte
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axles, steering; Rep. gr. 40 ; Drive shaft: Removing and in‐
erm
ab
stalling drive shafts .
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hole
spec
es, in part or in w
t to the co
rrectness of i
Secure both drive shafts to suspension struts using tensioning
l purpos
straps - T10038- .
The surface protection of the shafts must not be damaged.
nf
ercia
orm
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– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
Prote AG.
box.


– Unbolt propshaft from bevel box -arrows- ⇒ Rep. gr. 39 ;


tightening propshaft. agen
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es, in part or in w
t to the co
– Secure support - T10323- with a bolt on inside rear threaded

hole for subframe.
rrectness of i
– A securing bolt from the subframe is suitable for this.

l purpos
– Place cloth -A- on support and put propshaft on that.

nform
mercia
at
om
ion
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ate
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Cop py
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Note
♦ When removing and installing, do not damage seal in the

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

haust gas recirculation; Removing and installing exhaust gas
recirculation cooler .
– Remove all but one »easily accessible« connecting bolt be‐
tween engine and gearbox.
– Remove securing bolts -arrows- of assembly mounting for en‐

gine ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview
- assembly mountings .
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– Remove securing
s bolts -arrows- of assembly mounting for
s c
gearbox.
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itte
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ility
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wit
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hole
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es, in part or in w
t to the co
rrectness of i
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– Then use spindles of support bracket - 10 - 222 A- to lower

engine/gearbox »only« on gearbox side as far as dimension
nform
ercia
-a-.
m
at
Dimension -a- = about 110mm

om
ion
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The gearbox is separated from the engine in this position.

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his
ate
do
riv
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐

p
cum
or
box support - 3282- under gearbox.

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Cop py
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Prote AG.

– Mount safety support -1- and hook -2- on gearbox as shown.
– Mount safety support -3- and pin -4- on gearbox as shown.

– Remove »last« connecting bolt between engine and gearbox.
– Push gearbox off engine and lower it carefully, ensuring
»clearance« to other components.
Transporting gearbox ⇒ page 153 .
Secure gearbox to assembly stand ⇒ page 159 .
Install gearbox ⇒ page 148 .
4.2.2 Removing gearbox, Passat 2015 ►,

Passat estate 2015 ►, Passat estate
2019 ► vehicles with petrol engine
Brief description
AG. Volkswagen AG d
The gearbox is removed downwards separately.
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»From above«: db ara
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The battery is disconnected in and,autif located engine compart‐ ra
ss c
ment, removed. The air filter and starter are removed. The engine
ce
le
and gearbox must be supported before the left subframe mount‐

un
pt
an
d
ing is removed.
itte
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»From below«:
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-Subframe- is removed together with -pendulum support- and

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spec
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t to the co

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tion in
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equipment required
AG. Volkswagen AG d
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t to the co
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nform
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♦ Support - 10 - 222 A- a
com
tion in
♦ Adapter - 10 - 222 A /29-

r
te o
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s
iva
do
♦ Adapter - 10 - 222 A /18-

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♦ Shackle - 10 - 222 A /12- qty. 2

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♦ Pin - 3282/29- t. C rig
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♦ Engine and gearbox jack - V.A.G 1383 A- or engine and gear‐

box jack - VAS 6931-
♦ Adjustment plate - 3282/67-
♦ Hose clamps to 25 mm - 3094-
♦ Tensioning strap - T10038-
♦ Engine bung set - VAS 6122-

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en AG dual clutch gearbox 0DL - Edition 12.2019
gen AG
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♦ Insert tool, 18 mm - T10179-ed
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
r
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s
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Cop py
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♦ Socket, multi-point bit

- T10061-
♦ Square tube -
T40091/1- , qty. 2
♦ Connecting piece -
T40091/3- , qty. 2
♦ Spindle - T40093 /3-
from engine support
supplementary set -
T40093- , qty. 2 agen
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♦ Adapter -
es, in part or in w
T40093/3-6- , qty. 2
t to the co
(check and modify as

necessary
⇒ page 105 )
rrectness of i
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tion in
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♦ or adapter -
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T40093/3-6A- : qty. 2
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ara
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orise 7-speed dual clutchnte gearbox 0DL - Edition 12.2019
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Check adapters - s
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T40093/3-6- and modify
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the marked area.
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– Round off front
hole
spec
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– Protect adapter
against corrosion.
– Then, mark adapters
rrectness of i
- T40093/3-6- as -
l purpos
T40093/3-6A- .
At a later point, support
nform
ercia
bracket - 10-222 A- will

be fitted onto longitudinal
m
at
members with adapters -
om
ion
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front section of the
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T40093/3-6A- with p by
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textile-reinforced ad‐
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hesive tape ⇒ Elec‐
AG.
tronic parts catalogue

(ETKA chemical sub‐
stances) .
Removing
– Raise vehicle. All 4
supports of lifting
platform must be at
same height.
– Move selector lever
to position »P«.
– Remove engine cov‐
er panel ⇒ Rep. gr.
10 ; Engine cover
panel; Removing and
installing engine cov‐
er panel .
Battery in engine com‐
partment
– Remove battery and
battery tray ⇒ Electri‐
cal system; Rep. gr.
27 ; Battery; Remov‐
ing and installing bat‐
tery tray .
Battery in luggage com‐
partment
– Disconnect battery ⇒
Electrical system;
Rep. gr. 27 ; Battery;
Disconnecting and
reconnecting battery .

– Remove air filter housing and bracket located beneath ⇒ Rep.

gr. 24 ; Air filter; Assembly overview - air filter housing .
Caution


– Remove air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
– Lay lint-free cloths on gear oil cooler and gearbox to catch
escaping coolant.
Note
AG. Volkswagen AG d
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♦ On a warm engine, the cooling ed by system is under high pressure. guar
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♦ Before pulling off theaucoolant
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ac
coolant expansion tank
ss with a cloth and open carefully.
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– Clamp off coolant hoses using hose clamps, up to 25 mm in

erm
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diameter - 3094- , and detach them.

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es, in part or in w
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cted agen
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Rep. gr.34 - Controls, housing
AG.

– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
It is advisable to remove the lower bolt first.
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– Unscrew all upper bolts securing engine to gearbox.

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pe
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t to the co
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m
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tion in
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port eyes for support bracket - 10-222A- , remove these now. s
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– Install support bracket - 10-222 A- as follows:

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ng
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Required material:
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Cop py
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♦ Adapter - 10 - 222 A /18-
gh ht
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♦ Shackle - 10 - 222 A /12- : qty 2 (required if spindles of support cted agen
Prote AG.
bracket cannot be hooked into lifting eyes of engine).
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Square tube - T40091/1- , qty. 2
♦ Connecting piece - T40091/3- , qty. 2
♦ Spindles - T40093 /3- , qty. 2
♦ Adapter - T40093/3-6- , qty. 2 (check and modify as necessary
⇒ page 105 )
♦ or adapter - T40093/3-6A- : qty. 2
– On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐

tween wing mounting flange and sheet metal for mounting
wing underneath it.
♦ Installation position:
“L” = -1- adapter is to be inserted on “right” side of vehicle ( adapt‐
er is engaged in recess of wing).
“R” (not shown in figure) adapter is to be inserted on “left” side of

vehicle.
Arrow -2- always points in direction of travel.

– Push adapter - 10 - 222 A /18- and two connecting pieces -

T40091/3- onto support bracket - 10-222 A- .
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
29- .
-A- = adapter - T40093/3-6A- (⇒ next figure)
– If present, pull off wires in front area of flange on both longi‐

tudinal members -arrow-. Do not disconnect pipe/hose sys‐
tem.
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– If necessary, carefully unclip wanyagenpipes for air conditioning
AG. Volkswagen AG d
oes
system in front area. Doynot Vo disconnect pipe/hose system
lks not ⇒
gu
Heating, air conditioning;
ed b
Rep. gr. 87 ; Refrigerant circuit; ara
nte
ris
System overviewut-h refrigerant circuit .
o eo
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nl
pt
du
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Position adapter - T40093/3-6A- on left longitudinal member

rrectness of i
directly behind filler pipe for washer fluid reservoir.

l purpos
• Each of the adapters - T40093/3-6A- locks with pin -A- behind

the web of the longitudinal member -arrow-.
nform
ercia
– Screw in spindles - T40093 /3- .

m
at
om
– Connect spindles - T40093 /3- via square tubes - T40091/1-

ion
c
to engine support bracket - 10-222 A- , and tighten (⇒ previous

in t
or
his
e
illustration).
at
do
priv

um
for
en
ng
t.
yi
– Take up weight of engine/gearbox assembly and support
Co
op py
bracket on spindles . t. C rig
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pyri by
co Vo
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cted
Rep. gr. 66 ; Noise insulation .
agen
Prote AG.



-arrows-.

sender - G266- .
– Remove subframe ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe .
– Unbolt drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
ut ra
– Secure drive shaft to suspension
ss a
strut with tensioning strap - c
T10038- .
ce
le
un
pt
an
d

itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew bolts -1- and -2-, and remove gearbox carrier from
bevel box.
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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Vo
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by c lksw
cted agen
Prote AG.

– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
– Unbolt propshaft from bevel box -arrows-
rise ⇒ Rep. gr. 39 ;
d
nte
Propshaft; Removing and installingut propshaft .
ho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
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ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
cum
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fo
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ng
t.
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Cop py
t. rig
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Vo
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by
cted agen
Prote AG.


hole for subframe.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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un
pt
an
d
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ab
ility
ot p
Note
wit
is n
h re
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spec
t to the co
rrectne
ss o
cial p
f inform
mer

atio
m

o
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove securing bolts -arrows- of assembly mounting for

gearbox.


-a-.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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un
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ot

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es, in part or in w
t to the co
Note
Be careful of all lines when lowering gearbox.

rrectness of i
l purpos

nform
ercia

m
a
com
tion in
4.2.3 Removing gearbox, Tiguan 2016 ► ve‐

r
te o
thi
hicles with 2.0 l - 105 kW, 110 kW, 130

s
iva
do
r
rp
kW, 140 kW diesel engine, all-wheel

um
fo
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t.
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drive
Co
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Brief description p by
co Vo
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The gearbox is removed downwards together with the bevel box. Prote AG.
»From above«:
The battery, air filter and starter are removed. Wiring harness of
steering rack is disconnected and »moved clear«. This allows it
to be lowered together with subframe and steering rack. The en‐
gine and gearbox must be supported before the left and right
assembly mounting is removed.
»From below«:
Remove noise insulation beneath engine and cover in front left
wheel housing.


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

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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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
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ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
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Prote AG.
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-
♦ Engine and gearbox jack - VAS 6931-


♦ Insert tool 18 mm - T10179- or insert tool AF 18 - T10509-
AG. Volkswagen AG d
agen oes
olksw not
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wit
is n
♦ Bar - 2024 A / 1- of lifting tackle - 2024 A-
h re
ole,
spec
♦ Socket, multi-point bit - T10061-
t to the co
♦ Adapter - 10 - 222 A /3-
rrectne
♦ Support bridge - T10323-
s
♦ Adapter - 10 - 222 A /16-
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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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.
Removing
height.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
– Remove battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;

Arteon 2018 ➤ ,APassat 2015 ➤ , Passat 2019 ➤ , Passat Variant 2015 ➤ , ...
n G. Volkswagen AG do
lkswage 7-speed es ndual clutch gearbox 0DL - Edition 12.2019
V o o t gu
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– Pry selector lever tcable
ho
ris
off selector shaft lever -arrow- using tee o
an open-ended sspanner.
au ra
c
s
ce
e
nl
pt
du
Caution
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
m

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
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pyri by
Vo
co lksw
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cted agen
Prote AG.



port eyes for support bracket - 10 - 222 A- , remove these now.
– Remove gas strut of bonnet from bottom ball-head pin and
prop up bonnet using workshop means ⇒ General body re‐
pairs, exterior; Rep. gr. 55 ; Bonnet; Removing and installing
gas strut .
– Mount support bracket - 10-222 A- :
Required material:
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Adapter - 10-222A/16-
♦ Fish plate - 2024 A / 1-
AG. Volkswagen AG d
♦ Bracket - T10346- agen oes
olksw not
byV gu
ara
♦ Bracket - T10346/1- rised
nte
ho eo
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♦ Flange bolt M6 x 40 ss a ra
c
ce
le
un
pt
an
d
itte
y li
tween wing mounting flange and sheet metal for mounting
rm
ab
wing underneath it.
pe
ility
ot
wit
, is n
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hole
“L” = -1-, adapter is inserted on “right” side of vehicle
spec
es, in part or in w
t to the co
“R” (not shown in illustration), adapter is to be inserted on “left”
side of vehicle
rrectness of i
l purpos
nform
ercia
Position adapters - 10-222A/29- behind console -1- next to shoul‐

der -2- in each case.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

• First, slide adapter - 10-222A/16- onto left side of support

bracket ⇒ page 117 .
• Adapter - 10-222A/16- serves to secure support bracket dur‐
ing subsequent work routine.
• Once support bracket is complete, adapter - 10-222A/16- is
located between adapter - 10 - 222 A /18- and left adapter -
10 - 222 A /29- .
– Push adapter - 10 - 222 A /18- and adapter - 10 - 222 A /3-
onto support bracket - 10-222 A- .
AG. Volkswagen AG d
agen oes
Secure support bracket - 10-222 A- as shown o lksw not
V gu
d by ara
e
– Bolt bracket - T10346- or -T10346/1- to rear left mounting
horis
hole nte
eo
for battery tray. aut ra
ss c
ce
– To do this, use a flange bolt M6 × 40 or a securing bolt for
le
un
pt
battery tray.
an
d
itte
y li
rm
ab
pe
ility
ot
Note
wit
, is n
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hole
Attach shackle - 10 - 222 A /12- to uppermost hole of fish plate -
spec
2024 A / 1- .
es, in part or in w
t to the co
– Secure bar - 2024 A / 1- with locating pin -arrow-.
rrectness of i
l purpos

bracket on spindles .
nform
ercia

Rep. gr. 66 ; Noise insulation; Removing and installing noise
m
a
com
t
insulation .
ion in
r
te o

thi
s
iva

do
r
rp

um
fo
en
ng
t.
yi Co
op
– Remove electrical wiring and retainers from sump at front C py
t. rig
-arrows-.
gh ht
pyri by
Vo
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by c lksw
– Raise wiring in area of sump and secure it. cted agen
Prote AG.


sender - G266- .
view - subframe
shaft .
G. Volkswagen AG d
lksw
agen
A
oes
not
straps - T10038- . by
Vo gu
ara
ed nte
ris
The surface protection of the shafts must notube
tho damaged. eo
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ss
ce
e
nl
pt
du
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itte
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erm
ab
ility
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wit
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es, in part or in w
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box.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
o
m
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t.
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Cop py
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Prote AG.


AG. Volkswagen AG d
agen oes
olksw not
V gu
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or eo
h
aut ra
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ce
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nl
pt
du
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erm
ab
ility
ot p
wit
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es, in part or in w
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rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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sd
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t.
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Cop py
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by c lksw
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Prote AG.

hole for subframe.

Note



gine ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview agen
AG. Volkswagen AG d
oes
- assembly mountings . yV
olksw not
g b ua
ed ran
oris tee
th or
au ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
gearbox.
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
cu
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m
f
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t.
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engine/gearbox »only« on gearbox side as far as dimension t. C rig
gh ht
-a-. yri
p by
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by c lksw
cted
agen
Prote AG.



4.2.4 Removing gearbox, Tiguan 2016 ►, ve‐

hicles with petrol engine, all-wheel drive
Brief description
The gearbox is removed downwards separately.
»From above«:
The battery is disconnected and, if located in engine compart‐
ment, removed. The air filter and starter are removed. Theksengine n AG. Volkswagen AG do
wage es n
and gearbox must be supported before the left subframe by V mount‐
ol ot g
ua
ing is removed. ris
ed ran
te
tho eo
»From below«: ss au ra
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
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
121
co Vo
by lksw
cted
4. Removing and installing gearbox
agen
Prote AG.

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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
♦ Support - 10 - 222 A-
agen
Prote AG.
♦ Hook - 10-222A/10-
♦ Adapter - 10-222A/28-
♦ Adapter - 10-222A/28-2-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ 2 × -T40091/1- and -T40091/3- from engine support basic set
- T40091-
♦ 2 × swivel joints - T40093/3- from engine support supplemen‐
tary set - T40093-


♦ Insert tool, 18 mm - T10179-
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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Shackle - 10 - 222 A /12-
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.
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Cop py
t. rig
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pyri by
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co
by lksw
cted agen
Prote AG.
♦ Pin - 3282/29-

Arteon 2018 ➤ , Passat 2015 ➤ , Passatolk2019 ➤ , Passat Variant 2015 ➤ , ...
. V swagen AG
7-speed dual clutch gearboxlk0DLgen AG
swa - Edition 12.2019 does n o ot g
yV ua
edb ran
Removing ris tee
tho or
au ac
– Raise vehicle. All 4 supports
ss of lifting platform must be at same
height.
ce
le
un
pt
an
d
– Move selector lever to position »P«. itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
spec
27 ; Battery; Removing and installing battery tray .
es, in part or in w
t to the co
rrectness of i
l purpos
Caution
nform
mercia
a
com
tio
n in
r

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Co
op py
t. C rig
gh ht
pyri by
Vo
o
– Do not bend or kink cable. by c lksw
cted agen
Prote AG.
– Remove charge air pipe with charge air hose ⇒ Rep. gr. 21 ;
Charge air system; Assembly overview - charge air system .
– Lay lint-free cloths on gear oil cooler and gearbox to catch
escaping coolant.
Note
♦ On a warm engine, the cooling system is under high pressure.

♦ Before pulling off the coolant hoses, cover the cap on the
coolant expansion tank with a cloth and open carefully.
– Clamp off coolant hoses using hose clamps, up to 25 mm in

diameter - 3094- , and detach them.

Volkswa
– Disconnect connector -1- for mechatronicswunitagenfor dual clutchAG does
AG. gen
gearbox - J743- . To do this, turn rotary
y V locking mechanism
olk not
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anti-clockwise -arrow-. edb ara
ris nte
tho eo
– Remove starter -A- ⇒ Electrical
ss
au system; Rep. gr. 27 ; Starter; ra
c
ce
e
nl
pt
du
an
It is advisable to remove the lower bolt first.
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
– Unscrew all upper bolts securing engine to gearbox.
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
A bolt is located in the starter motor hole -arrow-. This bolt can be yri
gh by
ht
op Vo
by c lksw
cted agen
Prote
Supporting engine
AG.

– Remove foam elements -arrows- on left and right for plenum

chamber seal.


tween wing and mounting plate for wing located underneath.

side of vehicle
– Push 2 swivel joints - T40091/3- onto support bracket - 10-222
A- .
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
29- .
– Unscrew bolts -arrows- for lock carrier bracket on left and right.
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
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erm
ab
ility
– Unscrew lower supports from adapters - 10 - 222 A /28- and
ot p
replace them with adapters -10-222 A /28-2- .
wit
is n
h re
ole,
– Unscrew bolts -arrows- for attaching engine support to lock
spec
carrier from adapter - 10-222 A /28-2- .
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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ng
t.
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Cop py
ht. rig
rig ht
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– Bolt adapter - 10-222 A /28-2- to lock carrier using securing
co Vo
by lksw
cted
bolt -1-. Specified torque: 8 Nm.
agen
Prote AG.

– Set-up square tubes - T40091/1- with one spindle each as

shown.
– Engage spindles in support eyes of engine. Use shackle - 10
- 222 A /12- if necessary.
– Take up weight of engine/gearbox assembly using spindles .
Rep. gr. 66 ; Noise insulation .
AG. Volkswagen AG d
– Remove lower part of front left wheel housing liner ⇒ General ksw
agen oes
not
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner;
y Vol As‐ gu
db ara
sembly overview - front wheel housing liner . or
ise nte
th eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
-arrows-.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
um
r
fo
en
ng
sender - G266- .
t.
yi Co
Cop py
– Remove subframe ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
t. rig
gh ht
yri
view - subframe . p by
o Vo
by c lksw
cted agen
– Unbolt drive shafts from gearbox ⇒ Running gear, axles, Prote AG.
– Secure drive shaft to suspension strut with tensioning strap -

T10038- .

– Unscrew bolts -1- and -2-, and remove gearbox carrier from
bevel box.
– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.
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
t to the co
rrectness 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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.



hole for subframe.
Note
♦ When removing and installing, do not damage seal aingethe

propshaft flange -arrow-. Vol
ksw es n
ot g
d by ua
ran
♦ Renew propshaft if damaged. ⇒ Rep. gr. ris39 ; Propshaft;
e
Re‐ tee
ho
moving and installing propshaft au
t or
ac
ss
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
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Cop py
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gearbox.

-a-.
AG. Volkswagen AG d
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mer
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Be careful of all lines when lowering gearbox. t. C rig
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Transporting gearbox ⇒ page 153 . cted agen
Prote AG.



hicles with diesel engine, front-wheel
drive
Brief description
The gearbox is removed downwards separately. The engine re‐
mains in the vehicle.
Battery, battery carrier and air cleaner housing are removed
»from above«. Engine and gearbox must then be supported so
that left and right assembly mounting can be detached.
»From below«:
wheel housing.
-steering rack-.

equipment required
AG. Volkswagen AG d
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tion in
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t.
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rig ht
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Prote AG.
♦ Support - 10 - 222 A-

♦ Adapter - 10 - 222 A /29-

♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-

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♦ Bar - 2024 A / 1- of lifting tackle - 2024 A-

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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Prote AG.

♦ Adapter - 10 - 222 A /3-

AG. Volkswagen AG d
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♦ Adapter - 10 - 222 A /16-
t to the co
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ion
c
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ate
do
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t.
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Prote AG.
Removing
height.


Caution

lever cable must be renewed. gen AG
. Volkswagen AG
d
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– Carefully push locking tmechanisms
ho
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of selector lever cable to‐ eo
gether -arrows- andssremove selector lever cable upwards out
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o

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t.
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pyri by
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AG. Volkswagen AG d
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A bolt is located in the starter
d by motor hole -arrow-. This bolt can
V gube
ara
removed using socketo-risT10061- .
e nte
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h
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– If there are hose ss and cable connections in area of engine sup‐ c
ce
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un
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gas strut .
is n
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spec
Required material:
t to the co
♦ Adapter - 10 - 222 A /3-
rrectne
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /29- , qty. 2 ss o
cial p
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♦ Adapter - 10-222A/16-
mer
atio
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♦ Fish plate - 2024 A / 1-

o
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♦ Bracket - T10346-
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♦ Bracket - T10346/1-
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♦ Flange bolt M6 x 40
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tween wing mounting flange and sheet metal for mounting Prote
cted AG.
agen
wing underneath it.
side of vehicle


AG. Volkswagen AG d
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10 - 222 A /29- .
rrectness of i
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t.
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Secure support bracket - 10-222 A- as shown
gh ht
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– Bolt bracket - T10346- or -T10346/1- to rear left mounting hole Prote
cted AG.
agen
for battery tray.
battery tray.
Note

2024 A / 1- .

bracket on spindles .
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .


-arrows-.

sender - G266- .
– Remove subframe. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Assembly overview - subframe
olksw AG. V agen AG
agen do
– Disconnect both drive shaftsolks from gearbox ⇒ Running
w es n
ogear,
t gu
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axles, steering; Rep.sedgr. 40 ; Drive shaft: Removing and in‐
b ara
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stalling drive shafts
tho .
ir
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straps - T10038- .
spec
The surface protection of the shafts must not be damaged. t to the co

rrectness o
cial p
f inform
mer
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n
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Cop py
t. rig
gh ht
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Vo
co lksw
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cted agen
Prote AG.


gearbox.

-a-.
Note
The following diagrams show the gearbox in the all-wheel drive

version. The procedure for supporting the weight of the gearbox
is the same as that for front-wheel drive.
AG. Volkswagen AG d
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– Mount safety support -3- and pin -4- on gearbox as shown. spec
es, in part or in w
t to the co
rrectness of i

l purpos

nform
ercia

m
a
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tion in
r
te o
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rp
cum
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.


hicles with 2.0 l - 176 kW TDI
Brief description
The gearbox is removed downwards togetherolkwith
swa the bevel box.
ge es n
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»From above«: db
y V ua
ran
ise
r tee
The battery, airfilter and starter areutremoved. Wiring harness of
ho
or
steering rack isdisconnected andss »moved clear«. This allows it
a ac
to be lowered together with subframe and steering rack. The en‐
ce
le
un
pt
gine and gearbox must be supported before the left and right
an
d
itte
assembly mounting is removed.
y li
rm
ab
pe
ility
»From below«:
ot
wit
, is n
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hole
wheel housing.
spec
es, in part or in w
t to the co
-steering rack-.
rrectness of i
l purpos
nform
ercia
equipment required
m
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.
♦ Support - 10 - 222 A-

♦ Adapter - 10 - 222 A /29-

♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-

♦ Adjustment plate - 3282/67- wage
es n
lks ot g
Vo
♦ Hose clamps to 25 mm - 3094- d by ua
ran
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ac
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nform
mercia
a
com
tion in
r
te o
thi
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rp
cum
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t.
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op py
♦ Bar - 2024 A / 1- of lifting tackle - 2024 A- t. C rig
gh ht
yri by
cop Vo
by lksw
cted agen
Prote AG.
♦ Adapter - 10 - 222 A /3-
♦ Support bridge - T10323-

♦ Adapter - 10 - 222 A /16-
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mercia
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ion
c
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or
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ate
do
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for
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t.
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Cop py
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by
cted
Removing
agen
Prote AG.

height.

Caution


. Volkswagen AG
– Clamp off coolant hoses using hose clamps to k40
swamm - 3093-
gen AG does
not
by
Vol
gu
ara
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ise nte
– Seal connecting necks of gear oil cooler
ho using suitable plugs
r eo
ut
from engine bung set - VAS 6122-ss.a ra
c
ce
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nl
pt
du
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ab
ility
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
– Unscrew upper engine/gearbox connecting bolts using insert gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.

gas strut .
Required material:
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Adapter - 10-222A/16-
♦ Fish plate - 2024 A / 1-
♦ Bracket - T10346-
♦ Bracket - T10346/1-
♦ Flange bolt M6 x 40
AG. Volkswagen AG d
agen oes
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– On both sides of vehicle, insert
ed by Vadapters - 10 - 222 A /29- be‐ t gua
ran
tween wing mounting flange
ho
ris and sheet metal for mounting tee
wing underneath it. au t or
ac
ss
ce
le
un
pt
an
d
itte

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rm
ab
pe

ility
ot
side of vehicle
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
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do
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rp
cum
fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.


10 - 222 A /29- .
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
ho eo
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Secure support bracket - 10-222 A- as shown ss c
ce
le
un
pt
– Bolt bracket - T10346- or -T10346/1- to rear left mounting hole
an
d
itte
for battery tray.
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ab
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ility
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wit
battery tray.
, is n
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hole
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es, in part or in w
Note
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2024 A / 1- .
rrectness of i
l purpos

nform
ercia

m
bracket on spindles . a
com
tion in
r

te o
thi

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r
sulation .
rp
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ng

t.
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op
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐ C py
ht. rig
sembly overview - front wheel housing liner . rig ht
py by
co Vo
by lksw
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AG.
-arrows-.


sender - G266- .
view - subframe
shaft .

straps - T10038- .
AG. Volkswagen AG d
agen oes
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rise nte
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au ra
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un
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an
d
box.
itte
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ab
ility
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spec
t to the co
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cial p
f inform
mer
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n
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sd
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t.
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Cop py
t. rig
gh ht
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145
c by lksw
cted agen
Prote AG. 4. Removing and installing gearbox

AG. Volkswagen AG d
agen oes
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tion in
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ng
t.
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Cop py
t. rig
gh ht
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Vo
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by
cted agen
Prote AG.

hole for subframe.

Note


haust gas recirculation; Removing and installing exhaust gasn AG. Volkswagen AG do
recirculation cooler . wage es n
olks o V t gu
by ara
– Remove all but one »easily accessible« connecting
ris
ed bolt be‐ nte
tween engine and gearbox. tho eo
au ra
c
ss
ce
le

un
pt
an
d

itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
gearbox.
m
a
com
tion in
r
te o
thi
s
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do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

-a-.


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
4.3 Installing gearbox h eo
aut ra
ss c
ce
le
Install in the reverse order of removal observing the following:

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
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l purpos
nform
mercia
a
com
tion in
r
te o
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iva
do
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rp
cum
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Renew needle bearing in crankshaft ⇒ Rep. gr. 13 ; Crank‐

shaft; Renewing needle bearing in crankshaft .
Note
If the needle bearing in the crankshaft is damaged, the gears

cannot be selected properly any more because the clutch is sup‐
ported on this bearing.
– Lightly grease journal and splines on gearbox.

– Check for proper seating of both dowel sleeves between en‐
gine and gearbox.
– Check for proper seating of intermediate plate. agen
AG. Volkswagen AG d
oes
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It must be possible to guide the engine and gearbox
d by V
together by gu
ara
hand until the engine flange rise
and gearbox hflange make contact all nte
o eo
around. aut ra
c
ss
– If necessary, readjust gearbox support until engine and gear‐
ce
e
nl
pt
du
box are »aligned with each other«.
an
itte
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erm
ab
– Turn crankshaft slightly if necessary.
ility
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Install gearbox, taking care not to pinch any lines.
wit
, is n
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hole
– Tighten gearbox to engine.
spec
es, in part or in w
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
t to the co
moving and installing starter .
– If engine and gearbox were removed, install them ⇒ Rep. gr.
rrectness of i
10 ; Removing and installing engine; Installing engine
l purpos
Pay attention to selector lever cable when installing. Guide cable

as soon as possible into cable support bracket.
nform
ercia
– Install subframe. ⇒ Running gear, axles, steering; Rep. gr.

40 ; Subframe; Assembly overview - subframe
m
at
om
io
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
n
c
in t
or
40 ; Drive shaft; Removing and installing drive shafts . his

ate
do
riv

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cum
for
en
g
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;

n
t.
yi Co
Draining and filling coolant . Cop py
t. rig
gh ht
yri
– Install noise insulation ⇒ General body repairs, exterior; Rep. p by
co Vo
lksw
gr. 66 ; Noise insulation; Removing and installing noise insu‐
by
cted agen
Prote
lation .
AG.

AG. Volkswagen AG d
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat 2019 ➤ ri,s Passat Variant 2015 ➤ , ...
ed
nte
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aut
h
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nl
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5 Assembly mountings
an
itte
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⇒ “5.1 Assembly overview - assembly mountings”, page 150
ility
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5.1 Assembly overview - assembly mountings
h re
hole
spec
es, in part or in w
t to the co
1 - Bolt
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly
rrectness of i
mountings; Assembly
overview - assembly
l purpos
mountings
2 - Engine support
nf
ercia
orm
❑ ⇒ Rep. gr. 10 ; Assem‐
m
atio
m
bly mountings; Assem‐

o
n in
c
bly overview - assembly

or
thi
mountings
te
sd
iva
o
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rp
cu
3 - Engine mounting
o
m
f
en
ng
❑ ⇒ Rep. gr. 10 ; Assem‐

t.
yi Co
op
bly mountings; Assem‐ C py
ht. rig
bly overview - assembly rig ht
py by
mountings co Vo
by lksw
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Prote AG.
4 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
5 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
6 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
7 - Bolt
❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
8 - Pendulum support
9 - Bolt
❑ For pendulum support to subframe
10 - Bolt
❑ For pendulum support to gearbox
❑ Gearbox with threaded insert ⇒ page 151
11 - Bolt
❑ For pendulum support to gearbox
❑ Gearbox with threaded insert ⇒ page 151

12 - Bolt
❑ For securing gearbox mounting to gearbox console.
❑ Tightening sequence ⇒ page 152
❑ 60 Nm +90°
13 - Bolt
❑ For securing gearbox mounting to gearbox console.
❑ Qty. 2
❑ 60 Nm +90°
14 - Gearbox mounting
❑ Check adjustment ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - checking adjustment of
assembly mountings
❑ Adjust ⇒ Rep. gr. 10 ; Assembly mountings; Adjusting assembly mountings
15 - Bolt
❑ Gearbox mounting to body
16 - Bolt
❑ For securing gearbox console to gearbox.
❑ 40 Nm +90°
17 - Gearbox bracket
❑ Illustration does not correspond to version in vehicle.
18 - Bolt
❑ For securing gearbox console to gearbox. n AG. Volkswagen AG do
lkswage es n
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❑ Renew after removal d byV ua
ran
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❑ Tightening sequence ⇒ pageut152
ho tee
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❑ 40 Nm +90° ss
ce
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un
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Gearbox with threaded insert (e.g. “Heli-Coil”) for securing pen‐

pe
ility
dulum support.
ot
wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes

for the pendulum support.
rrectness of i
♦ Distinguishing feature: shoulder along beginning of thread

-arrow-.
l purpos
♦ Note appropriate securing bolts and specified torque ⇒ Rep.

gr. 10 ; Assembly mountings; Assembly overview - assembly
nform
ercia
mountings .
m
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Cop py
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Prote AG.
5. Assembly mountings 151

Install left assembly mounting as follows:

– Renew all bolts -1- and -2-.
– First screw in all new bolts by hand.
– Then tighten bolts -1- of gearbox bracket -A-.
– The gearbox bracket -A- can be levered into its seat with a
screwdriver while bolts -2- are being tightened.
AG. Volkswagen AG d
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Prote AG.

6 Transporting gearbox
♦ Lifting tackle - 2024 A-
♦ Workshop hoist - VAS 6100-
Always secure heavy parts when transporting them.

Also remember there is oil in the gearbox. .Do not turn gearbox
olkswag AG
with breathers downwards duringkstransportAG V
or whileenon repair
wagen does
stand. Oil will run out. by
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Note ss
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If necessary, pull off breather cap and close using suitable plugs
d
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to achieve an oil-tight seal.

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Transporting gearbox
h re
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Gearbox can be lifted with lifting tackle - 2024 A- .

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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6. Transporting gearbox 153

7 Dismantling and assembling gearbox
7.1 Assembly overview - gearbox

⇒ “7.1.1 Renewing bleeder”, page 156
⇒ “7.1.2 Renewing sealing cap”, page 156
1 - Retaining ring
❑ Renew
2 - Clutch end cover
❑ A cover which has been
removed must not be in‐
stalled again.
❑ Lubricate external seal
with dual clutch gearbox
AG. Volkswagen AG d
oil - G 052 182 A2- be‐ ksw
agen oes
not
l
fore installing. by V o gu
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❑ Removing and horis installing nte
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⇒ page 12 s aut ra
c
s
3 - Retaining ring
ce
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un
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❑ Renew
itte
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4 - Shim
pe
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❑ Determine thickness
, is n
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again if a new clutch has

hole
spec
been fitted ⇒ page 11

es, in part or in w
t to the co
5 - Tapered ring
6 - Clutch
rrectness of i

⇒ page 11
l purpos
7 - Sealing ring, right

nform
ercia
⇒ page 186
m
a
com
ti
8 - Breather pipe
on in
r
te o

thi
s
⇒ page 156
iva
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9 - Breather cap
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10 - Plug Cop py
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11 - Seal p by
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❑ Renew
agen
Prote AG.
12 - Gear oil cooler

❑ Removing and installing gear oil cooler ⇒ page 160
13 - Bolt, 20 Nm + 45°
❑ Renew
14 - Filter housing, 20 Nm
15 - Seal
❑ Renew

16 - Heat shield
17 - Oil filter
18 - Bolt, 5 Nm + 90°
❑ Renew
19 - Cable support bracket
❑ For selector lever cable to gearbox
20 - Gearbox selector lever
21 - Bolt, 10 Nm + 90°
❑ Renew
22 - Gearbox
23 - Left seal
24 - Seal
❑ Renew
25 - Oil drain plug, 20 Nm
❑ For mechatronic unit
26 - Oil level pipe, 3 Nm
Caution
Comply
♦ with the torque
setting precisely.
AG. Volkswagen AG d
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The
♦ oil level pipe can
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break between the se
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thread and the collar.thori eo
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un
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Note
an
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ab
♦ The oil level pipe comes in dif‐

pe
ility
ferent lengths and colours.

ot
wit
, is n
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♦ If the oil level pipe is renewed, it

hole
spec
is essential that the oil level pipe

es, in part or in w
appropriate for the gearbox is in‐

t to the co
stalled ⇒ Electronic Parts Cata‐

logue “ETKA” .
rrectness of i
♦ Do not install the oil level pipe

from another gearbox! The oil
l purpos
level pipe determines the oil level

in the gearbox.
nform
ercia
♦ Fitting a different oil level pipe

can result in the oil level in the
m
a
com
gearbox being too high or too

ion in
low.
r
te o
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s
iva
do
❑ Drain and fill oil ⇒ page 166

r
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27 - Seal
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❑ Renew C py
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28 - Oil drain plug, 45 Nm
p by
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29 - Bolt, 10 Nm
Prote AG.
30 - Gearbox input speed sender - G182- and oil temperature sender in multi-plate clutch - G509-
7. Dismantling and assembling gearbox 155

31 - Mechatronic unit for dual clutch gearbox - J743-

32 - Bolt, 8 Nm + 45°
❑ Renew
33 - Cover
❑ With seal
❑ Renew
34 - Bolt, 10 Nm + 45°
❑ Renew
35 - Securing clip
❑ Renew
36 - Seal
❑ Renew
7.1.1 Renewing bleeder

Removing
– Pull off cap -arrow- by hand.
lkswage es n
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erm
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– Insert screwdriver -1- between collar of gearbox and breather

ility
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pipe -2-.
wit
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– Pry off breather pipe -2- with screwdriver -1-.

h re
hole
spec
Installing
es, in part or in w
t to the co
– Push on breather pipe -2- powerfully by hand.

Breather pipe must be heard and felt to engage.
rrectness of i
– Put on cap.
l purpos
nform
mercia
at
7.1.2 Renewing sealing cap

om
ion
c
in t
or

his
ate
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for
en
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♦ -1- Internal puller - Kukko 21/2-
♦ -4- Counter support - Kukko 22/1-

♦ Special wrench - T40297-
♦ Knife, commercially available

Removing
height.
– Switch selector lever to »P« position. agen
AG. Volkswagen AG d
oes
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– Remove front left wheel. byV gu
ara
ed
ris nte
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– Remove front left wheel housing aliner
ut
h ⇒ General body repairs,
ra
exterior; Rep. gr. 66 ; Wheel housing
ss liners; Removing and c
ce
installing front wheel housing liner .

e
nl
pt
du
an
itte
– Pierce centre of cap with a knife -1- and remove rubber coating
y li
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ab
around it. Diameter of opening approx. 15 mm.

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t to the co
rrectness of i
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nform
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at
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ion
c
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ate
do
priv
cum
for
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rig ht
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157
cted agen
Prote AG.
7. Dismantling and assembling gearbox
– Pull sealing cap out of gearbox housing using internal puller

14 … 19 mm -B-, e.g. -Kukko 21/2- , and counter support
-A-, e.g. -Kukko 22/1- .
– Thoroughly clean sealing surface on gearbox housing with a
lint-free cloth.
Installing
AG. Volkswagen AG d
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– Using key - T40297- , drive new sealing cap into gearbox
ce
le
un
pt
housing to stop. Take care not to cant sealing cap.
an
d
itte
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– Check gear oil level ⇒ page 164 .
erm
ab
ility
ot p
– Install front left wheel housing liner ⇒ General body repairs,
wit
is n
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
h re
ole,
installing front wheel housing liner .
spec
– Install front left wheel ⇒ Running gear, axles, steering; Rep.
t to the co
gr. 44 ; Wheels, tyres; Changing wheels .
rrectness o
cial p
f inform
mer
atio
om
n
c
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

8 Securing to engine and gearbox sup‐

port
Keep in mind that there is oil in the gearbox. Do not turn gearbox
with breathers downwards during transport or while on repair
stand. Oil will run out.
Note
If necessary, pull off breather cap and close using suitable plugs
to achieve an oil-tight seal.
Example: securing gearbox to assembly stand.
AG. Volkswagen AG d
agen oes
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nl
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t to the co
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ate
do
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Prote AG.
8. Securing to engine and gearbox support 159

9 Gear oil circuit
9.1 Removing and installing gear oil cooler


Removing
– Move selector lever to position “P”.
– Remove battery and batteryn Atray
G. Vo⇒ Electrical
lkswagen AG system; Rep. gr.
27 ; Battery; Removingwage
olks and installing battery . s not
doe
V gu
d by a
– Lay lint-freeorcloths
ise on gear oil cooler and gearbox to racatch
nte
escapingaucoolant.
th eo
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ss c
– Clamp off coolant hoses using hose clamps -3094- and re‐
ce
e
nl
pt
move from cooler.

du
an
itte
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ab
ility
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es, in part or in w
t to the co
rrectness of i
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– Unscrew bolts -arrows- and remove gear oil cooler -A-.

nform
mercia
Caution
at
om
ion
c
in t
or
No coolant must be allowed to drip into gearbox!

his
ate
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for
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Installing
♦ Renew O-rings -arrows- after each removal.
♦ Coat O-rings with gear oil to prevent pinching of rings during
assembly.
♦ If sealing surface on gear oil cooler is damaged, it must be
renewed.
AG. Volkswagen AG d
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– Carefully remove strainer -1- of oil cooler, if present, with a ss c
ce
le
screwdriver and check for contamination.

un
pt
an
d
itte
– Clean strainer if necessary and clip back in place.
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t to the co
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– Carefully bring gear oil cooler -A- into position. When doing
o
cial p
f
this, observe sealing surface and O-rings.
inform
mer
– Screw in new bolts -arrows- incrementally in diagonal se‐

atio
m
quence and tighten to 20 Nm + 45°.

o
n
c
i
or
n thi
te
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Prote AG.
– Attach coolant hoses to gear oil cooler and remove hose

clamps -3094- .
– Install battery with battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
– Check coolant level and top up with coolant as needed ⇒ Rep.
gr. 19 ; Cooling system, coolant; Draining and filling coolant .
– Checking and adjusting oil level ⇒ page 164 .
9.2 Removing and installing gear oil filter

Oil filter change – »yes or no?«
The oil filter does not have to be changed as a matter of course.
Do not change the filter if:
♦ The gear oil cooler or its O-rings have been renewed and no
coolant has got into the oil.
9. Gear oil circuit 161

♦ The oil seal for the selector shaft has been renewed.
♦ The oil seal for the flange shaft was renewed.
♦ Leaking covers in the mechatronic unit, dual clutch or oil pump
have been renewed.
The filter must be changed if:
♦ Coolant has got into the oil.
♦ Metal particles have been found in the oil.
♦ The clutch is burnt out or has a mechanical defect.
Note
Refer to general repair instructions ⇒ page 6 .
Removing
– Remove air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
Note
♦ A residual amount of oil remains in oil filter. It runs out when

filter housing is unscrewed.
♦ Before unscrewing the filter housing, cover the area around
the oil filter with a sufficient number of cloths.
– First loosen filter housing -1- by about 7 turns.

– Wait about 10 seconds. swage
es n
olk ot g
yV
This allows the oil to flow from filter shousing
d b back into gearbox. ua
ran
ir e tee
o
– Now remove filter housing with au filter.
th or
ac
ss
– Renew missing or damaged heat shield -2-.
ce
e
nl
pt
du
an
Installing
itte
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erm
ab

ility
ot p
the following:
wit
, is n
h re
– Thoroughly clean oily areas on gearbox.

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.
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Cop py
t. rig
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pyri by
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co
162
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
– Insert new oil filter with collar -arrow- downwards.

– Screw in filter housing and tighten to 20 Nm.
– Install air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
– Check oil level and top up ⇒ page 164 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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un
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an
d
itte
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rm
ab
pe
ility
ot
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, 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
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cum
fo
en
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t.
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Cop py
ht. rig
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by lksw
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Prote AG.
9. Gear oil circuit 163

10 Gear oil
10.1 Checking gear oil level

If DSG oil must be added, use only oil listed in ⇒ Electronic parts
catalogue “ETKA” .
n AG . Volkswagen AG
Special tools and workshop equipmentksrequired
wage does
not
Vol gu
♦ Vehicle diagnosis, testing and by
edinformation system - VAS ara
ris nte
5051B- tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Used oil collection and extraction unit - V.A.G 1782-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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Cop py
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by
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Prote
♦ Adapter for oil filling - VAS 6262 A-
AG.
Prerequisites
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed
♦ Vehicle diagnosis, testing and information system - VAS
5051B- is connected.
♦ At start of work, oil temperature must not be above 45°C.
♦ Test temperature: 35 - 45°C

Check
– Connect vehicle diagnosis, testing and information system -
VAS 5051B- and identify the vehicle in Guided functions .
– Select Dual clutch gearbox .
– Select Check oil level .
Note
If the oil temperature is above 45°C, allow the gearbox to cool

down.
Engine is running at idling speed with selector lever in “P”.

– Remove oil drain plug -arrow-.
AG. Volkswagen AG d
agen oes
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b ara
– Renew oil seal -arrow- ofrisbolt.
ed
nte
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Note
ce
e
nl
pt
du
an
itte
y li
Even if oil level is too low, a small amount of oil will initially run out
erm
ab
of oil level pipe because pipe fills up during operation.

ility
ot p
wit
, is n
h re
– Let surplus oil flow out.

hole
spec
– When excess oil has run out (when it begins only to drip), in‐
es, in part or in w
t to the co
stall plug with new seal.

– Top up oil if no oil flows out.
rrectness of i
Topping up
l purpos
nf
ercia
orm
m
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Prote AG.
10. Gear oil 165

– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a-, and
shorten it as necessary.
Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
– Screw adapter of adapter for filling oil - VAS 6262 A- hand-

tight into inspection hole.
WARNING
Shake bottles thoroughly before opening to ensure that sedi‐

ment at the bottom of the bottle mixes well with the oil.
– Fill 1.0 litres of oil.

– Pull off adapter for oil filling - VAS 6262- at plug-in connector
and check:
If oil now flows out of hole in adapter:
Oil does not need topping up.
– Allow surplus oil to drain out.
– When excess oil has run out (when it begins only to drip), re‐
move adapter for filling oil - VAS 6262 A- and install plug with
new seal. AG. Volkswagen A gen G do
swa es n
If no oil drips out of inspection
by
Vol hole:
k ot g
ua
d ran
se
– If a further litre has
tho to be added ⇒ page 164 .
ri tee
or
au ac
ss
ce
le
WARNING
un
pt
an
d
itte
y li
An oil level which is too low or too high will impair the function
erm
ab
ility
of the gearbox.
ot p
wit
is n
h re
ole,
spec
Torque setting for drain plug: 45 Nm

t to the co
10.2 Draining and filling gear oil

rrectne
If DSG oil must be added, use only oil listed in ⇒ Electronic parts
catalogue “ETKA” .
s
Please also refer to the notes on the oil filter change regarding
s o
cial p
»dirty oil« ⇒ page 161 .

inform
mer
Brief description
atio
m
First read the oil temperature. If it is above 50°C, allow the gear‐
o
n
c
i
or
box to cool down.

thi
te
sd
va
With engine stopped, unscrew and remove overflow pipe and let
i
o
pr
cum
r
the oil drain out. Then reinstall overflow pipe and »overfill« gear‐
fo
en
ng
box with oil.

t.
yi Co
Cop py
Then start engine and drain excess oil until oil level attains level
ht. rig
rig ht
by
of overflow pipe. copy Vo
by lksw
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Prote
AG.


5051B-
♦ Used oil collection and extraction unitag-eV.A.G

n AG. Vo1782-
lkswagen AG
do w es n
olks ot g
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pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Adapter for oil filling - VAS 6262 A-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
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Prerequisites yri
p by
co Vo
by lksw
cted
♦ Engine switched off
agen
Prote AG.
♦ Vehicle level, all mountings of lifting platform evenly at same

height
♦ Noise insulation removed if previously fitted
♦ Selector lever at “P”
5051B- is connected.
♦ At start of work, oil temperature must not be above 45 °C.
Procedure
– Comply with rules for cleanliness when working on gearbox
⇒ page 5 .
– Only gear oil available as spare part is allowed to be used for
dual clutch gearbox. Other oils will lead to malfunctions or fail‐
ure of the gearbox ⇒ Electronic Parts Catalogue (ETKA) .
10. Gear oil 167

WARNING
Danger of injury from hot gear oil!
– Connect vehicle diagnosis, testing and information system -

VAS 5051B- and identify the vehicle in Guided functions .
AG. Volkswagen AG d
– Select Dual clutch gearbox . agen oes
olksw not
byV gu
ara
d
– Select Check oil level . orise nte
h eo
aut ra
ss c
ce
le
Note
un
pt
an
d
itte
y li
erm
If the oil temperature is higher than 45°C, allow gearbox to cool
ab
ility
down.
ot p
wit
is n
h re
ole,
spec
WARNING
t to the co
Do not start engine if there is no oil in gearbox.
rrectne
– Engine switched off - do not start engine!
ss
– Remove oil drain plug -arrow-.
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.
– Renew oil seal -arrow- of bolt.

– Remove oil level pipe -arrow- and allow oil to run out.
– Remove oil drain plug -arrow- from mechatronic unit.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
Note orise nte
eo
h
aut ra
s c
A further approx. 1.2 litres of oil will run out. 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
– Renew seal -arrow- and reinstall oil drain plug of mechatronic
unit, tightening to 20 Nm.
rrectness of i
l purpos
Note
♦ Normally, there is no need to remove oil filter.
nf
ercia
orm
♦ Oil filter change “Yes or no?” ⇒ page 161
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
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10. Gear oil 169

– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a-, and
shorten it as necessary.
Dimension -a- = 210 mm
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During filling, the adapter for oil filling - VAS 6262 A- and bottle
must always be held higher than the gearbox.
– Fill 5.5 litres of oil.
rrectness of i
– When changing bottles, close tap on adapter.
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– Close tap on adapter when 5.5 litres of oil have been added
to gearbox.
nform
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– Start engine. The adapter for filling oil - VAS 6262 A- may re‐
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– Depress brake pedal and select each selector lever position thi
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– Then check oil level and top up. ⇒ page 164
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35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
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1. Currently, no repairs can be made to gears and shafts 171

39 – Final drive - differential

1 Gear oil
⇒ “1.1 Checking gear oil level”, page 172
⇒ “1.2 Draining and filling gear oil”, page 174
1.1 Checking gear oil level

⇒ “1.1.1 Checking gear oil level, bevel box 0A6 ”, page 172
⇒ “1.1.2 Checking gear oil level, bevel box 0CP ”, page 173
1.1.1 Checking gear oil level, bevel box “0A6”

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– Put used oil collection and extraction unit - VAS 6622A- un‐
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172 Rep. gr.39 - Final drive - differential

– Unscrew oil filler plug -1-.

Renew oil filler plug after each removal.
Oil level is correct when bevel box is filled to lower edge of filler
hole.
Note
♦ Clean bevel box thoroughly to remove any remains of the

emerged oil.
♦ Disregard -item 2-.
– If necessary, top up gear oil ⇒ page 174 .

– Screw in new oil filler plug -1-.
– Tighten bolt to specified torque ⇒ page 189 .
1.1.2 Checking gear oil level,lkbevel

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♦ The bevel box is bolted to side of the gearbox and has its own
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♦ Specifications for gear oil ⇒ Electronic Parts Catalogue “ET‐

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height.
sulation .
– Before starting work, check which bevel box is installed
⇒ page 34 .
– Put used oil collection and extraction unit - VAS 6622A- un‐
derneath.
1. Gear oil 173

agen
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– Unscrew oil fillerriplug
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Renew oil filler splug
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• On current bevel boxes, the oil level is beneath the oil filler
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hole and can therefore not be checked.
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• Should the oil level be up to the lower edge of the oil filler hole,
ility
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extract 100 ml of gear oil ⇒ page 177 .
wit
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es, in part or in w
t to the co
♦ Clean bevel box thoroughly to remove any remains of the
emerged oil.
rrectness of i
♦ Disregard -item 2-.
l purpos
– If necessary, top up gear oil ⇒ page 174 .
nf
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– Screw in new oil filler plug -1-.
orm
m
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– Tighten bolt to specified torque ⇒ page 191 .
om
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1.2 Draining and filling gear oil

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⇒ “1.2.1 Draining and filling gear oil, bevel box 0A6 ”, page 174 m
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⇒ “1.2.2 Draining and filling gear oil, bevel box 0CP ”, page 177 C py
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Note
♦ The gear oil in the bevel box must only be drained in the event
of repairs. The oil is not intended to be changed on a regular
basis.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue


♦ Filling device - VAS 6291 A-
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♦ Adapter for oil filling - VAS 6291/3-
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Requirement
• Vehicle is level.
height.
sulation .
– If fitted, remove right drive shaft heat shield from bevel box
-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft; Removing and installing drive shaft .
– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
1. Gear oil 175

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♦ Wear protective goggles.
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spec
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es, in part or in w
t to the co
– Unscrew oil drain plug -2-, and drain gear oil.
rrectness of i
– Screw in new oil drain plug.
l purpos
Note
nform
mercia
To collect escaping gear oil, leave used oil collection and extrac‐
a
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tion unit - VAS 6622- underneath.
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– Screw adapter for oil filling -VAS 6291/3- in to stop.

– Engage angled piece of filling device for all-wheel drive cou‐
pling 2 - VAS 6291 A- with adapter for oil filling -VAS 6291/3- .
• Do not allow hose to sag.
– Top up with oil.
Note
♦ If bevel box has been properly filled, oil runs out at adapter
-A-.
♦ Continue with filling procedure if no oil has run out yet.
– After bevel box has been properly filled, unscrew adapter -

VAS 6291/2- .
– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oil again to lower edge
of filler hole.
– Screw in new oil filler plug.
Note
Clean bevel box thoroughly to remove any remains of the

emerged oil. AG. Volkswagen AG d
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– If present, install heat shield above right drive shaftho⇒ Running
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nform
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1. Gear oil 177

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♦ Filling device - VASori6291
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♦ Adapter for oil filling - VAS 6291/3- rrectness of i
l purpos
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mercia
at
om
ion
c
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♦ For some oil bottles adapter - VAS 6262/6- must be used as
well.

Requirement
• Vehicle is level.
height.


sulation .
– If fitted, remove right drive shaft heat shield from bevel box
shaft; Removing and installing drive shaft .
– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
WARNING
Risk of injury from hot gear oil.

♦ Wear protective goggles.
♦ Wear acid-resistant gloves
– Unscrew oil drain plug -2-, and drain gear oil.

– Screw in new oil drain plug.
Note
To collect escaping gear oil, leave used oil collection and extrac‐
tion unit - VAS 6622- underneath.
wage
– Unscrew oil filler o plug -1-.
lks es n
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1. Gear oil 179

– Screw adapter for oil filling -VAS 6291/3- in to stop.

– Engage angled piece of filling device for all-wheel drive cou‐
pling 2 - VAS 6291 A- with adapter for oil filling -VAS 6291/3- .
• Do not allow hose to sag.
– Top up with oil.
AG. Volkswagen AG d
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♦ If bevel box has been properly filled, oil will emerge from
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♦ Continue with filling procedure if no oil has run out yet.
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– If gear oil has emerged from adapter for oil filling - VAS
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hole
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es, in part or in w
wheel drive coupling 2 - VAS 6291 A- .
t to the co
– Remove adapter - VAS 6291/3- .
rrectness of i
Caution
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The correct oil level is beneath the oil filler hole and cannot be
nf
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checked.
orm
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If an elevated level is not rectified after filling, oil could escape
atio
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through the breather while the vehicle is being driven.

o
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The correct oil level can only be achieved by extracting 100 ml

t
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of gear oil after filling.
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– Extract 100 ml of gear oil from the bevel box using a commer‐
C py
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– Screw in new oil filler plug.
agen
Prote AG.
Note
Clean bevel box thoroughly to remove any remains of the

emerged oil.
– If present, install heat shield above right drive shaft ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
tion .

2 Oil seals
⇒ “2.1 Overview of fitting locations - seals”, page 181
⇒ “2.2 Renewing left seal”, page 181
⇒ “2.3 Renewing right oil seal”, page 184
⇒ “3.2 Renewing bevel box seals”, page 193
2.1 Overview of fitting locations - seals
1 - Stub shaft O-ring

❑ Renew
2 - Seal right, bevel box
⇒ page 196
3 - Stub shaft
4 - Right oil seal, stub shaft
❑ Item can be disregarded agen
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5 - Output shaft seal ed by ara
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❑ Removing and installing ut
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⇒ page 193 ss a c
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6 - Deflector ring
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7 - Left oil seal, stub shaft
wit
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hole
⇒ page 193
spec
es, in part or in w
8 - Seal left, bevel box
t to the co
⇒ page 193
rrectness of i
9 - Sealing ring, right
l purpos
❑ Removing and instal‐

ling, front-wheel drive
⇒ page 184
nf
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or
❑ Removing and instal‐ m
m
atio
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om
⇒ page 186
n in
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10 - Left seal
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⇒ page 181
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2.2 Renewing left seal
Prote AG.
2.2.1 Renewing oil seal for left flange shaft

2. Oil seals 181

♦ Puller - T10055-
♦ Thrust piece - T10457-
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♦ Electric drill, commercially available

inform
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Removing
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– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.

c
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or
gr. 40 ; Drive shafts; Removing and installing drive shafts .

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ing located behind it might be damaged.
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ss c
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– Grease drill bit -3- so that metal chips adhere to it.
nl
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– Seal drive shaft aperture on transmission with a clean cloth
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-2-.
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, is n
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outer sheet metal ring -1- of oil seal.
hole
spec
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t to the co
rrectness of i
l purpos
– Screw a self-tapping screw, approx. 4 mm in diameter, into
nf
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hole drilled in oil seal. Do not screw in sheet metal screw too
orm
far to avoid damaging bearing behind it.
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– Place drip tray for workshop hoist - VAS 6208- below gearbox.
or c
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– Pull out oil seal using puller - T10055- and adapter -
iva
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T10055/2- .
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Make sure no metal chips get into gearbox and into opening for
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drive shaft. Vacuum out metal chips first if necessary. C py
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– Carefully remove cloths and make sure that no metal chips get cop Vo
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into gearbox. cted agen
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– Carefully clean gearbox and opening for drive shaft.

If only the sheet metal ring could be pulled out, carefully lever out
rest of seal with a screwdriver.
Installing
the following:
Before installing the seal, apply sealing grease for oil seal - G 052
128 A1- to sealing lips and cavity, and apply oil to outer circum‐
ference.
Installation position:
Open side of oil seal faces gearbox.
– Drive oil seal in to stop with thrust piece - T10457- . Do not

cant oil seal in the process.
2. Oil seals 183

– Grease splines -arrow- of stub shaft with universal grease -

G 060 735 A2- .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
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⇒ “2.3.2 Renewing seal on right of gearbox, vehicles with all wheel
pt
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⇒ “3.2.2 Renewing seal on right of bevel box”, page 196
ility
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2.3.1 Renewing seal on right of gearbox,
h re
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spec
front-wheel drive vehicles
t to the co
♦ Puller - T10055-
rrectness o
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♦ Thrust piece - T50043- copy Vo
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♦ Drip tray for workshop hoist - VAS 6208-
♦ Electric drill, commercially available

Removing
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– Grease drill bit -3- so that smetal
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gearbox may otherwise
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– Seal drive shaft
ss
aperture on transmission with a clean cloth
ce
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-2-.
un
pt
an
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– Carefully drill a hole with a drill bit -3- (diameter 2 to 4 mm) into
erm
outer sheet metal ring -1- of oil seal. ab

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2. Oil seals 185

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– Screw a self-tapping screw, approx. 4 mm in diameter, into Vol ot g
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hole drilled in oil seal. Do not screw in sheet metal screw
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ed too ran
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– Place drip tray for workshop hoist - VAS 6208- below
s
gearbox.
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– Pull out oil seal using puller - T10055- and adapter -
an
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T10055/2- .
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Note
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es, in part or in w
Make sure no metal chips get into gearbox and into opening for
t to the co
drive shaft. Vacuum out metal chips if necessary.
– Carefully remove cloths. When doing this, make sure that no
rrectness of i
metal chips get into gearbox.
l purpos
– Carefully clean gearbox and opening for drive shaft.

If only the sheet metal ring could be pulled out, carefully lever out
nform
ercia
rest of seal with a screwdriver.

m
at
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Installing
ion
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Install in reverse order of removal. In the process, observe the
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ate
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do
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– Apply ATF to circumference and sealing lips of oil seal.

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Installation position: C py
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Open side of oil seal faces gearbox. cop Vo
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– Press oil seal in straight as far as possible by hand.
AG.

– Then check oil level and top up ⇒ page 164 .
– Grease splines -arrow- of stub shaft with universal grease -

G 060 735 A2- .
2.3.2 Renewing seal on right of gearbox, ve‐

hicles with all wheel drive

♦ Extractor hooks -T20143-
Removing
– Remove bevel box ⇒ page 35 .
– Lever out seal on gearbox using puller hook - T20143/1- or -
T20143/2- .
Installing AG. Volkswagen AG d
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Install in reverse order of removal.
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2. Oil seals 187

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3 Components of bevel box

⇒ “3.1 Assembly overview - components of bevel box”,
page 189
⇒ “3.2 Renewing bevel box seals”, page 193
⇒ “3.3 Renewing needle bearing (polygon bearing) for stub shaft”,
page 210
3.1 Assembly overview - components of

bevel box
⇒ “3.1.1 Assembly overview - components of bevel box, 0A6”,
page 189
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(Seals, stub shaft bearing, output flange in bevel box)

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❑ Between bevel box and
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bevel box
❑ To renew, remove bevel
box ⇒ page 35
rrectness of i
2 - Seal
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bevel box
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❑ Drive in to stop with
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spacer tube - VW 540

1B- .
5 - Seal
❑ For right stub shaft to
drive shaft
❑ Seal can be renewed
with bevel box installed
❑ Renewing ⇒ page 196
6 - Bevel box
⇒ page 35
7 - Cap
❑ To vent bevel box
3. Components of bevel box 189

8 - Breather pipe
❑ Press in until stop is reached
9 - Retaining ring wage
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❑ Insert in circumferential
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❑ Insert in circumferential groove in stub shaft
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11 - Right stub shaft
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❑ To remove and install, remove bevel box ⇒ page 35
h re
hole
spec
es, in part or in w
t to the co
12 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with stub shaft removed. The fact it is difficult to move
does not mean that the bearing is defective. An acoustic test can only be performed with the bearings
rrectness of i
installed.
l purpos
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
nform
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13 - Retaining ring
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❑ For needle roller bearing (polygon bearing)

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14 - Hexagon nut
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❑ Removing ⇒ page 203
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❑ Install using locking fluid - D 000 600-
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❑ Installing ⇒ page 204
AG.
❑ 480 Nm
15 - Output flange
16 - Cover
❑ Not fitted in all bevel boxes
❑ Renew after removing output flange if damaged
❑ Engage with output flange
17 - Seal
❑ For output flange
❑ To renew, remove bevel box ⇒ page 35
18 - Bolt
❑ Tighten diagonally and alternately
❑ 25 Nm
19 - Pinion housing
❑ With shaft bevel gear and inner race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
20 - O-ring
❑ Renew after removing pinion housing

❑ To renew, unscrew bolts ⇒ Item 18 (page 190) and carefully lever off pinion housing at projecting webs
on outside edge
❑ Do not remove hexagon nut ⇒ Item 14 (page 190) and output flange ⇒ Item 15 (page 190)
3.1.2 Assembly overview - components of bevel box, 0CP

(Seals, stub shaft bearing, output flange in bevel box)
1 - Seal
bevel box
box ⇒ page 35
2 - Seal
gearbox
box ⇒ page 35
3 - Plug
❑ With captive seal
❑ 15 Nm
4 - Seal
drive shaft agen
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❑ Renewing ⇒ pages a196
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5 - Bevel box
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⇒ page 35
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6 - Breather pipe
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hole
spec
❑ Press in until stop is

es, in part or in w
reached
t to the co
7 - Cap
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8 - Retaining ring
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9 - O-ring
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10 - Right stub shaft

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11 - Needle bearing (polygon bearing)
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does not mean that the bearing is defective. An acoustic test can only be performed with the bearings
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installed.

❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
12 - Retaining ring
❑ For needle roller bearing (polygon bearing)
13 - Retaining ring
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❑ Insert in circumferential
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14 - Retaining ringau ac
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15 - Washer
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16 - Output flange
t to the co
17 - Seal
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❑ Renew after removing output flange

❑ Renewing ⇒ page 205 nf
ercia
18 - O-ring
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❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
21 - O-ring
❑ Renew after removing pinion housing
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
❑ Do not remove output flange

3.2 Renewing bevel box seals

⇒ “3.2.1 Renewing left seal between bevel box and gearbox on
bevel box”, page 193
⇒ “3.2.2 Renewing seal on right of bevel box”, page 196
⇒ “3.2.3 Renewing bevel box output flange seal, 0A6, bevel box
removed”, page 200
⇒ “3.2.4 Renewing bevel box output flange seal, 0CP, bevel box
removed”, page 205
3.2.1 Renewing left seal between bevel box

and gearbox on bevel box
♦ Multi-purpose tool - VW 771/37-
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♦ Removal tool - T20143-

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♦ Thrust piece -T10380-
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♦ Thrust piece - T10379- mercia
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Prote AG.
Note
Seals (Qty. 2) can be renewed only with bevel box removed. Al‐
ways renew both seals.
Removing
Remove »outer« seal.
– Lever out seal using puller hook - T20143/2- .
Remove »inner« seal.
Note
So that new seal will not be damaged later on:

– Remove retaining ring -1- from stub shaft.

– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
tion of arrow.
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– Pull out seal for stub shaft on
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– Half-fill space between sealing lip and dust lip of new seal
-arrow- with sealing grease - G 052 128 A1- .
rrectne
ss o
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mer
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Drive in »inner« seal.
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– Half-fill space between sealing lip and dust lip of new seal
-arrow- with sealing grease - G 052 128 A1- .

– Carefully use plastic mallet to drive in stub shaft to stop.
AG. Volkswagen AG d
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– Fit new retaining ring -1- on stub shaft.

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3.2.2 Renewing seal on right of bevel box

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♦ Removal tool - T20143-

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♦ Hub grease cap puller - VW 637/2- es, in part or in w
t to the co
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♦ Drip tray - V.A.G 1306-

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♦ or drip tray for workshop hoist - VAS 6208-

♦ Sealing grease
♦ Grease for splines
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
Note
Seal can be renewed with bevel box installed.
Removing
– Raise vehicle.
– Remove noise insulation beneath engine/gearbox ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assem‐
bly overview - noise insulation .

AG. Volkswagen AG d
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– If fitted, remove drive shaft heat shield -1- from bevel box
itte
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ab
ility
shaft .
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The right drive shaft heat shield is secured with 2 or 3 nuts ⇒
h re
ole,
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft .
spec
– Remove right drive shaft. ⇒ Running gear, axles, steering;
t to the co
– Place drip tray or used oil collection and extraction unit - V.A.G
rrectne
1782- underneath.
ss o
cial p
f inform
mer
– Remove retaining ring -arrow A- and O-ring -arrow B- from
atio
stub shaft.
om
n
c
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pr
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Cop py
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rig ht
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Prote AG.
Note
Some bevel boxes have protective cap -arrow- installed on right.

Renew protective cap each time after removing.
Pull off protective cap.
– Position hub grease cap puller - VW 637/2- in recess -arrow-

and lever off protective cap.

– Lever out seal.
Installing
– Half-fill space between sealing lip and dust lip -arrow- with
sealing grease .

– Fit new retaining ring and new seal on stub shaft.
Bevel box with protectivewcap
agen
AG. Volkswagen AG d
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– Drive on new protective cap to stop.

spec
es, in part or in w

t to the co
– Then install retaining ring -arrow A- and O-ring -arrow B-.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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co lksw
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Prote AG.

– Grease splines of stub shaft using grease for clutch plate

splines .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shafts .
– Install heat shield -1- for drive shaft ⇒ Running gear, axles,
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion . wage es n
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3.2.3 Renewing bevel box output flange seal,
hole
spec
0A6, bevel box removed
es, in part or in w
t to the co
The output flange is secured with a nut -A-.
Disregard -B- and -arrows-.
rrectness of i
l purpos
nform
mercia
at
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ion
c
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for
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Cop py
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Prote AG.


equipment required
AG. Volkswagen AG d
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♦ Support clamp - VW 313-

nf
ercia
♦ Tube - VW 516-
rm
m
atio
m
♦ Thrust plate - 40-105-

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or c
thi

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sd
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♦ Gearbox support - T10108-

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♦ Support plate - T10108/1-

t.
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Prote AG.

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t to the co

♦ Two-arm puller - VAS 251 001- or e.g. two-arm puller - Kukko
rrectness of i
20/10-
l purpos
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -

Kukko 45-2-
nform
ercia

m
at
om
♦ Extractor hook - VW 771/37-

ion
c
in t
or
♦ Sealing grease
his
ate
do
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♦ Universal grease
p
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for
en
ng

t.
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Cop py
t. rig
♦ Two M10×30 bolts opyri
gh by
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ht
c
♦ Four M12×10 nuts
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Prote AG.
Note
The bevel box oil seal for the output flange can only be renewed
with the bevel box removed.

– Fit bevel box on gearbox support - T10108- onto hole

-arrow- marked with the number -5-.
A - Place four M12 x 10 nuts between bevel box and gearbox
support . Nuts function as spacers.
– Then align bevel box with hole opposite and secure.
– Place drip tray underneath.
– Drain oil from bevel box.
– Lock output flange for bevel box with stop plate - T10108/1- .
Screw in M10 x 30 bolts -arrows- to do this.
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Removing hexagon nut for output flange
erm
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ility
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A - 36 mm socket for 3/4" drive
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Swing bevel box so that output flange points upwards.

m
at
om
ion
c
– Pull output flange off shaft bevel gear of bevel box.

in t
or
his
ate
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -

do
riv
Kukko 45-2-
p
cum
for
en
ng
t.
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t. rig
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Prote AG.
– Pull out seal -A- for output flange.

– Clean residual locking fluid from thread of shaft bevel gear.
– Clean any oil seal residue away from area on shaft bevel gear.

Installing
– Drive in new oil seal to stop using thrust piece - T10049- .
– Half-fill space between sealing lip and dust lip with sealing
grease .
– Lightly lubricate splines of output shaft with universal grease .
– Pull in output flange using two arm puller -A-.

A - Two-arm puller - VAS 251 001- or e.g. two-arm puller - Kukko
20/10-
Please note the following:
• Use new or nearly new puller hooks!
• The output flange must not be canted.
• Fit puller hooks as far as they will go onto underside of pinion
housing.
• Take up slack on puller hooks fully with two arm puller
-arrows-.
• Puller hooks should not bend outwards.
• Interrupt pulling-on immediately when effort increases notice‐
able. olks
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♦ The puller must only open the flange so far that the nut can be
un
pt
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attached safely.
itte
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♦ The final position of the flange is attained by tightening the nut,

ility
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not by the puller.

wit
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ole,
spec
Coat thread of new hexagon nut with locking fluid D 000 600
t to the co
– Tightening new hexagon nut for output flange to specified tor‐

que.
rrectne
Specified torque ⇒ Item 14 (page 190)

A - 36 mm socket for 3/4" drive
ss o
cial p
f inform
mer
atio
om
n
c
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Prote AG.

Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.07 mm.
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– Install bevel box ⇒ page 35 . byV
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– Check gear oil level in bevel box ⇒ page 172 . tho tee
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The output flange is secured with a retaining ring -A-.
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Located behind retaining ring -A- is a washer -B-.
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♦ Support clamp - VW 313-

♦ Gearbox support - T10108-
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
♦ Extractor hook - T20143-
♦ Locking tool - T40265-
♦ Drift sleeve - 40-21-

♦ Drip tray - V.A.G 1306-

♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealing grease
♦ Universal grease
♦ 2 x bolts M10 x 30
♦ 4 nuts M12 x 10
Note
The bevel box oil seal for the output flange can only be renewed
with the bevel box removed.

– Fit bevel box on gearbox
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A - Place four
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– Place drip tray underneath.

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– Drain oil from bevel box.

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– Remove retaining ring -A- and washer -B-.

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– Swing bevel box so that output flange points upwards.

– Pull output flange off shaft bevel gear of bevel box.
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
– Lever out seal -A- for output flange.

• Take care not to damage the seat for the oil seal in the hous‐
ing.
– Clean any oil seal residue away from area on shaft bevel gear.
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Installing
– Place new O-ring -3- on bevel gear shaft -2- in pinion housing
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• O-ring must be located behind splines and in base of sur‐

rounding groove -arrow-.
– Drive new seal in onto limit stop.

– Half-fill space between sealing lip and dust lip with sealing
grease .
– Lightly lubricate splines of output shaft -A- with universal

grease .
– Carefully drive output flange -A- onto shaft as far as stop using
a plastic hammer.
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Measure radial run-out on output flange/shaft bevel gear.
Note
After securing the output flange, the radial run-out on the centring
pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.07 mm.
– Check gear oil level in bevel box ⇒ page 172 .
Specified torques
♦ ⇒ “3.1.2 Assembly overview - components of bevel box, 0CP”,
page 191
3.3 Renewing needle bearing (polygon bearing) for stub shaft
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♦ Pressure plate - VW 401-

♦ Pressure plate - VW 402-
♦ Press tool - VW 407-
♦ Press tool - VW 412-
♦ Assembly tool - 3253/5-
♦ Tensioning device - T10047-

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♦ Splitter - VAS 251 409- , or splitter 22 …75 mm , e.g. -Kukko

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♦ 2 bolts M10 x 90
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♦ 2 x hexagon socket head bolts M12 x 80 with M12 nuts

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– Remove retaining ring -1- from stub shaft.

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tion of arrow.
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– To avoid damage to running surface of bearing on shaft, turn

ion in
shaft during pressing procedure -arrow-.

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– Install heat shield. Specified torque ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Drive shaft; Removing and installing
m
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drive shaft .
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D4B804A300A-7-Speed Dual Clutch Gearbox 0DL

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Service

Passat 2019 ➤ , Passat Variant 2015 ➤ ,

Tiguan RUS 2017 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B804A300A

1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

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

3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

9 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

9.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

2.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

2.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

2.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1.1 General safety provisions

Risk of injury and accident by accidental engagement of gear

♦ Before working on vehicle with engine running, move se‐

lector lever into position “P” and apply handbrake.

Risk of irreparable damage to electronic components when

♦ Disconnect battery only after the ignition has been switch‐

Injury hazard as a result of automatic engine start in vehicles

♦ When working on the vehicle, always make sure that the

start-stop system is deactivated (switch off the ignition;

switch the ignition on again if necessary).

1.3 Notes on tow-starting/towing

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

1.4 Safety precautions when using testers

Risk of accident due to distraction and inadequate securing of

2 Rep. gr.00 - Technical data

2.1 Gearbox identification

The gearbox code is also indicated on the vehicle data stickers.

4 Rep. gr.00 - Technical data

joined together by a toothed connection. Together they take

automatically or manually via the Tiptronic system. There is no

sition is not transferred by mechanical means via the selector

3.2 Rules for cleanliness

♦ If repair work cannot be performed immediately, cover opened

3.3 General repair instructions

which can otherwise be found in the relevant sections of the man‐

Guided Fault Finding, vehicle self-diagnosis and test instruments

tester, Guided Fault Finding , Vehicle Self-Diagnosis

see ⇒ "Workshop equipment and special tools" .

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

do not run engine or tow vehicle.

♦ First thoroughly clean connecting points and surrounding

6 Rep. gr.00 - Technical data

Oil drain and inspection plug

face of housing or shaft for burrs resulting from removal or for

♦ Before installing seals, lightly oil outer diameter and half-fill

gearbox and top up if necessary ⇒ page 164 .

3.5 Nuts and bolts

4.1 Allocation gearbox - engine

4.1.1 Passat 2015 ►, Passat Estate 2015 ► olkswagen AG