7-Speed Dual Clutch Gearbox 0B5 (S Tronic)

Service
7-speed dual clutch gearbox 0B5 (S tronic)

Edition 02.2014
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 - front differential
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.
A005A403820
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤
7-speed dual clutch gearbox 0B5 (S tronic) - Edition 02.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 3
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2.4 Notes on tow-starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Safety functions of gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Allocation of gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Exploded view - flywheel and dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Exploded view - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3 Removing and installing ATF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.1 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2 Exploded view - selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Exploded view - selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.5 Manual release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.8 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.9 Removing and installing selector lever position display Y26 . . . . . . . . . . . . . . . . . . . . . . . . 51
2.10 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.11 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.12 Adjusting selector lever cable to basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.13 Renewing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.3 Tightening torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.2 Removing and installing tunnel cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Contents i
4.3 Removing and installing gearbox support with gearbox mounting . . . . . . . . . . . . . . . . . . . . 142
4.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.1 Exploded view - drain, filler and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.2 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.3 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8 ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8.1 Exploded view - ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8.2 Cleaning ATF lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.3 Removing and installing ATF lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
8.4 Removing and installing ATF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.5 Removing and installing ATF filter housing and connecting piece for ATF lines . . . . . . . . 186
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.1 Renewing ball bearing for input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.2 Renewing input shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.1 Exploded view - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.1 Exploded view - gear oil drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.2 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.3 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.4 Removing and installing gearbox oil temperature sender 2 G754 . . . . . . . . . . . . . . . . . . 204
3 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.1 Renewing oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.2 Renewing oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.1 Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.2 Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5 Centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.1 Exploded view - centre differential housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.2 Removing and installing centre differential housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.3 Removing and installing rear flange shaft, oil seal and ball bearing for rear flange shaft . . 225
5.4 Removing and installing rear splined shaft, oil seal and ball bearing . . . . . . . . . . . . . . . . . . 225
5.5 Renewing oil seal for rear splined shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5.6 Pressing vibration damper onto rear splined shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5.7 Removing and installing centre differential housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
6 Gearbox control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6.1 Overview of fitting locations - gearbox control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6.2 Guided Functions for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
ii Contents
00 – Technical data
1 Identification
(ARL003736; Edition 02.2014)
⇒ “1.1 Gearbox identification”, page 1
1.1 Gearbox identification

The “7-speed dual clutch gearbox 0B5, four-wheel drive” is in‐
stalled in the Audi A4 2008 ►, Audi A5 Cabriolet 2009 ► and Audi
A5 Coupé 2008 ►. Allocation
⇒ “4.1 Allocation of gearbox to engine”, page 8 .
The following details are given on the gearbox housing -arrows-:
LHF = Gearbox code letters
D04 = Manufacturing line code
0026 = Serial number
K100808 = Factory code:
• K = Kassel
Production date:
• 100808 = 10.08.2008
Note
The gearbox code letters can also be found on the vehicle data
sticker.
1. Identification 1
2 Safety precautions
⇒ “2.1 Safety precautions when working on vehicle”, page 2
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 3
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “2.4 Notes on tow-starting and towing”, page 3
2.1 Safety precautions when working on ve‐

hicle
Observe the following precautions to avoid possible injury and/or
damage to the vehicle:
WARNING
Accidents and injury can be caused if a gear is inadvertently

engaged while the engine is running.
♦ Prior to performing work with the engine running, move the
selector lever to position “P” and pull up the parking brake
button to apply the electromechanical parking brake.
Observe the following precautions to avoid possible injury and/or

irreparable damage to electrical and electronic components:
♦ Switch off ignition before disconnecting and connecting test
equipment.
Caution
When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
2 Rep. gr.00 - Technical data

2.2 Safety precautions when working on ve‐

hicles with start/stop system
Please note the following when working on vehicles with start/stop
system:
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
2.3 Safety precautions when using testers

and measuring instruments during a
road test
Observe the following precautions if test equipment has to be
used when road-testing the vehicle.
WARNING
Accidents can be caused if the driver is distracted by test

equipment or if test equipment is not secured.
Injuries can be caused if the passenger's airbag is triggered in
a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Always secure test equipment to the rear seat with a strap
and have it operated from there by a second person.
2.4 Notes on tow-starting and towing
Caution
Risk of irreparable damage to gearbox.

♦ When the vehicle is towed, the selector lever must be set
to position “N” and the vehicle must not be towed for a
distance of more than 50 km or at a speed in excess of
50 km/h.
Note
It is not possible to start the engine by tow-starting, for instance

if the battery charge is low or if the starter is not working.
2. Safety precautions 3
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 4
⇒ “3.2 General notes”, page 4
⇒ “3.3 General repair instructions”, page 5
⇒ “3.4 Contact corrosion”, page 7
⇒ “3.5 Safety functions of gearbox control unit”, page 7
3.1 Rules for cleanliness

♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ Use cleaning fluid - D 009 401 04- to clean the gearbox and
its components.
♦ Use lint-free cloths for cleaning, such as the “WYPALL X70 /
WORKHORSE” cloth from Kimberly-Clark Professional.
♦ Seal off open lines and connections immediately with clean
plugs or protective caps from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use sheeting or lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components: do not remove replacement
parts from packaging until just before installation.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
3.2 General notes

Gearbox
The engine torque is transferred to the gearbox via the flywheel.
The layout of the gearbox is basically similar to that of a 7-speed
manual gearbox. The two multi-plate "wet" clutches are regulated
hydraulically and actuated alternately so that the gearbox is op‐
erated like an automatic gearbox, i.e. the gears are engaged
automatically (or manually via the tiptronic function). There is no
clutch pedal. For further information please refer to ⇒ Self-study
programme No. 429 ; Audi Q5 - Engines and Transmissions .
Technical data
Manufactur‐ DL501-7Q
er's designa‐
tion
Service des‐ 0B5
ignation
Sales desig‐ S tronic
nation
Weight Approx. 142 kg (with flywheel, ATF and oil filling)
ATF and gear oil (MTF)
The dual clutch gearbox 0B5 uses separate oil chambers for ATF
and gear oil (MTF).
ATF = automatic transmission fluid
The gear oil in the dual clutch gearbox 0B5 is also referred to as
MTF (manual transmission fluid).

♦ For the dual clutch and the hydraulic sections, use only the
ATF available as a replacement part for dual clutch gearbox
0B5 ⇒ Electronic parts catalogue .
♦ For the gear clusters, the front final drive and the transfer box,
use only the gear oil (MTF) available as a replacement part for
dual clutch gearbox 0B5 ⇒ Electronic parts catalogue .
♦ Other types of ATF or gear oil cause malfunctions and/or fail‐
ure of the gearbox.
Variation of gear-change points for gradients
An additional gear change map automatically selects gear
changes for gradients depending on accelerator pedal position
and driving speed.
• Gear change map for extreme uphill gradients is matched to
engine output.
• Gear change map for extreme downhill gradients is matched
to the braking effect of the engine.
• Increased engine braking effect can also be obtained by di‐
rectly selecting a specific gear via the tiptronic function, e.g.
when towing a trailer on downhill gradients
3.3 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. The
usual basic safety precautions also naturally apply when carrying
out repair work.
To avoid repetition, a number of generally applicable instructions
for the various repair procedures are summarised here. They ap‐
ply to the work described in this Manual.
Guided Fault Finding, Vehicle self-diagnosis and Test Instru‐
ments
♦ Before servicing the gearbox, the cause of the fault should be
identified as exactly as possible using the vehicle diagnostic
tester via Guided Fault Finding , Vehicle Self-diagno-
sis and Test Instruments .
Environmental and waste disposal regulations for oil

♦ ATF, gear oil (MTF) and any other type of oil must be handled
with care.
♦ Dispose of drained oil properly.
♦ ATF or gear oil (MTF) that has been drained off must not be
used for refilling the gearbox.
♦ Always adhere to statutory environmental and waste disposal
regulations.
♦ Observe the information shown on the packaging of the oil.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ Workshop equipment and special tools
Gearbox
♦ Rules for cleanliness when working on the dual clutch gearbox
⇒ page 4 .
♦ Do not run the engine or tow the vehicle with the ATF oil pan
removed or when there is no gear oil (MTF) in the gearbox.
♦ When renewing gearbox, refer to
⇒ “7.2 Checking ATF level”, page 146 and
3. Repair instructions 5
⇒ “2.2 Checking gear oil level”, page 193 . Capacities

⇒ page 11 , specifications ⇒ Electronic parts catalogue .
♦ When installing gearbox, ensure that dowel sleeves are fitted
correctly.
O-rings, oil seals and gaskets
♦ Rules for cleanliness when working on the dual clutch gearbox
⇒ page 4 .
♦ Always renew O-rings, oil seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Before installing, lightly lubricate outer circumference and
sealing lips of oil seals with ATF or gear oil (MTF), depending
on fitting location.
♦ Lightly lubricate O-rings with ATF before installation to prevent
them from being crushed during assembly.
♦ Use only ATF for parts running in ATF. Other lubricants will
cause malfunction of the gearbox hydraulics.
♦ The open side of the oil seal should face the side containing
the fluid.
♦ After installation refer to
⇒ “7.2 Checking ATF level”, page 146 and
⇒ “2.2 Checking gear oil level”, page 193 . Specifications ⇒
Electronic parts catalogue .
Nuts, bolts
♦ Slacken bolts in reverse sequence to the specified tightening
sequence.
♦ Bolts and nuts used to secure covers and housings must be
tightened in steps according to the specified tightening se‐
quence and method.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Always renew self-locking bolts and nuts.
♦ Use a wire brush to clean the threads of bolts which are se‐
cured with locking fluid. Then install bolts with locking fluid; for
locking fluid refer to ⇒ Electronic parts catalogue .
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
Locking elements
♦ Do not over-stretch circlips.
♦ Renew circlips which have been damaged or over-tensioned.
♦ Circlips must be properly seated in the base of the groove.
Bearings
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.

♦ Lubricate bearings with gear oil (MTF) or ATF, depending on

fitting location.
♦ Do not interchange inner or outer races of bearings of the
same size.
♦ Always renew the tapered roller bearings on one shaft togeth‐
er and use new bearings from a single manufacturer.
Shims
♦ Use a micrometer to measure the shims at several points. Dif‐
ferent shim thicknesses make it possible to obtain the exact
shim thickness required; if necessary, fit 2 shims.
♦ Check for burrs and damage. Install only shims which are in
perfect condition.
Mechatronic unit
Caution
The gearbox control unit (mechatronic unit) can be damaged

by electrostatic discharge.
♦ Before handling the electrical connector or mechatronic
unit, the mechanic must discharge static by briefly touch‐
ing an earthed metal object, such as vehicle earth, lifting
platform or heater radiator, etc.
♦ Do not touch contact pins in gearbox connector with bare
hands.
3.4 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used on
the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con‐
ductive materials.
If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ We recommend only genuine spare parts: these have been
fully tested.
♦ We recommend the use of accessories approved by Audi.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
3.5 Safety functions of gearbox control unit

In the event of a failure of one or more components/sensors, the
gearbox control unit will activate appropriate backup functions.
This ensures that the gearbox will not be damaged, however, the
function and quality of the gear shifts will be impaired.
3. Repair instructions 7
4 Technical data
⇒ “4.1 Allocation of gearbox to engine”, page 8
⇒ “4.2 Capacities”, page 11
4.1 Allocation of gearbox to engine
Note
♦ Period of gearbox manufacture ⇒ Electronic parts catalogue

♦ Allocation of dual-clutch gearbox 0B5 to rear final drive ⇒
Electronic parts catalogue
Dual clutch gearbox 0B5 four-wheel drive

Gearbox Code letters LHJ, LJB, LWK, MNJ, LHK, LJD, MNL, LHL, LZL, MNG,
NVZ MSE, NGY MSA, NGU
Allocation Model A4 2008 ► A4 2008 ► A4 2008 ►
A5 Coupé 2008 ► A5 Coupé 2008 ► A5 Coupé 2008 ►
A5 Cabriolet 2009 ► A5 Cabriolet 2009 ► A5 Cabriolet 2009 ►
Engine 3.0 ltr. TDI 3.0 ltr. TFSI 2.0 ltr. TFSI
176 kW 245 kW 155 kW
Ratios 1st gear 48 : 13 = 3.692 48 : 13 = 3.692 48 : 13 = 3.692
2nd gear 47 : 22 = 2.136 47 : 21 = 2.238 47 : 21 = 2.238
3rd gear 52 : 37 = 1.405 53 : 34 = 1.559 53 : 34 = 1.559
4th gear 43 : 44 = 0.977 47 : 40 = 1.175 47 : 40 = 1.175
5th gear 38 : 51 = 0.745 43 : 47 = 0.915 43 : 47 = 0.915
6th gear 27 : 47 = 0.574 38 : 51 = 0.745 38 : 51 = 0.745
7th gear 24 : 52 = 0.462 37 : 60 = 0.617 37 : 60 = 0.617
Reverse 53 : 18 = 2.944 53 : 18 = 2.944 53 : 18 = 2.944
gear
Front axle Spur gear 31 : 29 = 1.069 31 : 29 = 1.069 35 : 31 = 1.129
drive
Bevel gear 29 : 8 = 3.625 29 : 8 = 3.625 29 : 8 = 3.625
drive
Ratio “i” 3.875 3.875 4.093
Rear axle Bevel gear 35 : 9 = 3.889 37 : 9 = 4.111 37 : 9 = 4.111
drive
Overall ratio “iov” in top gear 1.790 2.390 2.524
Ratio spread 8.0 6.0 6.0

Gearbox Code letters LJC, LWL, MNK LJP, LZK, MNF, MRZ, LJQ, LZM, MNH, MSB,
NGT NGV
Allocation Model A4 allroad 2008 ► A5 Coupé 2008 ► A4 allroad 2008 ►
A5 Cabriolet 2009 ►
Engine 3.0 ltr. TDI 3.2 ltr. FSI 2.0 ltr. TFSI
176 kW, 180 kW 195 kW 155 kW
Ratios 1st gear 48 : 13 = 3.692 48 : 13 = 3.692 48 : 13 = 3.692
2nd gear 47 : 22 = 2.136 47 : 21 = 2.238 47 : 21 = 2.238
3rd gear 52 : 37 = 1.405 53 : 34 = 1.559 53 : 34 = 1.559
4th gear 43 : 44 = 0.977 47 : 40 = 1.175 47 : 40 = 1.175


5th gear 38 : 51 = 0.745 43 : 47 = 0.915 43 : 47 = 0.915
6th gear 27 : 47 = 0.574 38 : 51 = 0.745 38 : 51 = 0.745
7th gear 24 : 52 = 0.462 37 : 60 = 0.617 37 : 60 = 0.617
Reverse 53 : 18 = 2.944 53 : 18 = 2.944 53 : 18 = 2.944
gear
drive
Bevel gear 29 : 8 = 3.625 29 : 8 = 3.625 31 : 8 = 3.875
drive
Ratio “i” 4.093 4.093 4.375
drive

Gearbox Code letters MNE, MCQ, NGZ, MSC, NGW, NHN, MSD, NGX, NHP,
NNB, NSD,PXL NRY, NYP, PWU NRZ, NYQ, PXM
Allocation Model RS 5 2011 ► RS 4 A4 2008 ► A4 allroad 2008 ►
2013 ► A5 Coupé 2008 ►
Engine 4.2 ltr. FSI 3.0 ltr. TDI 3.0 ltr. TDI
331 kW 176 kW, 180 kW 176 kW, 180 kW
Ratios 1st gear 48 : 13 = 3.692 48 : 13 = 3.692 48 : 13 = 3.692
2nd gear 47 : 21 = 2.238 43 : 20 = 2.150 43 : 20 = 2.150
3rd gear 53 : 34 = 1.559 43 : 32 = 1.344 43 : 32 = 1.344
4th gear 47 : 40 = 1.175 38 : 39 = 0.974 38 : 39 = 0.974
5th gear 43 : 47 = 0.915 34 : 46 = 0.739 34 : 46 = 0.739
6th gear 38 : 51 = 0.745 27 : 47 = 0.574 27 : 47 = 0.574
7th gear 37 : 60 = 0.617 24 : 52 = 0.462 24 : 52 = 0.462
Reverse 53 : 18 = 2.944 53 : 18 = 2.944 53 : 18 = 2.944
gear
drive
Bevel gear 31 : 8 = 3.875 29 : 8 = 3.625 29 : 8 = 3.625
drive
Ratio “i” 4.375 3.875 4.093
drive

Gearbox Code letters NHL, NRW, PWZ, NUK, NHM, NRX, NHQ, NSA, PWY
PJW PJX
Allocation Model A4 2008 ► A4 allroad 2008 ► A4 2008 ►
A5 Coupé 2008 ► A5 Coupé 2008 ►
4. Technical data 9

Engine 2.0 ltr. TFSI 2.0 ltr. TFSI 2.0 ltr. TDI (PR-TH3/
155 kW, 165 kW 155 kW, 165 kW TM4)
130 kW, 140 kW
Ratios 1st gear 48 : 13 = 3.692 48 : 13 = 3.692 48 : 13 = 3.692
2nd gear 43 : 20 = 2.150 43 : 20 = 2.150 43 : 20 = 2.150
3rd gear 45 : 32 = 1.406 45 : 32 = 1.406 43 : 32 = 1.344
4th gear 41 : 40 = 1.025 41 : 40 = 1.025 38 : 39 = 0.974
5th gear 37 : 47 = 0.787 37 : 47 = 0.787 34 : 46 = 0.739
6th gear 30 : 48 = 0.625 30 : 48 = 0.625 27 : 47 = 0.574
7th gear 27 : 52 = 0.519 27 : 52 = 0.519 24 : 52 = 0.462
Reverse 53 : 18 = 2.944 53 : 18 = 2.944 53 : 18 = 2.944
gear
drive
Bevel gear 29 : 8 = 3.625 31 : 8 = 3.875 29 : 8 = 3.625
drive
Ratio “i” 4.093 4.375 4.093
drive

Gearbox Code letters NHR, NSB, PXA NHS, NSC, PWW PJV
Allocation Model A4 allroad 2008 ► A4 2008 ► A4 allroad 2008 ►
A5 Coupé 2008 ►
Engine 2.0 ltr. TDI (PR-TH3/ 3.0 ltr. TFSI 2.0 ltr. TDI (PR-TD1)
TM4) 200 kW, 245 kW 140 kW
130 kW
Ratios 1st gear 48 : 13 = 3.692 48 : 13 = 3.692 48 : 13 = 3.692
2nd gear 43 : 20 = 2.150 43 : 20 = 2.150 43 : 20 = 2.150
3rd gear 43 : 32 = 1.344 45 : 32 = 1.406 43 : 32 = 1.344
4th gear 38 : 39 = 0.974 41 : 40 = 1.025 38 : 39 = 0.974
5th gear 34 : 46 = 0.739 37 : 47 = 0.787 34 : 46 = 0.739
6th gear 27 : 47 = 0.574 30 : 48 = 0.625 27 : 47 = 0.574
7th gear 24 : 52 = 0.462 27 : 52 = 0.519 24 : 52 = 0.462
Reverse 53 : 18 = 2.944 53 : 18 = 2.944 53 : 18 = 2.944
gear
drive
Bevel gear 31 : 8 = 3.875 29 : 8 = 3.625 31 : 8 = 3.875
drive
Ratio “i” 4.375 3.875 4.375
drive


Gearbox Code letters PJU
Allocation Model A4 2008 ►
A5 Coupé 2008 ►
Engine 2.0 ltr. TDI (PR-TD1)
140 kW
Ratios 1st gear 48 : 13 = 3.692
2nd gear 43 : 20 = 2.150
3rd gear 43 : 32 = 1.344
4th gear 38 : 39 = 0.974
5th gear 34 : 46 = 0.739
6th gear 27 : 47 = 0.574
7th gear 24 : 52 = 0.462
Reverse 53 : 18 = 2.944
gear
Front axle Spur gear 35 : 31 = 1.129
drive
Bevel gear 29 : 8 = 3.625
drive
Ratio “i” 4.093
Rear axle Bevel gear 37 : 9 = 4.111
drive
Overall ratio “iov” in top gear 1.890
Ratio spread 8.0
4.2 Capacities
⇒ “4.2.1 ATF capacity”, page 11
⇒ “4.2.2 Gear oil (MTF) capacity”, page 12
4.2.1 ATF capacity

Capacities Dual clutch gearbox 0B5: ATF
Initial filling by manufacturer approx. 7 to 7.5 ltr. 1)
ATF change capacity Refer to ⇒ ELSA maintenance
tables
Change interval ⇒ ELSA maintenance tables
– If fitted, renew ATF filter
(exchangeable filter) 2)
Lubricant For ATF specifications for dual
clutch gearbox 0B5 refer to ⇒
Electronic parts catalogue .
• 1) The manufacturer fills the gearbox to the normal level plus
0.5 ltr. The excess quantity of 0.5 ltr. is for filling the empty
ATF cooler after the gearbox is installed.
• 2)On vehicles with exchangeable ATF filter, the filter must
be renewed as well when changing the ATF ⇒ page 12 .
• From model year 2011 onwards, all gearboxes are fitted with
an exchangeable ATF filter.
• Only gearboxes with exchangeable ATF filter are available
as replacement parts; vehicles older than model year 2011
may therefore also be fitted with an exchangeable ATF filter.
4. Technical data 11
Caution
Risk of damage to gearbox

♦ Use only the ATF supplied as a replacement part for dual
clutch gearbox 0B5.
♦ Select correct type ⇒ Electronic parts catalogue .
♦ Other types of ATF or other oils cause malfunctions and/
or failure of the gearbox.
♦ The ATF filling unit must be clean and the ATF must not
be mixed with other types of oil!
♦ ⇒ “7.2 Checking ATF level”, page 146

♦ ⇒ “7.3 Draining and filling ATF”, page 149
On gearbox versions with exchangeable ATF filter -2-:
Caution

• The exchangeable ATF filter -2- must always be renewed
when the ATF is changed.
– Renew ATF filter (exchangeable filter) ⇒ page 180 .
4.2.2 Gear oil (MTF) capacity

The gear clusters, front final drive and transfer box in the dual
clutch gearbox 0B5 have a common oil system. The same plug
is used for filling and inspection.
The gear oil in the dual clutch gearbox 0B5 is also referred to as
MTF (manual transmission fluid).
Capacities Dual clutch gearbox 0B5: gear
oil (MTF)
Initial filling by manufacturer approx. 4.35 ltr.
Oil change (all vehicles except No change required:
Audi RS 5/RS 4) ♦ Lifetime filling; change only
after performing repair work
Oil change for Audi RS 5/RS 4 Oil change interval for Audi
RS 5/RS 4:
♦ ⇒ ELSA maintenance ta‐
bles
– After changing the gear oil,
run the appropriate “Guided
Function” on the vehicle di‐
agnostic tester
⇒ page 231 .

Capacities Dual clutch gearbox 0B5: gear

oil (MTF)
Lubricant For gear oil specifications for
dual clutch gearbox 0B5 refer
to ⇒ Electronic parts cata‐
logue .
♦ ⇒ “2.2 Checking gear oil level”, page 193
♦ ⇒ “2.3 Draining and filling gear oil”, page 197
4. Technical data 13
30 – Clutch
1 Clutch
⇒ “1.1 Exploded view - flywheel and dual clutch”, page 14
⇒ “1.2 Removing and installing flywheel”, page 15
⇒ “1.3 Removing dual clutch”, page 15
⇒ “1.4 Installing dual clutch”, page 15
1.1 Exploded view - flywheel and dual clutch
Note
All repair work and tightening torques are described in Workshop Manual “Servicing 7-speed dual clutch gear‐
box 0B5 (S tronic)”.
1 - Flywheel
❑ Different versions are
available; for correct
version refer to ⇒ Elec‐
tronic parts catalogue
❑ Removing and installing
⇒ Servicing dual clutch
gearbox; Rep. gr. 30 ;
Clutch; Removing and
installing flywheel
2 - Clutch cover
❑ Different versions (with‐
out or with thrust washer
⇒ Item 7 (page 15) );
observe notes and allo‐
cation in ⇒ Electronic
parts catalogue
Clutch; Removing dual
clutch , and ⇒ Servicing
dual clutch gearbox;
Rep. gr. 30 ; Clutch; In‐
stalling dual clutch
3 - Bolt
❑ Tightening torque and
sequence ⇒ Servicing
Rep. gr. 30 ; Clutch; Ex‐
ploded view - flywheel
and dual clutch
4 - O-ring
❑ Renew
5 - Dual clutch
❑ Different versions are
available; for correct version refer to ⇒ Electronic parts catalogue
❑ Removing ⇒ Servicing dual clutch gearbox; Rep. gr. 30 ; Clutch; Removing dual clutch
❑ Installing ⇒ Servicing dual clutch gearbox; Rep. gr. 30 ; Clutch; Installing dual clutch
14 Rep. gr.30 - Clutch

• After renewing dual clutch, run appropriate “Guided Function” using vehicle diagnostic tester ⇒ page 231
6 - Gearbox housing
7 - Thrust washer
❑ Not installed in all versions; note allocation to clutch cover in ⇒ Electronic parts catalogue
8 - Ball bearing
❑ For input shaft
❑ Renewing ⇒ Servicing dual clutch gearbox; Rep. gr. 35 ; Input shaft
9 - Circlip
❑ For ball bearing
❑ Renew
10 - Circlip
❑ For dual clutch
❑ Renew
11 - Oil seal
❑ For input shaft
❑ Renewing ⇒ Servicing dual clutch gearbox; Rep. gr. 35 ; Input shaft; Renewing oil seal for input shaft
12 - Bolt
❑ Tightening torque ⇒ Servicing dual clutch gearbox; Rep. gr. 30 ; Clutch; Exploded view - flywheel and
dual clutch
1.2 Removing and installing flywheel

• Gearbox removed
Note
All repair work and tightening torques are described in Workshop

Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tronic)”.
Description of work sequence ⇒ Servicing dual clutch gearbox;

Rep. gr. 30 ; Clutch; Removing and installing flywheel
1.3 Removing dual clutch

• Gearbox removed
Note


Rep. gr. 30 ; Clutch; Removing dual clutch
1.4 Installing dual clutch

• Gearbox removed
Note

1. Clutch 15

Rep. gr. 30 ; Clutch; Installing dual clutch
16 Rep. gr.30 - Clutch

34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Exploded view - mechatronic unit”, page 17
⇒ “1.2 Removing and installing oil pan”, page 20
⇒ “1.3 Removing and installing ATF filter”, page 21
⇒ “1.4 Removing and installing mechatronic unit”, page 22
1.1 Exploded view - mechatronic unit

Removing and installing printed circuits for mechatronic unit for
dual clutch gearbox - J743- ; refer to Workshop Manual “Servicing
7-speed dual clutch gearbox 0B5 (S tronic)” ⇒ Servicing dual
clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Exploded view -
mechatronic unit
1 - ATF drain plug

❑ Tightening torque
⇒ “7.1 Exploded view -
drain, filler and inspec‐
tion plugs”, page 146
2 - Seal
❑ Renew
3 - Bolt
❑ For tightening torque
and sequence, see
Workshop Manual
“Servicing 7-speed dual
clutch gearbox 0B5 (S
tronic)” ⇒ Servicing dual
clutch gearbox; Rep. gr.
34 ; Mechatronic unit;
Exploded view - mecha‐
tronic unit
4 - Spreader rivet
❑ In original equipment
version for securing
gasket to ATF oil pan
❑ Not essential for instal‐
lation
5 - Magnet
❑ 2x
❑ Insert in recess in ATF
oil pan
❑ Ensure that the magnet
is in full contact with the
ATF oil pan
6 - Bolt
❑ For tightening torque
and sequence, see
Workshop Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tronic)” ⇒ Servicing dual clutch gear‐
box; Rep. gr. 34 ; Mechatronic unit; Exploded view - mechatronic unit
7 - O-rings
❑ Renew
1. Mechatronic unit 17
8 - ATF pressure pipes (clutch pressure)

9 - Retaining plate
❑ For ATF pressure pipes (clutch pressure)
10 - Bolt
❑ For tightening torque, see Workshop Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tronic)” ⇒
Servicing dual clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Exploded view - mechatronic unit
11 - O-rings
❑ Renew
12 - O-rings
❑ Renew
13 - ATF pipes
❑ Different versions possible
14 - O-rings
❑ Renew
15 - O-ring
❑ Renew
16 - Filter housing for exchangeable ATF filter
❑ For gearboxes with exchangeable ATF filter
17 - O-ring
❑ Renew
18 - Cap for ATF filter
❑ Tightening torque ⇒ page 157
19 - Exchangeable ATF filter
❑ Renew after changing ATF or after performing gearbox repairs
❑ Note correct allocation ⇒ Electronic parts catalogue (also called filter element)
❑ ⇒ “8.4.2 Removing and installing exchangeable ATF filter”, page 180
20 - Bolt
❑ 3x
21 - O-rings
❑ Renew
22 - ATF line (return)
❑ Removing and installing ⇒ page 157
23 - ATF line (supply)
24 - Bolt
18 Rep. gr.34 - Controls, housing

25 - Bolt
❑ For gearboxes with in-line ATF filter
❑ 3x
27 - Bolt
28 - O-rings
❑ Renew
29 - Connection piece for ATF lines
30 - In-line ATF filter
❑ Renew in-line ATF filter after replacing or repairing gearbox
❑ ⇒ “8.4.1 Removing and installing in-line ATF filter”, page 178
31 - ATF filler and inspection plug
❑ Tightening torque ⇒ “7.1 Exploded view - drain, filler and inspection plugs”, page 146
32 - O-rings
❑ Renew
33 - Bolt
❑ 8 Nm
34 - Connector housing
– To remove, unscrew bolt -item 33- and turn connector housing anti-clockwise
35 - Gearbox housing
36 - O-rings
❑ Renew
37 - ATF pipes
❑ Different versions are available; for correct version refer to ⇒ Electronic parts catalogue
38 - Bolt
❑ For tightening torque, see Workshop Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tronic)” ⇒
Servicing dual clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Exploded view - mechatronic unit
39 - Wiring harness for speed sensors
❑ Removing and installing; see Workshop Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tronic)”
⇒ Servicing dual clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Exploded view - mechatronic unit
40 - O-ring
❑ Renew
41 - ATF intake filter
❑ Removing and installing; see Workshop Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tronic)”
⇒ Servicing dual clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Exploded view - mechatronic unit
42 - Mechatronic unit for dual clutch gearbox - J743-
❑ ⇒ “1.4 Removing and installing mechatronic unit”, page 22
• After renewing the mechatronic unit for dual clutch gearbox - J743- , run the appropriate “Guided Function”
on a vehicle diagnostic tester ⇒ page 231
• Disconnecting printed circuit from mechatronic unit for dual clutch gearbox - J743- ; refer to Workshop
Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tronic)” ⇒ Servicing dual clutch gearbox; Rep. gr.
34 ; Mechatronic unit; Exploded view - mechatronic unit
43 - Gasket
❑ Renew
❑ Installing ⇒ page 21
44 - ATF oil pan
❑ ⇒ “1.2 Removing and installing oil pan”, page 20
1.2 Removing and installing oil pan

Removing
Note
♦ ⇒ “3.3 General repair instructions”, page 5 .

♦ ⇒ “3.1 Rules for cleanliness”, page 4 .
– If fitted, remove diagonal struts (left and right) ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Subframe; Exploded view - sub‐
frame .
– Remove subframe cross brace ⇒ Running gear, axles, steer‐

ing; Rep. gr. 40 ; Subframe; Removing and installing subframe
cross brace .
Caution
Risk of damage to parts of the running gear.

♦ Do not let the vehicle down on the wheels if the gearbox
mounting, steering rack or subframe cross brace are not
properly installed.
– Drain ATF ⇒ page 149 .
Caution

♦ The engine must not be started when there is no more ATF
in the gearbox.

– Slacken bolts -1 … 15- in diagonal sequence.

– Remove ATF oil pan.
Note
-Arrows- can be disregarded.
Installing
Installation is carried out in reverse sequence; note the following:
– Clean sealing surfaces.
– Renew bolts and gasket for ATF oil pan.
– Insert studs -arrow- on new gasket -2- into ATF oil pan -1-.
– Secure gasket to ATF oil pan with clips -3- (if fitted).
Note
Clips -item 3- are only used as an assembly aid during production.
– Clean magnets -arrows- in ATF oil pan.

– Ensure that magnets make full contact with ATF oil pan.
– Tighten bolts for ATF oil pan; see Workshop Manual “Servicing
7-speed dual clutch gearbox 0B5 (S tronic)” ⇒ Servicing dual
clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Exploded view
- mechatronic unit .
– Install subframe cross brace ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Subframe; Exploded view - subframe .
– Install diagonal struts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Exploded view - subframe .
– Fill up with ATF ⇒ page 146 .
1.3 Removing and installing ATF filter

For description of work sequence, see Workshop Manual “Serv‐
icing 7-speed dual clutch gearbox 0B5 (S tronic)” ⇒ Servicing
dual clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Exploded
view - mechatronic unit .
1.4 Removing and installing mechatronic

unit
Removing
• Gearbox in vehicle
Caution

in the gearbox and the mechatronic unit for dual clutch
gearbox - J743- has been removed.
Note

♦ Notes on dual clutch gearbox 0B5 ⇒ page 4 .
– Shift selector lever into position “P”.

– Switch off ignition and take out ignition key.

Caution

♦ Before handling electrical connectors, mechanic must dis‐
charge static. To do so, touch vehicle earth, heater radi‐
ator, or lifting platform, with your hand.
hands.
– Turn fastener anti-clockwise -arrow- and unplug electrical con‐

nector on gearbox.
– Remove ATF oil pan ⇒ page 20 .
For description of further work sequence, see Workshop Manual
“Servicing 7-speed dual clutch gearbox 0B5 (S tronic)” ⇒ Serv‐
icing dual clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Re‐
moving and installing mechatronic unit .
Installing
Caution

hands.
– Make sure that electrical connector on mechatronic unit is

properly engaged and secured.
– Observe measures required after connecting battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
– Install ATF intake filter; refer to work sequence in Workshop
Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tronic)”
⇒ Servicing dual clutch gearbox; Rep. gr. 34 ; Mechatronic
unit; Removing and installing mechatronic unit .
– Install ATF oil pan ⇒ page 20 .
• After renewing mechatronic unit for dual clutch gearbox -
J743- , run appropriate “Guided Function” on vehicle diagnos‐
tic tester ⇒ page 231
2 Selector mechanism
⇒ “2.1 Exploded view - selector mechanism”, page 24
⇒ “2.2 Exploded view - selector lever handle”, page 26
⇒ “2.3 Exploded view - selector lever cable”, page 28
⇒ “2.4 Checking selector mechanism”, page 28
⇒ “2.5 Manual release from position P”, page 31
⇒ “2.6 Removing and installing selector mechanism”, page 32
⇒ “2.7 Dismantling and assembling selector mechanism”,
page 38
⇒ “2.8 Removing and installing selector lever handle”,
page 41
⇒ “2.9 Removing and installing selector lever position display Y26
”, page 51
⇒ “2.10 Removing and installing selector lever cable”,
page 51
⇒ “2.11 Checking and adjusting selector lever cable”, page 57
⇒ “2.12 Adjusting selector lever cable to basic setting”,
page 58
⇒ “2.13 Renewing selector shaft oil seal”, page 61
2.1 Exploded view - selector mechanism
WARNING
Accidents and injury can be caused if a gear is inadvertently

engaged while the engine is running.
Check selector mechanism before dismantling ⇒ page 28 .

1 - Selector lever handle

❑ ⇒ “2.2 Exploded view -
selector lever handle”,
page 26
2 - Trim ring
page 26
3 - Selector lever boot
page 26
4 - Clamp
page 26
5 - Selector lever position dis‐
play - Y26-
❑ ⇒ “2.9 Removing and in‐
stalling selector lever
position display Y26 ”,
page 51
6 - Nut
❑ Secures selector mech‐
anism to body
❑ 4x
❑ 10 Nm
7 - Gasket
8 - Selector lever sensors con‐
trol unit - J587- and tiptronic
switch - F189-
❑ ⇒ “2.7.2 Removing and
installing selector lever
sensors control unit J587 ”, page 40
9 - Shift unit
❑ Can only be renewed as a complete unit
❑ ⇒ “2.6 Removing and installing selector mechanism”, page 32
• After removing and installing shift unit, run appropriate “Guided Function” using vehicle diagnostic tester
⇒ page 231
10 - Selector lever lock solenoid - N110-
❑ ⇒ “2.7.1 Removing and installing selector lever lock solenoid N110 ”, page 38
11 - Gear selector position P switch - F305-
❑ Consists of two reed contacts on printed circuit board in selector lever lock solenoid - N110-
❑ Can only be renewed together with selector lever lock solenoid - N110-
⇒ “2.7.1 Removing and installing selector lever lock solenoid N110 ”, page 38
12 - Noise insulation
❑ Not fitted on all vehicles
❑ For correct version, refer to ⇒ Electronic parts catalogue
13 - Retaining washers
❑ Renew
❑ 4x
❑ For securing noise insulation to shift unit
2. Selector mechanism 25
14 - Retaining clip
❑ Secures selector lever cable to shift unit
15 - O-ring
❑ Renew
16 - Selector lever cable
❑ Do not bend or kink
❑ ⇒ “2.3 Exploded view - selector lever cable”, page 28
17 - Cover plate
❑ Above selector lever lock solenoid - N110-
2.2 Exploded view - selector lever handle

⇒ “2.2.1 Exploded view - selector lever handle, vehicles up to
model year 2011 except for Audi RS 5”, page 26
⇒ “2.2.2 Exploded view - selector lever handle, vehicles from
model year 2012 onwards and Audi RS 5/RS 4”, page 27
2.2.1 Exploded view - selector lever handle, vehicles up to model year 2011 ex‐
cept for Audi RS 5
1 - Clamp
❑ Secures selector lever
handle to selector lever
❑ Renew
⇒ “2.8.1 Removing and
handle - vehicles up to
model year 2011 except
for RS 5”, page 41
2 - Trim ring
⇒ “2.8.2 Detaching se‐
lector lever boot from
selector lever handle -
vehicles up to model
year 2011 except for
RS 5”, page 44
3 - Selector lever handle
handle - vehicles up to
model year 2011 except
for RS 5”, page 41
❑ ⇒ “2.8.2 Detaching se‐
lector lever boot from
selector lever handle -
vehicles up to model
year 2011 except for
RS 5”, page 44
play - Y26-


page 51
2.2.2 Exploded view - selector lever handle, vehicles from model year 2012 on‐
wards and Audi RS 5/RS 4

play - Y26-
page 51
2 - Selector lever handle with
interlock button (side)
handle with interlock
button (side) - vehicles
from model year 2012
onwards”, page 44
❑ Remove and install to‐
gether with selector lev‐
er handle
⇒ “2.8 Removing and in‐
handle”, page 41
4 - Selector lever handle with
interlock button (front)
handle with interlock
button (front) - vehicles
from model year 2012
onwards and RS 5/
RS 4”, page 47
❑ Fitted on all Audi RS 5/
RS 4 vehicles since
market launch
2.3 Exploded view - selector lever cable
1 - Retaining clip
❑ Secures selector lever
cable to shift unit
2 - O-ring
❑ Renew
3 - Bolt
❑ For adjusting selector
lever cable
❑ Secured to shift unit
❑ 13 Nm
4 - Selector lever cable
❑ Do not bend or kink
❑ Different versions (ac‐
cording to vehicle); for
correct version refer to
⇒ Electronic parts cata‐
logue
❑ ⇒ “2.10 Removing and
cable”, page 51
❑ Selector lever cable
must be renewed if rub‐
ber sleeve is damaged
❑ Before installing, lightly
lubricate ball socket with
polycarbamide grease -
G 052 142 A2- .
❑ When installing, make
sure that rubber sleeve
on gearbox end is not
twisted
❑ ⇒ “2.11 Checking and
adjusting selector lever
cable”, page 57
• After adjusting selector lever cable, run appropriate “Guided Function” on vehicle diagnostic tester
⇒ page 231
5 - Gearbox selector lever
6 - Retaining clip
❑ Secures selector lever cable to cable support bracket
❑ Depending on version: lock nut (13 Nm)
7 - Cable support bracket
8 - Bolt
❑ 8 Nm
9 - Bolt
❑ 8 Nm
2.4 Checking selector mechanism

Overview:
♦ 1. Checking operation of selector mechanism ⇒ page 29

♦ 2. Checking ignition key removal lock ⇒ page 30

♦ 3. Checking door locking disable ⇒ page 30
♦ 4. Checking interlock button on selector lever handle
⇒ page 31
1. Checking operation of selector mechanism
• It should not be possible to operate the starter while the se‐
lector lever is in position “S”, “D” or “D/S”, “R” or in the “tiptronic
gate”.
• When travelling at speeds above 5 km/h and shifting into se‐
lector lever position “N”, the solenoid for the selector lever lock
must not engage and block the selector lever. The selector
lever can be shifted into a driving gear.
• When travelling at speeds below 2 km/h (almost stationary)
and shifting into selector lever position “N”, the solenoid for the
selector lever lock should only engage after about 1 second.
The selector lever cannot be shifted out of “N” position until
the brake pedal is depressed.
Selector lever in position “P”:
– Pull up parking brake button to apply electromechanical park‐
ing brake.
– Switch off ignition.
• The selector lever is locked and cannot be shifted out of “P”
position, even when the interlock button on the handle is
pressed in.
– To obtain the “ignition on” position, briefly press key in ignition
lock or entry and start authorisation button - E408- .
– Do not depress brake pedal.
• The selector lever is locked and cannot be shifted out of “P”
position, even when the interlock button on the handle is
pressed in. Selector lever lock solenoid - N110- blocks selec‐
tor lever.
– Press and hold brake pedal.
• Selector lever lock solenoid - N110- releases selector lever. It
is possible to shift into a driving gear. With interlock button on
selector lever handle pressed, shift selector lever slowly from
“P” position through “R, N, D, S or D/S” and check whether the
selector lever position display - Y6- in the instrument cluster
shows the correct selector lever position in each case.
Vehicles from model year 2012 onwards:
– Pull selector lever from “D/S” towards the rear and release
selector lever.
• The selector lever will return automatically to the position “D/
S”. The selector lever position display - Y6- in the instrument
cluster should change from “D” to “S1” and then back to “D”
when the selector lever is pulled back once again.
Continued for all vehicles:
Selector lever in position “N” and ignition switched on:
• After a short delay: Selector lever is locked and cannot be
shifted out of “N” position even when pressing the interlock
button on the selector lever handle. Selector lever lock sole‐
noid - N110- blocks selector lever.
– Depress brake pedal.
• Selector lever lock solenoid - N110- releases selector lever.

Shifting into position “D” or “D/S” is possible.
Selector lever in position “D” or “D/S”, ignition switched on:
– Shift selector lever into “tiptronic gate”.
• The illuminated “D” or “D/S” symbol in the selector lever posi‐
tion display - Y26- should go out and the “+” and “–” symbols
should light up.
• The selector lever position display - Y6- in the instrument clus‐
ter should change from “D” to “M1” when the selector lever is
moved into the “tiptronic gate”.
– If the specified results are not obtained, perform Guided
Fault Finding using vehicle diagnostic tester .
– Adjust selector lever cable ⇒ page 57 .

– Check interlock button on selector lever handle ⇒ page 31 .
If results do not match specifications:
– Perform Guided Fault Finding routine using vehicle diag‐
nostic tester .
2. Checking ignition key removal lock
ing brake.
– Briefly press ignition key in ignition lock to reach position “ig‐
nition on”.
– Press and hold brake pedal.
• When interlock button in selector lever handle is pressed, it
should be possible to move selector lever out of position “P”
without “catching”.
• It should not be possible to remove the ignition key when the
selector lever is in any position other than “P”.
– Pull out ignition key.
• It should only be possible to remove ignition key in selector
lever position “P”.
• It should not be possible to shift selector lever out of “P” posi‐
tion with interlock button pressed and foot brake depressed.
If the ignition key removal lock does not function as described,
perform Guided Fault Finding using vehicle diagnostic tester .
3. Checking door locking disable - vehicles with keyless locking
and starting system
– To obtain the “ignition on” position, briefly press the entry and
start authorisation button - E408- .
– Do not move selector lever to position “P”; select e.g. position
“N”.
• A warning message should be displayed in the instrument
cluster.

• The vehicle cannot be locked.

– Switch on ignition and shift selector lever into position “P”.
• The vehicle can now be locked.
– Perform Guided Fault Finding routine using vehicle diag‐
nostic tester .
4. Checking interlock button on selector lever handle
Check that interlock button moves freely:
• Interlock button should move easily when pressed without
force.
• Interlock button should spring back fully on its own when re‐
leased.
– If specified results are not obtained, check that selector lever
handle is correctly installed ⇒ page 41 .
– Check whether selector lever is bent.
Function test:
• Ignition switched on
Press the interlock button on the selector lever handle to move
the handle into the positions listed below; it should not be possible
to move the selector lever into these positions unless the interlock
button is pressed.
♦ “P” to “R” (also depress brake pedal)
♦ Vehicles up to model year 2011 only: “D” to “S”
♦ “N” to “R” (brake pedal also has to be depressed after a short
delay when vehicle is stationary)
♦ “R” to “P”
– Check whether selector lever handle is correctly installed
⇒ page 41 .
– Check electrical connectors on selector mechanism.
– Perform Guided Fault Finding using vehicle diagnostic
tester and check selector lever lock solenoid - N110- .
2.5 Manual release from position P
Note
♦ If the battery is disconnected or discharged, the selector lever

cannot be shifted from position “P”. In this case, the vehicle
cannot be pushed or towed.
♦ When you operate the manual release mechanism the selec‐
tor lever lock solenoid - N110- will release the lock without
current supply.
Procedure
– Remove front ashtray insert.
– Use screwdriver to pry off the cover cap in the ashtray housing
-arrow-.
Note
The shape of the cover cap may differ from the illustration.
– Carefully insert tool (e.g. screwdriver) through centre opening

in ashtray housing and into cylinder -arrow- on selector lever
lock solenoid - N110- and at the same time press and hold
interlock button and move selector lever out of position “P”.
Note
♦ This releases the selector lever lock in position “P” by way of

the locking lever -1-.
♦ The cylinder -arrow- on selector lever lock solenoid - N110-
may be partially concealed by noise insulation or wiring (move
clear to one side).
2.6 Removing and installing selector mech‐

anism
Special tools and workshop equipment required
♦ Removal lever - 80 - 200-
♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Counterhold tool - T10172- with -T10172/5-
♦ Gearbox support - T10337-
Removing
– Remove ashtray (front) ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing ashtray
(front) .
– Unplug electrical connectors -2- and -4-.
Note
♦ Insulating mat is not shown in illustration.

♦ The assistance of a second mechanic is required to detach the
selector mechanism from below.
– Remove insulating mat above selector mechanism.

– Remove bolts -1, 3, 5, 6-.
Vehicles with single exhaust system:
– Remove front exhaust pipe/front silencer ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencers; Exploded view - silencers .
Vehicles with 6-cyl. or 8-cyl. petrol engine:
– Remove front silencer (right-side) ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Removing and installing front silencer .

frame .

cross brace .
Caution

properly installed.
– If fitted, remove bolts -arrows- and detach heat shield -1- for
propshaft.

Vehicles with bolted propshaft:

– Remove bolts from connection between propshaft and gear‐
box (counterhold using counter-hold tool - T10172- with -
T10172/5- ).
– Slide propshaft together towards rear final drive. The constant
velocity joints can be moved axially.
– Place propshaft on front cross member.
Vehicles with propshaft with splines on gearbox end:
Note
Please refer to the vehicle data sticker or the identification on the

rear final drive to find out which type of rear final drive is installed
in the vehicle. Then select the appropriate Workshop Manual for
the rear final drive.
– Remove propshaft (version with splines on gearbox end); refer

to Workshop Manual “Rear final drive 0BC” ⇒ Rear final drive;
Rep. gr. 39 ; Propshaft; Removing and installing propshaft ,
or “Rear final drive 0BF and 0BE - sport differential” ⇒ Rear
final drive; Rep. gr. 39 ; Propshaft; Removing and installing
propshaft .
Vehicles with 6-cyl. or 8-cyl. petrol engine:
Caution
Risk of damage to flexible joint in front silencer.

♦ The flexible joint in the front silencer must not be bent fur‐
ther than 10°.
– Unbolt clamp -1-, push clamp towards rear and tie up front
silencer (left-side) to body.
Note
-Item 2- can be disregarded.

– Set up gearbox support - T10337- on engine and gearbox jack
- V.A.G 1383 A- and position underneath gearbox.
– Raise gearbox slightly.
WARNING
Risk of accident.
♦ Engine and gearbox jack - V.A.G 1383 A- must remain in
position when work is being carried out and must not be
left unattended.
– Remove bolts -arrows- for tunnel cross member.
– Lower gearbox by dimension -a- using engine and gearbox

jack - V.A.G 1383 A- .
• Dimension -a- = 70 mm (maximum)
– Use removal lever - 80 - 200- to press ball socket -2- on se‐

lector lever cable off gearbox selector lever.
– Pry off retaining clip -1- and detach selector lever cable from
gearbox.
Note
Do not bend or kink the selector lever cable.

– If fitted, remove nuts -arrows-.

– Lower cover for vehicle underbody (on inside) until heat shield
-1- for centre tunnel can be removed.
– Remove selector mechanism.
Installing
• Tightening torques
Note
♦ Before installing, lightly lubricate ball socket on selector lever

cable with polycarbamide grease - G 052 142 A2- .
♦ Do not bend or kink the selector lever cable.

– Install heat shield ⇒ General body repairs, exterior; Rep. gr.
66 ; Strips / trim panels / extensions; Exploded view - heat
shield .
– Install tunnel cross member ⇒ page 139 .
– Check selector mechanism ⇒ page 28 .
Note

– Install propshaft; refer to Workshop Manual “Rear final

drive 0BC” ⇒ Rear final drive; Rep. gr. 39 ; Propshaft; Explo‐
ded view - propshaft , or “Rear final drive 0BF and 0BE - sport
differential” ⇒ Rear final drive; Rep. gr. 39 ; Propshaft; Ex‐
ploded view - propshaft .
– Install exhaust system and perform stress-free alignment ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silenc‐
ers .
– Install ashtray (front) ⇒ General body repairs, interior; Rep.
(front) .
• After removing and installing the shift unit, run the appropriate
“Guided Function” using the vehicle diagnostic tester
⇒ page 231 .
2.7 Dismantling and assembling selector

mechanism
⇒ “2.7.1 Removing and installing selector lever lock solenoid
N110 ”, page 38
⇒ “2.7.2 Removing and installing selector lever sensors control
unit J587 ”, page 40
⇒ “2.7.3 Removing and installing gear selector position P switch
F305 ”, page 41
2.7.1 Removing and installing selector lever

lock solenoid - N110-
Removing
– Remove multimedia system operating unit - E380- ⇒ Com‐
munication; Rep. gr. 91 ; Infotainment system; Removing and
installing multimedia system operating unit - E380- .
(front) .
– Unscrew nuts -1, 3, 5, 6- a few turns, but do not remove com‐

pletely.
Note
This will lower the shift unit slightly and facilitate removal.
Caution
The selector mechanism can be damaged by broken retaining

clips, retaining tabs or other objects.
♦ Make sure that no parts or objects drop into the selector
mechanism. If this happens, the selector mechanism will
have to be renewed!

– Release retaining tabs -2- and -3- in direction of -arrow-, lift

front of sealing cap -A- slightly and hold in that position.
Note
This prevents the retaining tabs from engaging again.
– Using a screwdriver, release top retaining tab -1- of sealing

cap from retainer -B- in direction of -arrow- and lift out sealing
cap -A-.
– Unplug electrical connector on selector lever lock solenoid -

N110- .
– Press retaining hook -A- in direction of -arrow- and hold in this
position.
Note
The shift unit must be renewed if the retaining hook -A- breaks
off.
– Tilt bottom part of selector lever lock solenoid - N110- out in

direction of -arrow- so that ball head -1- disengages from op‐
erating lever on selector mechanism.
– Detach selector lever lock solenoid - N110- .
Installing
• Tightening torque
– Turn ball head -1- into correct position for installation.
– Guide selector lever lock solenoid - N110- into selector mech‐
anism at an angle from above and tilt bottom part in opposite
direction of -arrow-.
• Ball head -1- must engage fully in operating lever on selector

mechanism; press home with a small screwdriver if necessary.
– Secure selector lever lock solenoid - N110- to retaining hook
-A-.
– Place cover -A- over selector lever lock solenoid - N110- and
carefully engage -1 ... 3-.
– Attach electrical connectors.
– Check function of selector mechanism before continuing as‐
sembly ⇒ page 28 .
(front) .
– Install multimedia system operating unit - E380- ⇒ Commu‐
nication; Rep. gr. 91 ; Infotainment system; Removing and

sensors control unit - J587-
Removing
– Remove selector lever handle ⇒ page 41 .
– Remove multimedia system operating unit - E380- ⇒ Com‐
munication; Rep. gr. 91 ; Infotainment system; Removing and
(front) .
– Unplug electrical connector -1-.

– Release 4 retaining tabs -arrows- and lift out selector lever
sensors control unit - J587- .
Installing
– Make sure selector lever sensors control unit - J587- clicks in
place with 4 retaining tabs -arrows-.
– Secure wiring for selector lever position display - Y26-
-arrows-.
(front) .
– Install multimedia system operating unit - E380- ⇒ Commu‐
nication; Rep. gr. 91 ; Infotainment system; Removing and
– Install selector lever handle ⇒ page 41 .

2.7.3 Removing and installing gear selector

position P switch - F305-
♦ Fitting location: Gear selector position P switch - F305- con‐
sists of two microswitches -1- and - 2- and is installed on
printed circuit board -B- in selector lever lock solenoid - N110-
-A-.
Gear selector position P switch - F305- can only be renewed to‐
gether with selector lever lock solenoid - N110- .
N110 ”, page 38 .
2.8 Removing and installing selector lever

handle
⇒ “2.8.1 Removing and installing selector lever handle - vehicles
up to model year 2011 except for RS 5”, page 41
⇒ “2.8.2 Detaching selector lever boot from selector lever handle
- vehicles up to model year 2011 except for RS 5”, page 44
⇒ “2.8.3 Removing and installing selector lever handle with inter‐
lock button (side) - vehicles from model year 2012 onwards”, page
44
⇒ “2.8.4 Removing and installing selector lever handle with inter‐
lock button (front) - vehicles from model year 2012 onwards and
RS 5/RS 4”, page 47
⇒ “2.8.5 Moving interlock button (front) on selector lever handle
into installation position - vehicles from model year 2012 onwards
and RS 5/RS 4”, page 49

handle - vehicles up to model year 2011
except for RS 5
♦ Removal wedge - 3409-
♦ Hose clip pliers - V.A.G 1275-
Removing
ing brake.
– Shift selector lever into position “N”.
Note
The selector lever handle is removed together with the selector

lever boot.
– Carefully pry out selector lever boot at the side in direction of

-arrows- using removal wedge - 3409- and turn selector lever
boot inside out over selector lever handle.
– Use a cable tie to secure the interlock button in pulled-out po‐

sition -arrow-, as shown in the illustration.

– Turn selector lever boot -1- inside out over selector lever han‐
dle -2-.
– Release clamp -arrow- and detach selector lever handle to‐
gether with selector lever boot. Avoid touching the interlock
button.
Installing
Note
♦ To install the selector lever handle the interlock button has to

be pulled out to the stop and must be secured with either a
cable tie -arrow- or with the assembly aid supplied together
with the new handle.
♦ If, by mistake, the interlock button has not been secured, it
must not be pulled out of the selector lever handle by means
of mechanical tools. Apply a compressed-air gun at the bottom
of the handle and press the interlock button out with com‐
pressed air.
– Attach new clamp -arrow- to selector lever handle.

– Place selector lever handle fully on selector lever - interlock
button points towards the driver.
• The handle must engage in the annular groove on the selector
lever.
– Remove the cable tie or assembly aid, allowing the interlock
button mechanism to engage in the vertical groove on the se‐
lector lever. If necessary, press the interlock button into the
selector lever handle.
– Move selector lever to positions “R” and “S” to check button
mechanism.
• If the selector lever cannot be moved into the above positions,
the handle must be removed again ⇒ page 41 .
– Secure selector lever handle -2- on selector lever by tightening
clamp -arrow- using hose clip pliers - V.A.G 1275- .
– Clip retaining frame for selector lever boot -1- onto centre con‐
sole.
2.8.2 Detaching selector lever boot from se‐

lector lever handle - vehicles up to mod‐
el year 2011 except for RS 5
Removing
– Remove selector lever handle ⇒ page 41 .
– Tie together spring tips -1- on selector lever handle using cable
tie -3- as shown in illustration.
– Slide sleeve -2- of selector lever boot past retaining tabs on
spring tips -arrow-.
– Remove cable tie and detach sleeve with selector lever boot
from selector lever.
Installing
• Fitting location: the longer side of the retaining frame for the
selector lever boot faces the driver's side.
– Install selector lever handle ⇒ page 41 .

handle with interlock button (side) - ve‐
hicles from model year 2012 onwards
♦ Thin cable tie or assembly aid for interlock button on handle.

A new selector lever handle is supplied with the assembly aid
pre-fitted.
Removing
ing brake.
Note

lever boot.
– Carefully pry out selector lever boot at the sides in direction of

-arrows- using removal wedge - 3409- .

– Pull out interlock button on selector lever handle -arrow- and

secure in this position using cable tie -A- or assembly aid -B-
as shown in illustration.
Note
The assembly aid -B- is pre-fitted at the factory on a new selector

lever handle. The assembly aid must not be removed until the
new handle has been installed. This assembly aid can then be
kept for future use as a locking tool.
dle -3-.
– Turn locking ring as far as stop in direction of -arrow- so that
markings -a- and -b- are no longer in line.
– Pull off selector lever handle together with selector lever boot,
taking care not to touch interlock button -1-.
Installing
• When installing the selector lever handle, the interlock button
must be pulled out to the stop and secured with either a cable
tie -A- or with the assembly aid -B- supplied together with the
new handle.
If the interlock button was not properly secured when the handle
was removed, and has dropped inside the handle, it must be
pulled out and secured as described below before it can be in‐
stalled.
– Affix adhesive pad or double-sided adhesive tape -2- to inter‐
lock button -1- on selector lever handle.
Note
♦ Alternatively, a small suction cup can also be used (approx

15 mm dia., commercially available).
♦ The adhesive pad or double-sided adhesive tape must be
completely removed after installing the handle.
– Press a suitable tool -3- with clean, flat surface onto adhesive
surface as shown in illustration and pull out interlock button by
this means -arrow-.
– Secure interlock button in pulled-out position using cable tie
-A- or assembly aid -B-, as shown in illustration.
– Remove adhesive pad or double-sided adhesive tape -2- and
clean interlock button -1-.
Note
The selector lever can be moved by pulling the release rod -1-.
dle -4-.
– With interlock button facing driver's side, push selector lever
handle fully onto selector lever so that catch engages.

– Turn locking ring in direction of -arrow- until it engages; mark‐

ings -a- and -b- should be in line.
Caution
Risk of damage to selector lever handle

♦ The locking ring can only be turned when the handle has
been pushed on all the way.
– Remove the cable tie or assembly aid, allowing the interlock

button mechanism to engage in the vertical groove on the se‐
lector lever. If necessary, press the interlock button into the
selector lever handle.
– Move selector lever to positions “R” and “D/S” to check button
mechanism.
– Pull selector lever boot down and clip onto multimedia system
operating unit - E380- .

handle with interlock button (front) - ve‐
hicles from model year 2012 onwards
and RS 5/RS 4
♦ Thin cable tie or assembly aid for interlock button on handle.

A new selector lever handle is supplied with the assembly aid
pre-fitted.
Removing
ing brake.
Note

lever boot.
– Carefully pry out selector lever boot at the sides in direction of

-arrows- using removal wedge - 3409- .
dle -3-.
– Pull off selector lever handle -3- together with selector lever
boot -1-, taking care not to touch interlock button -2-.
Installing
– Turn locking ring in direction of -arrow- as far as stop.
• Markings -a- and -b- should not be in line.
• Interlock button faces direction of travel.
Caution
Risk of damage to the selector mechanism.

♦ The interlock button -2- must protrude from the selector
lever handle during installation. If the interlock button was
pressed in by mistake when the handle was removed, the
interlock button must be moved back to its installation po‐
sition ⇒ page 49 .
♦ If the interlock button has been pressed in and the handle
is installed with the interlock button in this position, the
handle and the pull rod of the selector mechanism -1- will
be damaged irreparably.
– Carefully press selector lever handle -3- fully onto selector

lever, taking care not to touch interlock button -2-.
• The handle must engage in the annular groove on the selector
lever.

– Turn locking ring in direction of -arrow- as far as stop.

• It must be possible to turn the locking ring; press handle -2- if
necessary.
• Markings -a- and -b- should be in line.
Note
♦ The handle is not locked until the locking ring has been turned.
Only then should you press the interlock button on the handle.
♦ There may be increased resistance when you press the inter‐
lock button for the first time after installation.
– Press interlock button -1- on selector lever handle.

– Move selector lever to positions “R” and “D/S” to check button
mechanism.
– Pull selector lever boot down and clip onto multimedia system
operating unit - E380- .
2.8.5 Moving interlock button (front) on selec‐

tor lever handle into installation position
- vehicles from model year 2012 on‐
wards and RS 5/RS 4
♦ Release tool - T40203-
Procedure
• Installation position: The interlock button -1- must protrude
from the selector lever handle.
If the interlock button has been pressed in, it must be moved back
into its installation position so that the selector lever handle can
be installed.
Note
For illustration purposes, the handle is shown without the selector

lever boot in the following steps.
– Carefully insert release tool - T40203- into selector lever han‐

dle -1- as far as stop.
• Recess on release tool - T40203- should face interlock button,
hook should point towards left.
– Hold selector lever handle -A- and turn release tool - T40203-
180° in direction of -arrow 1-.
– Hold handle and carefully pull out release tool - T40203-
-arrow 2-.

• When pulling out release tool - T40203- , interlock button -A-

on selector lever handle is pressed out and locked in position.
• Do not touch interlock button on selector lever handle before
installing handle so that interlock button is not pressed in
again.
2.9 Removing and installing selector lever

position display - Y26-
Removing
ing brake.
– Shift selector lever to position “S” or “D/S”.
– Release retaining spring -2- and detach selector lever position

display - Y26- -item 1- -arrow-.
– Unplug electrical connector.
Installing
Perform installation in reverse sequence of removal.
2.10 Removing and installing selector lever cable
Special tools and workshop

equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Socket and key - T40031-
Removing
ing brake.
– Shift selector lever to position “D” or “D/S”.

– Insert socket and key - T40031- through access hole -arrow-

in selector mechanism and slacken bolt on selector lever cable
approx. one turn.
Note
♦ Only loosen clamping bolt – do not remove.

♦ Clamping bolt can only be accessed with selector lever in po‐
sition “D” or “D/S”.
♦ With clamping bolt loosened, selector lever must remain in
position “D” or “D/S”.

frame .

cross brace .
Caution

properly installed.
Note
The following step is to facilitate access.

– Remove front exhaust pipe/front silencer ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencers; Exploded view - silencers .
Vehicles with twin exhaust system:
– Remove front silencers (left and right) ⇒ Rep. gr. 26 ; Exhaust

WARNING
Risk of accident.
left unattended.
– Lower gearbox by dimension -a- using engine and gearbox

jack - V.A.G 1383 A- .
• Dimension -a- = 70 mm (maximum)
– If fitted, remove nuts -arrows-.

– Lower cover for vehicle underbody (on inside) until heat shield
-1- for centre tunnel can be removed.

– Remove securing clips -1- from noise insulation -2- (if fitted).
– Detach noise insulation from shift unit -4- and slide noise in‐
sulation forwards over selector lever cable -3-.

gearbox.
Note
Depending on the version, a lock nut may be fitted instead of the

retaining clip.
Note
– Pull out retaining clip -1- for selector lever cable from the side.
– Pull selector lever cable -2- out of selector mechanism.
Installing
Note
♦ Renew O-ring on selector lever cable.

♦ Renew securing clips for noise insulation.
♦ Before installing, lightly grease cable eye and ball socket on
selector lever cable with polycarbamide grease - G 052 142
A2- .
– Fit O-ring -1- on selector lever cable.

– Insert selector lever cable -2- into shift unit -arrow-.
– Secure selector lever cable -2- with retaining clip -3-.
• Installation position: angled end of retaining clip -1- must point

towards selector mechanism.
– Press gearbox selector lever -1- on gearbox towards the rear

as far as it will go -arrow- until parking lock engages.
Note
When the parking lock has engaged it should no longer be pos‐

sible to rotate both front wheels in one direction at the same time.
– Then push gearbox selector lever forward 3 notches so that

gearbox is in position “D” or “D/S”.
– Check that selector lever is also in position “D” or “D/S” inside
the vehicle.

– Carefully press ball socket -2- of selector lever cable onto

gearbox selector lever in this position.
Note
Take care not to bend gearbox selector lever when pressing on

cable; support lever if necessary, as otherwise selector mecha‐
nism can no longer be adjusted accurately.
– Secure selector lever cable with retaining clip -1-.

– Depending on the version, a lock nut may be fitted instead of
the retaining clip -1- (tightening torque for lock nut: 13 Nm).
Note

ers .
2.11 Checking and adjusting selector lever

cable
Procedure
ing brake.
– Shift selector lever to position “D” or “D/S”.

approx. one turn.
Note

– Carefully move selector lever slightly forwards and backwards,

without shifting lever into a different selector lever position.
The selector lever cable is thereby slackened.
– Shift selector lever into “tiptronic gate”.
– Use socket and key - T40031- to tighten clamping bolt in this
position, taking care not to touch selector lever.
• After adjusting selector lever cable, run appropriate “Guided
Function” on vehicle diagnostic tester ⇒ page 231
If selector mechanism is not functioning correctly after adjusting
selector lever cable, proceed as follows:
– Adjust selector lever cable to basic setting ⇒ page 58 .
2.12 Adjusting selector lever cable to basic

setting
♦ Vehicle diagnostic tester

Procedure
• Guided Fault Finding using the vehicle diagnostic tester
has been completed; all faults repaired.
– Using the diagnostic tester in “Guided Fault Finding” mode, go
to Function/Component Selection and select the following
menu items:
♦ Drive system
♦ 0B5 gearbox
♦ 01 - Self-diagnosis-compatible systems
♦ 02 - Gearbox electronics
♦ 02 - Gearbox electronics, Functions
♦ 02 - Measured values
– Select the value for Gear from the menu.
– Compare the following readings:
♦ Value for Gear on vehicle diagnostic tester
♦ Selector lever position
♦ Gear indicated on selector lever position display - Y26- (on
selector mechanism)
♦ Selector lever position display - Y6- in instrument cluster
Requirement:
• The displays should match
If the displays do not match:
If the displays cannot be matched by adjusting the selector lever

cable:
Adjust selector lever cable to basic setting:
Note
♦ Do not bend or kink the selector lever cable.

♦ Item -1- can be disregarded.
– Press gearbox selector lever -1- on gearbox towards the rear

as far as it will go -arrow- until parking lock engages.
Note
When the parking lock has engaged it should no longer be pos‐

sible to rotate both front wheels in one direction at the same time.
– Then push gearbox selector lever forward 3 notches so that

gearbox is in position “D” or “D/S”.
– Check that selector lever is also in position “D” or “D/S” inside
the vehicle.

approx. one turn.
Note

– Detach socket and key - T40031- from torque wrench and

leave it inserted in access hole -arrow- in selector mechanism.

– Carefully press ball socket -2- of selector lever cable onto

gearbox selector lever in this position.
Note
♦ Take care not to bend gearbox selector lever when pressing

on cable; support lever if necessary, as otherwise selector
mechanism can no longer be adjusted accurately.
♦ -Item 1- can be disregarded.
– With vehicle diagnostic tester in Guided Fault Finding mode,

select 02 - Gearbox electronics and the function 02 -
Measured values .
– Select the value for Gear from the menu.

– Compare the following readings:
♦ Value for Gear on vehicle diagnostic tester
♦ Selector lever position
♦ Gear indicated on selector lever position display - Y26- (on
selector mechanism)
♦ Selector lever position display - Y6- in instrument cluster
Requirement:
• The displays should match
– Carefully move selector lever slightly forwards and backwards,

without shifting lever into a different selector lever position.
The selector lever cable is thereby slackened.
– Use socket and key - T40031- to tighten clamping bolt in this
position, taking care not to touch selector lever.
2.13 Renewing selector shaft oil seal

♦ Thrust piece - T10135-
Procedure
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum
chamber partition panel .
– Remove front exhaust pipe/front silencer or front exhaust pipe
or front silencer (right-side) ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers; Exploded view - silencers .
– Vehicles with 4-cylinder TDI engine: remove exhaust gas tem‐
perature sender 4 - G648- ⇒ Rep. gr. 26 ; Exhaust gas
temperature control; Removing and installing exhaust gas
temperature senders .
gearbox.
Note

– Drive out roll pin -1- at selector shaft lever -2- -arrow- until it is
possible to detach selector shaft lever from selector shaft.
Caution
Risk of damage to running surface of selector shaft.

♦ Apply screwdriver with care.
– Push a small screwdriver through the oil seal and pull it out.
– Lubricate outer circumference and space between sealing lips
of new oil seal with ATF.
• Installation position: open side of oil seal points towards gear‐
box
– Fit oil seal onto selector shaft.
– Press in oil seal onto stop using thrust piece - T10135- . Take
care to keep seal straight when installing.
– Before installing gearbox selector lever, knock back roll pin
through lever in opposite direction.
– Push selector shaft lever onto selector shaft and drive in roll
pin.
– Install exhaust gas temperature sender 4 - G648- ⇒ Rep. gr.
26 ; Exhaust gas temperature control; Exploded view - exhaust
gas temperature control .
ers .
– Install plenum chamber partition panel ⇒ General body re‐
3 Removing and installing gearbox

⇒ “3.1 Removing gearbox”, page 64
⇒ “3.2 Installing gearbox”, page 126
⇒ “3.3 Tightening torques for gearbox”, page 136
3.1 Removing gearbox

⇒ “3.1.1 Removing gearbox - vehicles with 4-cyl. petrol engine”,
page 64
⇒ “3.1.2 Removing gearbox - vehicles with 6-cyl. petrol engine”,
page 75
⇒ “3.1.3 Removing gearbox - vehicles with 8-cyl. petrol engine
(RS 5/RS 4)”, page 88
⇒ “3.1.4 Removing gearbox - vehicles with 4-cyl. TDI engine (PR-
TH3/TM4)”, page 99
⇒ “3.1.5 Removing gearbox - vehicles with 4-cyl. TDI engine (PR-
TD1)”, page 108
⇒ “3.1.6 Removing gearbox - vehicles with 6-cyl. TDI engine”,
page 116
3.1.1 Removing gearbox - vehicles with 4-cyl. petrol engine


equipment required
♦ Support bracket - 10 - 222
A-
V.A.G 1383 A-
♦ Used oil collection and ex‐
traction unit - VAS 6622- or
-V.A.G 1782-
♦ Engine bung set - VAS
6122-
♦ Counterhold tool - T10172-
with -T10172/5-
3. Removing and installing gearbox 65

Preparing gearbox support - T40173- :

– Mounting block attached at -position 1- must be removed.
– Mounting block attached at -position 2- must be rotated so that
the longer side faces upwards, as shown in illustration.
Removing
– Bring front wheels into straight-ahead position.
Caution

♦ Observe measures required when disconnecting battery
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting
and connecting battery .

– Disconnect earth wire -2- from battery terminal ⇒ Electrical
system; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .

Vehicles with hydraulic power-assisted steering:

– Extract power steering hydraulic fluid from reservoir -3- with
used oil collection and extraction unit - VAS 6622- .
Note
-Items 1, 2, and 4- can be disregarded.

– Remove engine cover panel -arrows-.

– Pull off retaining clip -1- and move selector lever cable clear.
Note
– Remove bolts -2 … 5- securing gearbox to engine (accessible

from above).
Note
Item -A- can be disregarded.

Note
Bolt -2- secures the starter to the gearbox and has an additional
spacer sleeve -arrow-.
– Set up support bracket - 10 - 222 A- with adapter - 10 - 222

A /3- on suspension turrets (left and right), as shown in illus‐
tration.
– Hook spindles -10 - 222 A /11- onto engine lifting eyes (front
and rear).
– Remove both front wheels.

– Remove cover -1- for drive shaft from wheel housing (both
sides).

– Remove noise insulation -1- and -2- ⇒ General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Removing and instal‐
ling noise insulation .
– Remove bolt -1-.
Note
Caution
Risk of damage to flexible joint in front exhaust pipe.

♦ The flexible joint in the front exhaust pipe must not be bent
further than 10°.
– Unscrew bolts -arrows- and push clamp towards rear.
– Lower front exhaust pipe slightly and tie to cross piece

-arrow-.

propshaft.

T10172/5- ).
– Tie propshaft up to one side.
Note

– Remove propshaft; refer to Workshop Manual “Rear final

drive 0BC” ⇒ Rear final drive; Rep. gr. 39 ; Propshaft; Re‐
moving and installing propshaft , or “Rear final drive 0BF and
0BE - sport differential” ⇒ Rear final drive; Rep. gr. 39 ; Prop‐
shaft; Removing and installing propshaft .
Caution

hands.

nector on gearbox.
– Move electrical wiring harness clear.

– Remove bolts -arrows- for ATF lines.
Note
-Items 1 and 2- can be disregarded.
Vehicles with in-line ATF filter:
Note
Place a cloth below the connection to catch escaping ATF.
– Unscrew bolt -arrow-, detach ATF line -1- from gearbox and
place to one side.
Note

– Pull out retaining clip -arrow- and disconnect ATF line from in-
line ATF filter.
Note
– Seal off open lines and connections with clean plugs from en‐
gine bung set - VAS 6122- .
Vehicles with exchangeable ATF filter:

– Remove bolt -arrow- and detach ATF lines -1, 2- from gearbox.


frame .

cross brace .
Caution

properly installed.
Vehicles with electromechanical power-assisted steering:

– Unplug electrical connector -2- from power steering control
unit - J500- (to do so, release retainer -arrow- and press down
release catch).
– Unplug electrical connector -1- on power steering control unit
- J500- .

– If fitted, remove bolts (left and right) -arrows- and detach heat
shields -1-.

– Detach intermediate steering shaft from steering rack and

telescope shaft upwards ⇒ Running gear, axles, steering;
Rep. gr. 48 ; Steering column; Exploded view - steering col‐
umn .
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Unbolt drive shafts (left and right) from flange shafts on gear‐
box.
– Pull cover -1- off bottom of gearbox -arrow-.
– To slacken bolts for flywheel, counterhold crankshaft with

counter-hold tool - T10355- .
Note
♦ When you then turn the crankshaft, only turn crankshaft in di‐
rection of engine rotation.
♦ -Arrow- can be disregarded.

– Remove 3 bolts -arrow- for flywheel (turn crankshaft 120° in

direction of engine rotation each time).

– Place used oil collection and extraction unit - VAS 6622- below
connection.
– Remove bolts -arrows-, detach hydraulic line -1- from steering
rack and place to one side.

– Remove bolt -1- for starter.
– Detach starter from gearbox but do not remove starter.
– Remove remaining engine/gearbox securing bolts -6 … 10-.
Note
Caution
Risk of leaks on ATF oil pan.

♦ Do not apply gearbox support - T40173- at ATF oil pan.
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐

box support - T40173- (already prepared) underneath gear‐
box.
Gearbox support must be positioned as follows at front of gear‐
box:
• On left side of gearbox, mounting block -2- engages in opening
for flywheel on gearbox housing.
• On right side of gearbox, gearbox support is applied to differ‐
ential housing. Place flat rubber block -1- between the two to
protect housing.

– Use tensioning strap -1- to secure gearbox.
Note
The illustration does not show engine and gearbox jack - V.A.G
1383 A- .
– Detach gearbox from engine and lower carefully using engine

and gearbox jack - V.A.G 1383 A- .
3.1.2 Removing gearbox - vehicles with 6-cyl. petrol engine


equipment required
A-
V.A.G 1383 A-
-V.A.G 1782-
6122-
with -T10172/5-
♦ Adapter - T40058-

♦ Articulated wrench, 12 mm - T40220-

Removing
Caution

tery.

battery .


Note
Vehicles with 3.2 ltr. FSI engine:

– Remove engine cover panel (rear) -top arrows-.
Vehicles with 3.0 ltr. TFSI engine:

– Lift off engine cover panels -1- and -2-.

Vehicles with 3.0 ltr. TFSI evo engine:

– Carefully detach engine cover panel from retaining studs one
by one in direction of -arrows-.

sides).



– Remove nuts -arrows- and bolt -1-, detach catalytic converter

(right-side) from exhaust manifold and press to right side of
vehicle.
Note
To loosen securing nuts -arrow- on catalytic converter (right-side)

-A-, use articulated wrench, 12 mm - T40220- .
– Remove bolt -arrow- for ATF lines.

Note
– Remove bolts -arrows- and detach ATF line -1- from gearbox.
Note


line ATF filter.
Note
– Tie up ATF lines -1- and -2-.
Note
Note
– Remove bolts -arrows-, detach ATF lines -1, 2- from ATF filter
housing and tie up.


– If fitted, remove bolt -arrow- and move coolant circulation
pump - V50- to side.

Note

from above).
Note
– Attach a nut loosely to catalytic converter (right-side) to pre‐

vent it from dropping.
Vehicles with 3.0 ltr. TFSI engine:

– Set up support bracket - 10 - 222 A- with adapter -T40093/6-
on suspension turrets (left and right), as shown in illustration.
– Hook spindles -10 - 222 A /11- onto engine lifting eyes (left
and right).
– Partly take up weight of engine via the spindles.

Vehicles with 3.2 ltr. FSI engine:

– Set up support bracket - 10 - 222 A- with connecting piece -
T40091/3- on suspension turrets (left and right), as shown in
illustration.
– Hook spindle -10 - 222 A /11- onto engine lifting eye (right-
side).
– Attach remaining parts of support bracket - 10 - 222 A- as

shown in illustration. Set up support -T40093/3- on metal
flange of longitudinal member.
– Hook spindle -10 - 222 A /11- onto engine lifting eye (left-side).

frame .

cross brace .
Caution

properly installed.


release catch).
– Unplug electrical connector -1- on power steering control unit
- J500- .

– Remove bolts (left and right) -arrows- and detach heat shields
-1-.
(right-side).
(left-side).
box.

propshaft.

T10172/5- ).
Note


Caution

hands.

nector on gearbox.

– Disconnect electrical connector -2- at engine speed sender -

G28- and move wiring clear at gearbox.
Note

umn .
– Remove bolt -1-, press retainer off gearbox and swivel back
towards rear -arrow-.

– Insert guide stud of adapter -T40058- as follows:

• The larger diameter -arrow 1- faces engine.
• The smaller diameter -arrow 2- faces adapter.

adapter - T40058- and angled ring spanner.
Note
rection of engine rotation -arrow-.
♦ The illustration shows a 3.0 ltr. TFSI engine.
– Remove 6 bolts -arrow- for flywheel (turn crankshaft 60° in di‐

rection of engine rotation each time).

connection.


Note
Caution


box.
box:
protect housing.
Note
1383 A- .

3.1.3 Removing gearbox - vehicles with 8-cyl. petrol engine (RS 5/RS 4)


equipment required
V.A.G 1383 A-
-V.A.G 1782-
6122-
♦ Turning over tool - T40257-
♦ 21 mm spanner - T40263-


Removing
Caution

tery.

battery .

Note



Note

from above).
Note
– Move electrical wiring harness clear at top of gearbox.

sides).



Note



frame .

cross brace .
Note
Different types possible depending on model and equipment ver‐

sion.
Caution

properly installed.

-1-.
(right-side).
(left-side).
box.
– Remove nut -2-.
Note


gearbox.
– Pull off clip -1- and disconnect ATF line.
– Unscrew bolt -4-, detach ATF line -3- from gearbox and place
to one side.
Note
Note
Items marked -2- and -arrow- can be disregarded.

gearbox.
– Pull off clip -1- and disconnect ATF line.
– Unscrew bolt -4-, detach ATF line -3- from gearbox and place
to one side.
Note

– Unplug electrical connectors and move wiring clear:
1- to solenoid valve for power assisted steering - N119- (vehi‐
cles with hydraulic power assisted steering)
2- at engine speed sender - G28-

– Unplug electrical connector at gearbox oil temperature sender

2 - G754- .
Caution

hands.
– Touch gearbox housing with your hand (without gloves) to dis‐

charge any static electricity.

nector on gearbox.
– Move wiring harness clear -arrows-.

umn .


– Press bracket off gearbox and swivel towards rear -arrow-.
Note
– Fit turning over tool - T40257- onto 21 mm spanner - T40263- .

– Apply turning over tool - T40257- to bolts on vibration damper.
• The semi-circular recess -arrow A- on turning over tool -
T40257- faces semi-circular recess -arrow B- on vibration
damper..
– To slacken bolts for flywheel, counterhold crankshaft with turn‐
ing over tool - T40257- and 21 mm spanner - T40263- .
Note
♦ Disregard notch on turning over tool - T40257- .

rection of engine rotation -arrow-.



connection.

release catch).
– Unplug electrical connector -1-.

– Remove bolt -1- and push heat shield for starter slightly to one
side.
Note


Note
On vehicles with electromechanical power steering, bolt -7- has

a nut with locking element on the engine side.
Note
Caution


box.
box:
protect housing.

Note
1383 A- .

3.1.4 Removing gearbox - vehicles with 4-cyl. TDI engine (PR-TH3/TM4)

equipment required
A-
V.A.G 1383 A-
-V.A.G 1782-
6122-
with -T10172/5-


Removing
Caution


battery .


– Remove exhaust gas temperature sender 4 - G648- -item 1-

⇒ Rep. gr. 26 ; Exhaust gas temperature control; Removing
and installing exhaust gas temperature senders .

Note
– Release fastener -arrow- and move coolant circulation pump

- V50- -item 1- to one side.

– Remove engine/gearbox securing bolts -2, 4, 5- (accessible

from above).
Note
Bolt -3- is removed from below.
Note
– Set up support bracket - 10 - 222 A- with adapter - 10 - 222

A /3- on suspension turrets (left and right), as shown in illus‐
tration.
– Hook spindles -10 - 222 A /11- onto engine lifting eyes (front
and rear).

sides).


– Remove front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes/

Note



Caution

hands.

nector on gearbox.
Note
Note
– Remove bolts -arrows-, detach ATF lines -1- and -2- from
gearbox and tie up.


cross brace .
Caution

properly installed.

release catch).
Note
shields -1-.

umn .

(right-side).
box.
– Remove trim cap from vibration damper.

– To slacken bolts for flywheel, counterhold crankshaft with an‐
gled ring spanner -1- at central bolt on vibration damper.
Note
When you then turn the crankshaft, only turn crankshaft in direc‐
tion of engine rotation -arrow-.



– Remove remaining engine/gearbox securing bolts
-3, 6 … 10-.
Note
Bolt -item 3- in previous illustration can be accessed using an

articulated socket wrench -arrow-.
Note
Caution


box.
box:
protect housing.

Note
1383 A- .

3.1.5 Removing gearbox - vehicles with 4-cyl. TDI engine (PR-TD1)

equipment required
V.A.G 1383 A-
-V.A.G 1782-
6122-
with -T10172/5-

♦ Piston compressing tool - T40142-


Removing
Caution


battery .
– Carefully detach engine cover panel from retaining studs one

by one in direction of -arrows-. Pull out engine cover panel
evenly, without jerking.

Note
Depending on the version, a lock nut may be fitted instead of the

retaining clip.

from above).

Note

sides).


cross brace .
Caution

properly installed.
– Remove SCR catalytic converter ⇒ Rep. gr. 26 ; Emission

control system; Removing and installing catalytic converter .

– Remove bolt -2- for retainer.

– Push retainer -1- in direction of -arrow B- and pivot to the rear
-arrow A-.
Note
The exhaust pipe remains installed.
Note


Caution

hands.

nector on gearbox.

Note
– Remove bolts -1- and -2-, detach ATF lines -3- and -4- from
gearbox and tie up.

release catch).
Note
shields -1-.

umn .

(right-side).
box.
– Remove trim cap from vibration damper.

– To slacken bolts for flywheel, counterhold crankshaft with an‐
gled ring spanner -1- at central bolt on vibration damper.
Note



Note
Caution


box.
box:
protect housing.
Note
1383 A- .

– Loosen bolt -1- for torque reaction support -2-.

– Lower gearbox using engine and gearbox jack - V.A.G 1383
A- just enough so that torque reaction support is positioned at
very bottom of its adjustment range -arrow-.
– Tighten bolts and insert piston compressing tool - T40142- as
a spacer, as shown in illustration.
3.1.6 Removing gearbox - vehicles with 6-cyl. TDI engine

equipment required
A-
V.A.G 1383 A-
-V.A.G 1782-
6122-
with -T10172/5-

♦ Adapter - T40058-


Removing
Caution

tery.

battery .

Note


sides).


– Remove front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes/

– Remove particulate filter ⇒ Rep. gr. 26 ; Emission control

system; Removing and installing particulate filter .


Note
Note
– Remove bolts -arrows- and detach ATF line -1- from gearbox.
Note
Note

line ATF filter.
Note

– Tie up ATF lines -1- and -2-.
Note
Note
– Remove bolts -arrows-, detach ATF lines -1, 2- from ATF filter
housing and tie up.

from above).
Note

– Set up support bracket - 10 - 222 A- with -10 - 222 A /1- on

suspension turrets (left and right), as shown in illustration.
– Hook spindle -10 - 222 A /11- onto engine lifting eye (front left).
– Partly take up weight of engine with spindle.

frame .

cross brace .
Caution

properly installed.
-1-.

(right-side).
box.
Caution

hands.

nector on gearbox.
– Disconnect electrical connector -2- at engine speed sender -

G28- and move wiring clear at gearbox.
Note

umn .

propshaft.

T10172/5- ).
Note






adapter - T40058- .
Note


connection.


Note
Caution

– Place gearbox on prepared engine support - T40173- .

box:
protect housing.
Note
1383 A- .

3.2 Installing gearbox


♦ Ring spanner insert, 16 mm - V.A.G 1332/14-
♦ Assembly aid - T40169-
♦ Transportation lock - T40170-

Tightening torques for installing gearbox ⇒ page 136

Procedure
Note
♦ Renew bolts which are tightened by turning through a speci‐

fied angle.
♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Hose connections and air pipes and hoses must be free from
oil and grease before fitting.
♦ Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Electronic parts catalogue .
♦ To ensure that the air hoses can be connected securely, you
must spray the screw threads on used screw-type clips with
rust remover prior to installation.
♦ Re-attach all cable ties at the same locations when re-instal‐
ling.
There are two different types of ATF filter, depending on the en‐
gine version and date of manufacture. In-line ATF filter -5- and in-
line ATF filter -10-.
♦ The exchangeable ATF filter -10- must be renewed every time
the ATF is changed or the gearbox is repaired.
♦ The in-line ATF filter -5- must be renewed when the gearbox
is renewed or if the ATF is very dirty. Removing and installing
⇒ page 178 .
Caution
Risk of damage to components.

When a gearbox with in-line ATF filter -5- is replaced with a
gearbox with exchangeable ATF filter -10-:
♦ the ATF supply line and ATF return line must be renewed
⇒ page 153 . The ATF lines are NOT interchangeable.
Leakage and damage to the ATF lines will occur if the ATF
lines are not renewed.
♦ The exchangeable ATF filter -10- must be renewed every
time the ATF is changed in the future. Please make ap‐
propriate entries in the vehicle data and repair history. An
exchangeable ATF filter change may not be shown auto‐
matically in the Maintenance tables.
♦ If a gearbox with exchangeable ATF filter is fitted, ensure
that a breather hose is installed ⇒ page 129 .

Checking that breather hose is properly installed - vehicles with

exchangeable ATF filter in gearbox:
• Angled connector of breather hose -2- must be pressed onto
connection -1-.
– If loose, press angled connector on until it engages audibly.
– Check that the two mounting clips -4- are seated in the correct
position on the ribs -5- of the housing:
• The distance -a- between mounting clip (rear) and housing
flange must measure 130 mm.
• ATF breather -3- must remain clear.
– Clean ATF lines and ATF cooler after renewing or repairing
gearbox ⇒ page 162 .
– Before installing gearbox, it is important to clean any residue
from threads for engine/gearbox connection in cylinder block
using a tap.
Caution


box.
box:
• On right side of gearbox, use a block wrapped with elastic
material -1- to apply gearbox support to centre differential
housing.

– The following preparations must be made before joining the

engine and gearbox:
– Insert assembly aid - T40169- into gearbox housing and fly‐
wheel from below, as shown in illustration.
• The assembly tool must engage in the semi-circular recess
-1- and in the inspection hole -2-.
Note
There is only one inspection hole at the periphery; turn the fly‐
wheel accordingly.
– Insert pin of assembly aid into hole on gearbox housing.
– Insert transportation lock - T40170- into gearbox housing from

below and clamp onto flange shaft -1-.
– Check whether aluminium bolts for engine/gearbox connec‐
tion can be reused and mark bolts if necessary ⇒ page 138 .
Vehicles with 4-cyl. petrol engine:

– Check that dowel sleeves -A- for centralising engine/gearbox
are in the cylinder block; install any missing dowel sleeves.
– Join gearbox with engine and tighten bolts -6- and -7-.

Vehicles with 6-cyl. or 8-cyl. engine:

– Check that dowel sleeves -A- for centralising engine/gearbox
are in the cylinder block; install any missing dowel sleeves.
Note
On vehicles with electromechanical power steering and 8-cylinder

engine, bolt -7- has a nut with locking element on the engine side.
– Join gearbox with engine and tighten bolts -6- and -7-.
Vehicles with 4-cyl. TDI engine (PR-TD1):
– Loosen bolts -1- for torque reaction support -2- and remove
piston compressing tool - T40142- .

– Secure tunnel cross member ⇒ page 139 .
Note
1383 A- .
– Lower engine and gearbox jack - V.A.G 1383 A- with gearbox

support - T40173- and move aside.
– Tighten engine/gearbox connecting bolts accessible from be‐
low.
– Remove transportation lock - T40170- and assembly aid -
T40169- .
Note
The following step is necessary to ensure that the flywheel makes

even and proper contact on the drive plate and does not cant.
– Slightly press flywheel -2- using lever -1- against drive plate
-3- in direction of -arrow-.

Note
Use ring spanner insert, 16 mm - V.A.G 1332/14- , to tighten bolts.
– Secure flywheel to drive plate as follows:

– Install first bolt -arrow- and tighten hand-tight (2 Nm).
– Turn crankshaft at vibration damper 240° in direction of engine

rotation using counterhold tool - T10355- .
– Tighten bolt accessible in this crankshaft position to specified
torque ⇒ page 14 .
– Turn crankshaft 120° further each time and tighten remaining
2 bolts to specified torque ⇒ page 14 .
Note
-Arrow- can be disregarded.
Vehicles with 6-cylinder engine:
Note




rotation -arrow- with adapter - T40058- .
– Turn crankshaft 60° further each time and tighten remaining 5
bolts to specified torque ⇒ page 14 .
Note



rotation -arrow- using turning over tool - T40257- and 21 mm
spanner - T40263- .
– Turn crankshaft 60° further each time and tighten remaining 5
bolts to specified torque ⇒ page 14 .
The remaining installation steps are carried out in reverse se‐
quence; note the following:
– Secure intermediate steering shaft to steering rack ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering column; Exploded
view - steering column .
– Install selector lever cable ⇒ page 51 .
– Electrical connections and routing
– Install ATF lines ⇒ page 153 .
– Secure drive shafts (left and right) to flange shafts of gearbox
⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Exploded view - drive shaft .
– Install heat shield for drive shaft ⇒ page 136 .
Vehicles with 4-cyl. TDI engine (PR-TH3/TM4):
– Install exhaust gas temperature sender 4 - G648- ⇒ Rep. gr.
26 ; Exhaust gas temperature control; Exploded view - exhaust
gas temperature control .
Vehicles with 4-cyl. TDI engine (PR-TD1):
– Adjust and tighten torque reaction support ⇒ Rep. gr. 10 ;
Assembly mountings; Exploded view - assembly mountings .
Note



Note
♦ Bolt -2- secures the starter to the gearbox and has an addi‐
tional spacer sleeve -arrow-.
♦ The spacer sleeve must be fitted between the starter and the
gearbox.

– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Ex‐
ploded view - starter .
– Tighten remaining gearbox/engine securing bolts -3 … 5-.

ers .
– Install hydraulic lines for power steering ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Hydraulic power steering; Ex‐
ploded view - hydraulic lines, reservoir .
– Install covers for drive shafts and noise insulation ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded
view - noise insulation .
necting battery .
Caution
Overvoltage can cause irreparable damage to control units.

♦ Do not use charger for boost starting.
– Check selector lever cable and adjust if necessary

⇒ page 57 .
– Fill up hydraulic fluid for power steering ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Hydraulic power steering; Check‐
ing power steering fluid level .
– ⇒ “7.2 Checking ATF level”, page 146 .
– ⇒ “2.2 Checking gear oil level”, page 193

3.3 Tightening torques for gearbox
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine or gear oil may be used,
but do not use graphite lubricant.
♦ Do not use parts which have been degreased.
♦ Tolerance for tightening torques is ± 15 %.
Component Nm
Bolts and nuts M6 9
M7 15
M8 20
M10 40
M12 65
Heat shield for drive shaft - tightening torque
– Tighten bolts -arrows- for drive shaft heat shield to 23 Nm.
Dual clutch gearbox to 4-cyl. petrol engine

Item Bolt Nm
1 1) M10x50 2) 65
2 3), 7 M12x100 4) 30 + 90°
3 5), 6 M12x75 4) 30 + 90°
4, 5 5) M12x120 4) 30 + 90°
8, 9 M10x75 4) 15 + 90°
10 M12x50 4) 30 + 90°
A Dowel sleeves for centralising
• 1) Also secures starter.
• 2)Property class 10.9; the steel bolt can be re-used any
number of times.
• 3)Also secures starter, with additional spacer sleeve be‐
tween starter and gearbox.
• 4) Bolts can be used twice only ⇒ page 138 .
• 5) Also secures bracket for wiring.

Dual clutch gearbox to 6-cyl. petrol engine

Item Bolt Nm
1 1) M10x50 2) 65
2 1), 3, 4 … 6 M12x100 3) 30 + 90°
7 M12x125 3) 30 + 90°
8 M10x60 3) 15 + 90°
9, 10 M10x60 3) 15 + 90°
number of times.
Dual clutch gearbox to 8-cyl. petrol engine (RS 5, RS 4)

Item Bolt Nm
1 1) M10x50 2) 65
2 1), 3, 4, 5, 6 M12x100 3) 30 +90°
7 4) M12x175 3) 30 +90°
8, 9, 10 M10x60 3) 15 +90°
• 2)Property class 10.9. The steel bolt can be re-used any
number of times.
• 3)Aluminium bolts must not be used more than twice
⇒ page 138 .
• 4)Vehicles with electromechanical power steering: with nut
and washer. Counterhold nut when loosening and tighten‐
ing.

Dual clutch gearbox to 2.0 ltr. TDI engine

Item Bolt Nm
1 1) M10x50 2) 65
2 3) M12x100 4) 30 + 90°
3 5), 6 M12x75 4) 30 + 90°
4, 5 M12x120 4) 30 + 90°
7, 8 M10x40 4) 15 + 90°
9 M12x50 4) 30 + 90°
number of times.
• 3)Also secures starter, with additional spacer sleeve be‐
tween starter and gearbox.
Dual clutch gearbox to 6-cyl. TDI engine

Item Bolt Nm
1 1) M10x50 2) 65
2 1), 4…6 M12x100 3) 30 + 90°
7 M12x125 3) 30 + 90°
8 M10x60 3) 15 + 90°
9, 10 M10x95 3) 15 + 90°
number of times.
♦ Aluminium bolts -2 … 10- can be used twice only. After they

have been used once, an “X” -arrow- must therefore be chi‐
selled onto the bolts.
♦ To prevent damage to the bolts, they must not be clamped in
a vice when marking them. Clamp a 14 mm socket with 1/2"
drive in the vice instead, and insert the bolt into the socket, as
shown in illustration.
♦ Bolts marked with an “X” must not be used again.

4 Assembly mountings
⇒ “4.1 Exploded view - assembly mountings”, page 139
⇒ “4.2 Removing and installing tunnel cross member”,
page 140
⇒ “4.3 Removing and installing gearbox support with gearbox
mounting”, page 142
⇒ “4.4 Removing and installing gearbox mounting”, page 143
4.1 Exploded view - assembly mountings
1 - Nut
❑ 20 Nm
2 - Bolt
❑ 70 Nm
3 - Bolt
❑ 40 Nm
4 - Nut
❑ 20 Nm
5 - Gearbox support
stalling gearbox support
with gearbox mounting”,
page 142
6 - Gearbox mounting
stalling gearbox mount‐
ing”, page 143
7 - Stop (bottom)
❑ For gearbox mounting
8 - Bolt
❑ 20 Nm
9 - Tunnel cross member
stalling tunnel cross
member”, page 140
❑ On some versions an
additional air deflector is
bolted to the underside
of the tunnel cross
member to cool the self-
locking centre differen‐
tial ⇒ page 140
4. Assembly mountings 139

Air deflector -A-

♦ Tightening torque for bolts -arrows-: 3 Nm
4.2 Removing and installing tunnel cross

member

Removing
– Remove rear noise insulation -2- ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
Audi RS 5, RS 4:
– Remove bolts -arrows- and detach air deflector -A-.

Note
If the tunnel cross member is being removed in order to check or

top up the gear oil level (MTF), the gearbox must be brought back
to the normal position after the tunnel cross member is removed.
Only then can the gear oil level be topped up correctly
⇒ “2.2 Checking gear oil level”, page 193 .
WARNING
Risk of accident.
left unattended.

– Unscrew nuts -arrows- and remove tunnel cross member.

Installing
Tightening torques:
• ⇒ “4.1 Exploded view - assembly mountings”, page 139 .
• ⇒ Fig. ““Air deflector -A-”“ , page 140 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .
4.3 Removing and installing gearbox sup‐

port with gearbox mounting
Removing
– Remove tunnel cross member ⇒ page 140 .
– Remove bolts -arrows- and detach gearbox support from gear‐
box together with gearbox mounting.
Installing

4.4 Removing and installing gearbox

mounting
Removing
– Remove gearbox support together with gearbox mounting
⇒ page 142 .
– Remove bolts -1- and detach stop -2- (bottom) for gearbox
mounting.
– Remove nut -4- and detach gearbox mounting -5- from gear‐
box support -3-.
Installing
– Fit gearbox support -3- on gearbox mounting -5-.
– Hand-tighten nut -4-.
– Tighten bolts -1- for stop (bottom) -2-.
– Tighten nut -4-.
– Install gearbox support with gearbox mounting ⇒ page 142 .

5 Transporting gearbox
• Gearbox removed
dual clutch gearbox; Rep. gr. 34 ; Transporting gearbox .

6 Securing to engine and gearbox sup‐

port
• Gearbox removed
dual clutch gearbox; Rep. gr. 34 ; Securing to engine and gearbox
support .
6. Securing to engine and gearbox support 145

7 ATF
⇒ “7.1 Exploded view - drain, filler and inspection plugs”,
page 146
⇒ “7.2 Checking ATF level”, page 146
⇒ “7.3 Draining and filling ATF”, page 149
7.1 Exploded view - drain, filler and inspec‐

tion plugs
Note
All repair work and tightening torques are also described in Work‐
shop Manual “Servicing 7-speed dual clutch gearbox 0B5 (S
tronic)”.
1 - ATF drain plug

❑ Tightening torque: 45
Nm
2 - Seal
❑ For ATF drain plug
❑ Renew
3 - Filler and inspection plug for
gear oil (MTF)
❑ In gearbox section, front
final drive and transfer
box
Nm
4 - ATF filler and inspection
plug
Nm
5 - Drain plug for gear oil (MTF)
Nm
❑ On some versions the
gearbox oil temperature
sender 2 - G754- also
serves as a drain plug
for the gear oil (MTF);
tightening torque, re‐
moving and installing
⇒ page 200
7.2 Checking ATF level


♦ Used oil collection and extraction unit - VAS 6622-
♦ Safety goggles
Caution

clutch gearbox 0B5.
Note
♦ The ATF temperature is taken from the reading on the vehicle

diagnostic tester .
♦ The ATF level will vary according to the ATF temperature.
♦ If the ATF level is checked when the ATF temperature is too
low, this will result in overfilling.
♦ If the ATF level is checked when the ATF temperature is too
high, this will result in underfilling.
♦ Both overfilling and underfilling will impair the function of the
gearbox.
Test conditions
• Gearbox must not be in emergency running (backup) mode.
• Vehicle must be absolutely horizontal (drive it onto a four pillar
lifting platform or over an inspection pit).
• Selector lever at position “P”.
• Parking brake button must be pulled up to apply the electro‐
mechanical parking brake.
• Extraction hose of an exhaust gas extractor connected and
extractor switched on.
• Air conditioner and heating system switched off.
• Vehicle diagnostic tester is connected.
7. ATF 147
• The ATF temperature must not be higher than approx. 30°C

at the beginning of the test (the temperature will rise during the
test).
Checking ATF level
– Using the diagnostic tester in “Guided Fault Finding” mode, go
to Function/Component Selection and select the following
menu items:
♦ Drive system
♦ 0B5 gearbox
♦ 01 - Self-diagnosis-compatible systems
♦ 02 - Gearbox electronics
♦ 02 - Gearbox electronics, Functions
♦ 02 - Measured values
– Select the value for Gearbox oil temperature (ATF) from
the menu.
– Read off ATF temperature.
Caution

♦ The engine must not be started if only a little or no ATF
remains in gearbox after repair work or after excessive
ATF leakage.
♦ In this case the gearbox must be filled with ATF before
proceeding further ⇒ page 149 .

noise insulation .
– Start engine with selector lever in position “P”.
– With brake pedal still depressed, select all gear positions (“P”,
“R”, “N”, “D”, “S” or “D/S”) one after the other at idling speed,
maintaining each position for at least 2 seconds.
– Allow engine to continue running at idling speed.

gearbox.
WARNING
Risk of eye injury.

♦ Wear safety goggles.
– When ATF reaches temperature of 30 ℃, unscrew ATF in‐

spection plug -arrow-.
• The ATF level is correct if a small amount of fluid comes out
at the ATF inspection plug when the ATF temperature is be‐
tween 30 °C and 50 °C. If this is not the case, top up ATF
⇒ page 149 .
Note
The ATF inspection plug must be screwed in again before the ATF
reaches a temperature of 50 °C.
– Tighten ATF inspection plug; for tightening torque refer to

⇒ “7.1 Exploded view - drain, filler and inspection plugs”, page
146 .
7.3 Draining and filling ATF

♦ ATF filling unit - V.A.G 1924-
♦ Safety goggles
7. ATF 149
Caution

in the gearbox.
Note
Always adhere to waste disposal regulations.
Draining ATF
• Engine not running.
• Selector lever at position “P”.
• Parking brake button must be pulled up to apply the electro‐
mechanical parking brake.
noise insulation .
gearbox.
WARNING
Risk of eye injury.

– Remove ATF drain plug -arrow- and allow ATF to drain off.
– Renew seal for ATF drain plug.
– Tighten ATF drain plug. Tightening torque
146

Caution

• Depending on engine and equipment version, two differ‐
ent filter versions are possible: in-line ATF filter -5- and
exchangeable ATF filter -10-.
• The exchangeable ATF filter -10- must be renewed every
time the ATF is changed ⇒ page 180 .
Filling gearbox with ATF
Caution

clutch gearbox 0B5.
♦ The engine must not be started if only a little or no ATF
remains in gearbox after repair work or after excessive
ATF leakage.
– Fill reservoir of ATF filling unit -V.A.G 1924- with ATF for dual
clutch gearbox 0B5. For ATF specification refer to ⇒ Elec‐
tronic parts catalogue .
– Secure reservoir for ATF filling unit -V.A.G 1924- as high as
possible on vehicle.
7. ATF 151
– Remove ATF inspection plug -arrow-.

– Insert filler nozzle of ATF filling unit -V.A.G 1924- into ATF in‐
spection hole.
– Fill with ATF using ATF filling unit - V.A.G 1924- until ATF
comes out of inspection hole.
– Start engine and turn off after 20 seconds.
– Continue filling with ATF using ATF filling unit - V.A.G 1924-
until ATF comes out of inspection hole.
– Start engine and allow to run at idling speed.
– Continue filling with ATF using ATF filling unit - V.A.G 1924-
until ATF comes out of inspection hole again.
– Fit ATF inspection plug.
– Check ATF level ⇒ page 146 .

8 ATF circuit
⇒ “8.1 Exploded view - ATF circuit”, page 153
⇒ “8.2 Cleaning ATF lines”, page 162
⇒ “8.3 Removing and installing ATF lines”, page 164
⇒ “8.4 Removing and installing ATF filter”, page 178
⇒ “8.5 Removing and installing ATF filter housing and connecting
piece for ATF lines ”, page 186
8.1 Exploded view - ATF circuit

⇒ “8.1.1 Exploded view - ATF cooler, ATF lines and in-line ATF
filter”, page 153
⇒ “8.1.2 Exploded view - ATF cooler, ATF lines and exchangeable
ATF filter”, page 157
8.1.1 Exploded view - ATF cooler, ATF lines

and in-line ATF filter
Exploded view - ATF cooler, ATF lines and in-line ATF filter - ve‐
hicles with 4-cyl. and 6-cyl. engine
Note
♦ There are two different types of ATF filter, depending on the

engine version and date of manufacture. In-line ATF filter -5-
and in-line ATF filter -10-.
⇒ page 178 .
Note
The illustration shows the ATF line layout on a 6-cyl. engine.
8. ATF circuit 153

1 - ATF cooler
❑ Integrated in radiator for
engine coolant
⇒ Rep. gr. 19 ; Radia‐
tor/radiator fans; Re‐
moving and installing ra‐
diator
2 - O-ring
❑ Renew
❑ Lightly lubricate with
ATF before inserting
3 - ATF pipe/hose assembly
(return)
❑ First push in ATF pipe/
hose assemblies with
new O-rings by hand as
far as stop
❑ Cleaning ⇒ page 162
4 - O-ring
❑ Renew
(supply)
far as stop
6 - Bolts
❑ 5 Nm
7 - Union nut
❑ 29 Nm
8 - Bolt
❑ 9 Nm
9 - Bolt
❑ 9 Nm
❑ Mark for reconnection to ATF pipe/hose assembly
❑ Removing and installing: Vehicles with 4-cyl. engine ⇒ page 164 ; vehicles with 6-cyl. engine
⇒ page 166
❑ Mark for reconnection to ATF pipe/hose assembly
❑ Removing and installing: Vehicles with 4-cyl. engine ⇒ page 164 ; vehicles with 6-cyl. engine
⇒ page 166
12 - Retaining clip
❑ Press onto connection between ATF line and in-line ATF filter and then pull to check that retaining clip
has engaged properly

13 - O-ring
❑ Renew
❑ Lightly lubricate with ATF before inserting
14 - Bolt
❑ 9 Nm
16 - Bolt
❑ 20 Nm
17 - Bolt
❑ First push in ATF lines with new O-rings by hand as far as stop
❑ Retaining tab on bottom ATF line should rest on threaded hole in gearbox
❑ Retaining tab on top ATF line should rest on retaining tab on bottom line
❑ 20 Nm
18 - O-rings
❑ Renew
19 - Union nut
❑ 29 Nm
Exploded view - ATF cooler, ATF lines and in-line ATF filter - ve‐
hicles with 8-cyl. engine
Note

⇒ page 178 .
8. ATF circuit 155

1 - ATF cooler
engine coolant
diator
2 - O-ring
❑ Renew
(supply)
hose assembly with new
O-rings by hand as far
as stop
4 - Bolt
❑ 5 Nm
5 - Bolt
❑ 9 Nm
far as stop
7 - Bolt
❑ 9 Nm
8 - Retaining clip
❑ Press onto connection and then pull to check that retaining clip has engaged properly
9 - O-ring
❑ Cannot be renewed at present. ATF line must be renewed if leakage occurs.
11 - Bolts
❑ 23 Nm
12 - Bolt
❑ 20 Nm
13 - O-rings
❑ Renew
14 - Bolt
❑ Secures ATF line together with bracket for exhaust system at gearbox
❑ 23 Nm
15 - O-ring

16 - Retaining clip
❑ ⇒ “8.3.3 Removing and installing ATF lines - vehicles with 8-cyl. engine”, page 168
18 - Nut
❑ 9 Nm
19 - O-ring
20 - ATF pipe/hose assembly (return)
21 - Retaining clip
22 - Bolt
❑ 5 Nm
23 - O-ring
❑ Renew
8.1.2 Exploded view - ATF cooler, ATF lines

and exchangeable ATF filter
Exploded view - ATF cooler, ATF lines and exchangeable ATF
filter - vehicles with 4-cyl. and 6-cyl. engine
Note

⇒ page 178 .
Note
The illustration shows the ATF line layout on a 6-cyl. engine.
8. ATF circuit 157

1 - ATF cooler
engine coolant
diator
2 - O-ring
❑ Renew
(return)
far as stop
4 - Bolt
❑ 5 Nm
5 - O-ring
❑ Renew
(supply)
far as stop
7 - Bolts
❑ 5 Nm
8 - Bolt
❑ 9 Nm
9 - O-rings
❑ Renew
10 - ATF/oil pipes
❑ Must be renewed if removed
11 - O-rings
❑ Renew
12 - Bolt
❑ 9 Nm
❑ With bracket (depending on version) ⇒ page 159
❑ ⇒ “8.3 Removing and installing ATF lines”, page 164

❑ Retaining tab should rest on threaded hole in gearbox

14 - Bolt
❑ 20 Nm
15 - O-ring
❑ Renew
❑ With bracket (depending on version) ⇒ page 159
❑ ⇒ “8.3 Removing and installing ATF lines”, page 164
❑ Retaining tab should rest on bottom retaining tab
17 - O-ring
❑ Renew
18 - O-ring
❑ Renew
19 - Bolt
❑ 10 Nm
20 - Filter housing
⇒ “8.5 Removing and installing ATF filter housing and connecting piece for ATF lines ”, page 186
❑ Note correct allocation ⇒ Electronic parts catalogue (also called filter element)
❑ Lightly lubricate O-ring on filter with ATF before fitting
22 - O-ring
❑ Renew
❑ 8 Nm
24 - Union nuts
❑ 29 Nm
Bracket for ATF lines - tightening torque

– Tighten bolt -arrow- to 9 Nm.
Exploded view - ATF cooler, ATF lines and exchangeable ATF
filter - vehicles with 8-cyl. engine
8. ATF circuit 159

Note

⇒ page 178 .
1 - ATF cooler
engine coolant
diator
2 - ATF/oil pipes
❑ Must be renewed if re‐
moved
❑ Lightly lubricate O-rings
with ATF before insert‐
ing
3 - O-ring
❑ Renew
installing ATF lines - ve‐
hicles with 8-cyl. en‐
gine”, page 168
5 - O-rings
❑ Renew
installing ATF lines - ve‐
hicles with 8-cyl. en‐
gine”, page 168
7 - Bolt
❑ 20 Nm

❑ Secures ATF supply line and bracket for catalytic converter

8 - Bolt
❑ 20 Nm
❑ First push in ATF return line ( ⇒ Item 4 (page 160) ) and then ATF supply line ( ⇒ Item 6 (page 160) )
with new O-rings into filter housing by hand as far as stop
9 - O-ring
10 - Retaining clip
11 - Bolt
❑ 9 Nm
12 - ATF pipe/hose assembly (supply)
❑ First push in ATF pipe/hose assembly with new O-ring by hand as far as stop
13 - Bolt
❑ 10 Nm
14 - Nut
❑ 5 Nm
15 - Filter housing
⇒ “8.5 Removing and installing ATF filter housing and connecting piece for ATF lines ”, page 186
❑ Lightly lubricate O-ring on filter with ATF before fitting
17 - O-ring
❑ Renew
❑ 8 Nm
19 - Bolts
❑ 5 Nm
20 - O-ring
❑ Renew
21 - ATF pipe/hose assembly (return)
❑ First push in ATF pipe/hose assembly with new O-ring by hand as far as stop
22 - O-ring
23 - Bolt
❑ 5 Nm
24 - O-ring
❑ Renew
8. ATF circuit 161

25 - Retaining clip
26 - Nut
❑ 9 Nm
8.2 Cleaning ATF lines

♦ Hose, approx. 18 mm dia.

♦ Compressed-air gun (commercially available)
♦ Safety goggles
Procedure
Note
⇒ “3.1 Rules for cleanliness”, page 4 .

WARNING
Risk of eye injury.

connections.


– Remove bolt -arrow- and detach ATF line -1- from gearbox.
Note
If in-line ATF filter is not being removed, ATF line to in-line ATF
filter -2- does not have to be disconnected.

line ATF filter.
Note
Disregard -item 2- if not removing in-line ATF filter.

– Blow out ATF lines and ATF cooler with compressed air (not
more than 10 bar).
Note
If the ATF which emerges during cleaning is very dirty, the ATF
cooler and ATF lines must additionally be flushed out with clean
ATF.

– Always renew in-line ATF filter after renewing gearbox or if
ATF is very dirty ⇒ page 178 .
8. ATF circuit 163


– Renew exchangeable ATF filter if ATF is very dirty
⇒ page 180 .
Note
♦ For vehicles equipped with an exchangeable ATF filter, this

filter is supplied together with a new gearbox.
♦ The exchangeable ATF filter must be renewed every time the
ATF is changed.
– Install ATF lines ⇒ page 164 .
8.3 Removing and installing ATF lines

⇒ “8.3.1 Removing and installing ATF lines - vehicles with 4-cyl.
petrol engine”, page 164
⇒ “8.3.2 Removing and installing ATF lines - vehicles with 4-cyl‐
inder TDI engine and with all 6-cylinder engines”, page 166
⇒ “8.3.3 Removing and installing ATF lines - vehicles with 8-cyl.
engine”, page 168
8.3.1 Removing and installing ATF lines - ve‐

hicles with 4-cyl. petrol engine
♦ Engine bung set - VAS 6122-

Removing
Note

connections.
– Mark connections between ATF line/hose assemblies and
ATF lines for re-installation.
– Unscrew union nuts -1- and -2-.
– Remove bolts -arrows- for ATF lines.

– Remove bolt -arrow- and detach ATF line -1- from gearbox.
Note
If in-line ATF filter is not being removed, ATF line to in-line ATF
filter -2- does not have to be disconnected.

line ATF filter.
Note
– Detach ATF lines.
8. ATF circuit 165


Installing
Tightening torques:
• ⇒ “8.1.1 Exploded view - ATF cooler, ATF lines and in-line ATF
filter”, page 153
• ⇒ “8.1.2 Exploded view - ATF cooler, ATF lines and exchange‐
able ATF filter”, page 157
Note
Renew O-rings
Caution

♦ All plugs from engine bung set - VAS 6122- which were
inserted in ATF lines and gearbox when dismantling must
be removed.
♦ If you forget to remove the plugs, the ATF cooling will be
ineffective and the gearbox will be damaged.
– First press ATF lines onto gearbox and cooler by hand until
they engage, then bolt on.
– Press retaining clip onto connection between ATF line and in-
line ATF filter and then pull to check that retaining clip has
engaged properly.
– Check ATF level and top up as required ⇒ page 146 .
8.3.2 Removing and installing ATF lines - ve‐

hicles with 4-cylinder TDI engine and
with all 6-cylinder engines

Removing
Note

♦ The ATF lines can only be removed and installed with the
gearbox removed from the vehicle.
• Gearbox removed ⇒ page 64 .

connection.
8. ATF circuit 167

– Unscrew union nuts -arrows-.

Note
The installation position is shown on a vehicle with a 6-cyl. engine

as an example.
Installing
Tightening torques:
filter”, page 153
Note
Renew O-rings
Caution

be removed.
– After installing gearbox, check and correct ATF level
⇒ page 146 .
8.3.3 Removing and installing ATF lines - vehicles with 8-cyl. engine


equipment required
A-
V.A.G 1383 A-
-V.A.G 1782-
6122-
♦ Engine support bracket,
supplementary set -
T40093-
Removing
Note

8. ATF circuit 169

shield -1-.

sides).
– Remove lock carrier cover ⇒ General body repairs, exterior;

Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
– Remove bolts -arrows- and detach air duct -1- from air cleaner
housing (left and right).

– Remove nut -arrow- and move ATF hose clear.
connection.
– Remove bolt -2- and detach ATF line.
Note
♦ For illustration purposes, the installation position is shown with

the engine removed.
– Remove bolts -2- and -arrows- and detach retaining bracket

with spring.
Note
♦ The bolt indicated by the top -arrow- also secures the ATF
supply line to the gearbox.
8. ATF circuit 171


connection.
– Pull off clip -1-, disconnect and detach ATF line.
– Remove bolts -2 and 4- and detach ATF line -3- from gearbox.
Note
Place a cloth below to catch escaping ATF.
– Pull off retaining clip -arrow-, disconnect and detach ATF pipe/
hose assembly.
Note
Vehicles with exchangeable ATF filter -A-:

connection.
– Pull off clip -1-, disconnect and detach ATF pipe/hose assem‐
bly (supply) -5-.
– Remove bolt -4- and detach ATF supply line -2- from gearbox.
– Detach ATF return line -3- from gearbox.

battery .

– Set up support bracket - 10 - 222 A- with adapters -T40093/6-

on suspension turrets (left and right), as shown in illustration.
– Hook spindles -10 - 222 A /11- onto engine lifting eyes.
– Remove nut -arrow- on longitudinal member (right-side) and

move earth wires clear.
– Unplug electrical connector -1- at headlight range control

sender 1 - G233- and move wiring clear -arrow-.
8. ATF circuit 173

– Remove bolt -1- for anti-roll bar on both sides.
Note

– Remove nut -1- for hydraulic line for power steering.
Note
-Arrows- can be disregarded.
– Unplug electrical connector -1- for servotronic solenoid valve

- N119- and move wiring clear.
Note
– Move hydraulic power steering hose clear on subframe (left-

side).

umn .
– Move electrical wiring clear on subframe (right-side).

– Unplug electrical connector -1- from left electrohydraulic en‐

gine mounting solenoid valve - N144- .
– Remove bolt -2- for engine mounting (left-side).
– Unplug electrical connector -2- from right electrohydraulic en‐

gine mounting solenoid valve - N145- .
– Remove bolt -1- for engine mounting (right-side).
connection.
– Pull off retaining clip -1- and disconnect ATF line.
– Remove nut -2-.
– Support subframe with engine and gearbox jack - V.A.G 1383

A- as shown in illustration.
8. ATF circuit 175

– Mark installation position of subframe on longitudinal mem‐

bers with felt-tip pen.
– Unscrew subframe bolts -1, 2 and 3- on both sides in stages
and in diagonal sequence.
Caution

properly installed.
– Using engine and gearbox jack - V.A.G 1383 A- , lower sub‐

frame only far enough to remove bottom ATF line; ensure
sufficient clearance for hydraulic hoses (left-side) and electri‐
cal wiring (right-side).
Installing
Tightening torques:
filter”, page 153 .
Note
Renew O-rings
Caution

be removed.
– Press retaining clips onto ATF line connections and then pull
to check that clips have engaged properly.
– Align subframe on longitudinal members according to mark‐
ings made before removal.
– Tighten bolts for subframe to torque setting only, do not yet
turn further (wait until wheel alignment has been carried out)
⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe .

WARNING
Risk of accident if bolted connections are not tightened.

♦ The vehicle must not be driven if the subframe mountings
have not been fully tightened to the final setting.
– Install anti-roll bar ⇒ Running gear, axles, steering; Rep. gr.

40 ; Subframe; Removing and installing anti-roll bar .
– Install electrical wiring ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
necting battery .
– Secure intermediate steering shaft to steering rack ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering column; Exploded
view - steering column .
– Install hydraulic line for power steering ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Hydraulic power steering; Exploded
view - hydraulic lines, reservoir .
– Install wheel housing liners ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liner; Exploded view - wheel
housing liner (front) .
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Tightening torque for wheel bolts .
– Check wheel alignment ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheel alignment .
WARNING
Risk of accident if bolted connections are not tightened.

♦ After completing wheel alignment, tighten bolts securing
subframe to final setting.

8. ATF circuit 177

8.4 Removing and installing ATF filter

⇒ “8.4.1 Removing and installing in-line ATF filter”, page 178
⇒ “8.4.2 Removing and installing exchangeable ATF filter”, page
180
8.4.1 Removing and installing in-line ATF filter
Note

engine version and date of manufacture.
♦ In-line ATF filter -arrow-
♦ Exchangeable ATF filter -A-; removing and installing
⇒ page 180


Removing in-line ATF filter
Note

♦ Before fitting a replacement gearbox, always renew the in-line
ATF filter and blow through the ATF lines and ATF cooler with
compressed air (not more than 10 bar). Flush with ATF if the
system is very dirty.

– If fitted, remove bolts (left-side) -arrows- and detach heat

shield -1-.
connections.
– Unscrew bolt -arrow-, detach ATF lines -1- and -2- from gear‐
box and place to one side.
8. ATF circuit 179

line ATF filter.
– Remove bolts -2- and detach in-line ATF filter.
Note
Installing
⇒ “8.1.1 Exploded view - ATF cooler, ATF lines and in-line ATF
filter”, page 153
Note
Renew O-rings
Caution

be removed.
– First insert ATF lines into gearbox by hand as far as stop, then
secure with bolts.
– Press retaining clip onto connection between ATF line and in-
line ATF filter and then pull to check that retaining clip has
engaged properly.
8.4.2 Removing and installing exchangeable

ATF filter

Note

engine version and date of manufacture.
♦ From model year 2011 onwards, all vehicles are fitted with an
exchangeable ATF filter.
♦ Only gearboxes with exchangeable ATF filter are available as
replacement parts; vehicles older than model year 2011 may
therefore also be fitted with an exchangeable ATF filter.
♦ The exchangeable ATF filter -A- must also be renewed every
time the ATF is changed.
♦ The in-line ATF filter -arrow- only has to be renewed when the
gearbox is renewed. Removing and installing ⇒ page 178 .

Removing exchangeable ATF filter
Note

♦ The exchangeable ATF filter must be renewed every time the
ATF is changed.
♦ Before fitting a replacement gearbox, always blow through the
ATF lines and ATF cooler with compressed air (not more than
10 bar). Flush with ATF if the system is very dirty.

8. ATF circuit 181


– If fitted, remove bolts (left-side) -arrows- and detach heat
shield -1-.

– If fitted, unfasten retaining strap -3- and remove locating ele‐
ment -1-.
connections.
– Unscrew cap -1- for exchangeable ATF filter and allow ATF to
drain off.

– Place cap -1- for exchangeable ATF filter on front of cross

brace.
– Pull out exchangeable ATF filter -2- in direction of -arrow-.
– Take out exchangeable ATF filter -1- from below.

– Take out cap -3- for exchangeable ATF filter from below.
8. ATF circuit 183

Installing
• Two different ATF filter housing versions are in use.
• If the locating element -arrow- (fitted at the factory) is not in‐
stalled, an ATF filter cap with a retrofittable locating element
must be installed.
Note
The retrofittable locating element and the corresponding ATF filter

cap are available in the ⇒ Electronic parts catalogue (from ap‐
prox. July 2014 onwards).
Caution
Risk of leaks at ATF filter!

♦ It is important that only the correct version of the ATF filter
cap is used for the corresponding ATF filter housing.
ATF filter cap versions for ATF filter housings:
Note
Note part number for ATF filter housing!
ATF filter hous‐ Corresponding ATF filter cap:

ing:
0B5.325.060.B 0B5.325.240.C
0B5.325.060.C 0B5.325.240.B
Note
♦ Seal on cap for exchangeable ATF filter must be renewed.

♦ Exchangeable ATF filter must be renewed.
Caution

The new exchangeable ATF filter -1- must not come into con‐
tact with water. Even small amounts of water, such as drips
from the engine compartment or wet hands will cause the sur‐
face of the exchangeable ATF filter to swell. Small particles of
paper can then separate from the surface of the filter and con‐
taminate the mechatronic unit.

– Place cap -3- for exchangeable ATF filter with new seal on
front of cross brace.
– Lubricate seal -2- on new exchangeable ATF filter -1- before
fitting.
– Lubricate seal -2- on cap -1- for exchangeable ATF filter.

– Tighten cap -1- for exchangeable ATF filter to specified torque.
⇒ “8.1.2 Exploded view - ATF cooler, ATF lines and exchange‐
– Secure locating element -1- on ATF filter cap -2- with retaining
strap -3-.
Note
The lug on the locating element -arrow- should rest against the
filter housing, as shown.
Caution
Risk of leaks on filter housing!

♦ Filter housings without a locating element must always be
fitted with a filter cap with a retrofittable locating element
-1-.
– Clean gearbox, cross brace and hydraulic lines leading to

steering rack.
8. ATF circuit 185

8.5 Removing and installing ATF filter hous‐

ing and connecting piece for ATF lines
♦ Used oil collection and extraction unit - VAS 6622A-
Engine bung set - VAS 6122-
Removing
Note
Rules for cleanliness when working on the dual clutch gearbox

⇒ page 4 .

noise insulation .
– Place used oil collection and extraction unit - VAS 6622A- be‐
low connections.

– Remove bolt -arrow- and detach ATF lines -1- and -2-.
Note
On vehicles in which the lines are routed above the gearbox, the
top securing bolt -top arrow- of the gearbox oil lines must be loos‐
ened 3 or 4 turns in order to detach the lines from the filter
housing.
– Remove bolts -arrows- and detach filter housing.
The ATF pipes -2- must not be left fitted in the mechatronic unit,
otherwise they would obstruct its removal.
8. ATF circuit 187

Installing
Caution
Risk of leaks!
♦ Always renew seals on oil lines and filter housing and coat
new seals with ATF.
♦ Ensure that sealing surfaces are clean.
– Pull ATF fluid pipes -2- out of filter housing -1- and press in as
far as stop with new seals -3-.
– Renew seal -4-.
Tightening torques:
• ⇒ “8 ATF circuit”, page 153 .
– First press ATF pipes/hoses onto filter housing and cooler by
hand until they engage, then bolt on.
– Fill up with ATF ⇒ “7.3 Draining and filling ATF”, page 149 .

35 – Gears, shafts
1 Input shaft
⇒ “1.1 Renewing ball bearing for input shaft”, page 189
⇒ “1.2 Renewing input shaft oil seal”, page 189
1.1 Renewing ball bearing for input shaft

• Gearbox removed
Note


Rep. gr. 35 ; Input shaft
1.2 Renewing input shaft oil seal

• Gearbox removed
dual clutch gearbox; Rep. gr. 35 ; Input shaft; Renewing input
shaft oil seal .
1. Input shaft 189

39 – Final drive - front differential

1 Final drive
⇒ “1.1 Exploded view - final drive”, page 190
1.1 Exploded view - final drive
Note
Repair work and tightening torques are described in Workshop

1 - Flywheel
Clutch; Removing and
installing flywheel
2 - Oil seal
❑ For flange shaft (left-
side)
❑ Between final drive and
gearbox housing
❑ Renewing ⇒ Servicing
Rep. gr. 39 ; Oil seals;
Renewing oil seal (left-
side)
3 - Shim
❑ Behind tapered roller
bearing outer race
4 - Tapered roller bearing outer
race
5 - Differential
6 - Bolt
❑ 10x
Rep. gr. 39 ; Final drive;
Exploded view - final
drive
7 - Circlip
❑ Renew
8 - Flange shaft (right-side)
❑ ⇒ “4.2 Removing and installing flange shaft (right-side)”, page 206
9 - Oil seal
❑ For flange shaft (right-side)
❑ Renewing ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Oil seals; Renewing oil seal (right-side)
10 - Cover for front final drive
❑ Removing and installing ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Oil seals; Renewing oil seal (left-
side)
190 Rep. gr.39 - Final drive - front differential

11 - O-ring
❑ On cover for front final drive
❑ Renew
12 - Shim
❑ Behind tapered roller bearing outer race
13 - Tapered roller bearing outer race
14 - Roll pin
15 - Gearbox selector lever
16 - Oil seal
❑ For selector shaft
❑ ⇒ “2.13 Renewing selector shaft oil seal”, page 61
17 - Bolt
❑ 3x
❑ Tightening torque ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Final drive; Exploded view - final drive
18 - Flange shaft (left-side)
❑ Removing and installing ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Differential; Removing and
installing flange shaft (left-side)
19 - Bearing plate
❑ Secured to flange shaft (left-side) together with bearing -item 20- by circlip -21-.
20 - Bearing
❑ For flange shaft (left-side)
❑ Pressed onto flange shaft (left-side)
21 - Circlip
❑ For bearing for flange shaft (left-side)
❑ Renew
22 - Oil seal
❑ For input shaft
❑ Renewing ⇒ Servicing dual clutch gearbox; Rep. gr. 35 ; Input shaft; Renewing oil seal for input shaft
1. Final drive 191

2 Gear oil
⇒ “2.1 Exploded view - gear oil drain and inspection plugs”, page
192
⇒ “2.2 Checking gear oil level”, page 193
⇒ “2.3 Draining and filling gear oil”, page 197
⇒ “2.4 Removing and installing gearbox oil temperature sender 2
G754 ”, page 204
2.1 Exploded view - gear oil drain and in‐

spection plugs
The gear clusters, front final drive and transfer box in the dual
clutch gearbox 0B5 have a common oil system. The same plug
is used for filling and inspection.
Note
All tightening torques are also described in Workshop Manual

“Servicing 7-speed dual clutch gearbox 0B5 (S tronic)”.
1 - ATF drain plug

Nm
2 - Seal
❑ For ATF drain plug
❑ Renew
3 - Filler and inspection plug for
gear oil (MTF)
box
Nm
4 - ATF filler and inspection
plug
Nm
5 - Drain plug for gear oil (MTF)
box
Nm
❑ On some versions the
gearbox oil temperature
sender 2 - G754- also
serves as a drain plug
for the gear oil (MTF);
tightening torque, re‐
moving and installing
⇒ page 200

2.2 Checking gear oil level

equipment required
-V.A.G 1782-
V.A.G 1383 A-
♦ Hand pump for gear oil -
VAS 6617-
♦ Safety goggles
2. Gear oil 193

Procedure
Note

♦ Always use the correct fluid for the different parts of the gear‐
box: gear oil (MTF) system and ATF system.
• Gear oil about 20 °C (room temperature).

• The hand pump for gear oil - VAS 6617- must be clean; flush
out with gear oil (MTF) if necessary. The oil must not be mixed
with other lubricants.
• The vehicle must be stationary with the engine switched off for
at least 15 minutes to allow the oil level to stabilise.
noise insulation .
Vehicles with in-line ATF filter -arrow- at rear left of gearbox:
– If fitted, remove bolts -arrows- and detach air deflector -A-.


Note

Only then can the gear oil level be topped up correctly.
– Remove bolts -2- and press in-line ATF filter to side.
Note
♦ Items marked -1- and -arrow- can be disregarded.

♦ The in-line ATF filter must be pressed to the side for access
to the filler and inspection plug for gear oil (MTF).
Vehicles not equipped with in-line ATF filter at rear left of gearbox:
Note
♦ On vehicles not equipped with an in-line ATF filter at the rear

left of the gearbox the tunnel cross member does not have to
be removed.
♦ A cloth should be placed on the tunnel cross member to pre‐
vent gear oil (MTF) from running into the casting pockets on
the tunnel cross member.
– Place suitable cloth on tunnel cross member.
2. Gear oil 195


gearbox.
WARNING
Risk of eye injury.

– Unscrew filler and inspection plug -arrow- at side of gearbox

housing.
• Gear oil level (MTF) must be up to bottom lip of filler and in‐
spection hole.
If gear oil level (MTF) is not up to bottom lip of filler and inspection
hole:
– Using hand pump for gear oil - VAS 6617- , fill up slowly with
gear oil (MTF) until oil comes out at filler and inspection hole.
• Gear oil (MTF) specifications ⇒ Electronic parts catalogue
– Repeat the procedure in several steps by adding gear oil
(MTF) every 15 seconds until the gearbox will not take any
more oil.
Note
Make sure to wait the required amount of time so that the various
oil chambers in the gearbox are filled evenly.
– Tighten plug.
⇒ “2.1 Exploded view - gear oil drain and inspection plugs”,
page 192


– Screw in bolts -2-.
Tightening torques:
Note

left of the gearbox the tunnel cross member must be cleaned.
♦ Any gear oil (MTF) which has run into the casting pockets on
the tunnel cross member must be removed completely.
– Remove cloth on tunnel cross member.

– Clean tunnel cross member and remove any remaining gear
oil.
2.3 Draining and filling gear oil
2. Gear oil 197


equipment required
-V.A.G 1782-
V.A.G 1383 A-
♦ Hand pump for gear oil -
VAS 6617-
♦ Safety goggles

Draining off gear oil
Note


noise insulation .
gearbox.
WARNING
Risk of eye injury.

Note

♦ In the following description, vehicles with drain plug for gear
oil (MTF) are differentiated from vehicles that are fitted with
gearbox oil temperature sender 2 - G754- instead of drain plug
for gear oil (MTF).
Vehicles with drain plug for gear oil (MTF) -arrow-:
Note
The drain plug for gear oil (MTF) is located behind the tunnel cross
member.
– Unscrew drain plug for gear oil (MTF) -arrow- under gearbox
housing.
– Drain gear oil (MTF).
– Tighten drain plug for gear oil (MTF) -arrow-.
146
2. Gear oil 199

Vehicles with gearbox oil temperature sender 2 - G754- -1- fitted

in place of drain plug for gear oil (MTF):
Note
Always switch off ignition before unplugging connector at gearbox

oil temperature sender 2 - G754- . If the ignition is on, the gearbox
reverts to a backup programme. This increments the counter for
high temperature operation, and after 10 minutes an entry is re‐
corded in the event memory of the automatic gearbox control unit
- J217- .
– Unplug connector -2- from gearbox oil temperature sender 2

- G754- , move clear to the top and tie up.
Note
Keep gear oil away from connector -2- and contacts on gearbox
oil temperature sender 2 - G754- . The connector contacts must
be cleaned immediately if they come into contact with gear oil
(MTF). The gear oil (MTF) causes contact problems in the con‐
nector contacts.
– Unscrew gearbox oil temperature sender 2 - G754- -1-.

– Drain gear oil (MTF).
– Tighten gearbox oil temperature sender 2 - G754- -1- and plug
in connector -2-.
• Tightening torque: gearbox oil temperature sender 2 - G754-
to gearbox, 45 Nm
Caution

If there is no gear oil (MTF) in the gearbox (or not enough oil):
♦ The engine must not be started.
♦ The vehicle must not be towed.
Filling up gear oil (MTF)

• The hand pump for gear oil - VAS 6617- must be clean; flush
out with gear oil (MTF) if necessary. The oil must not be mixed
with other lubricants.
• The vehicle must be stationary with the engine switched off for
at least 15 minutes to allow the oil level to stabilise.


Note

Only then can the gear oil level be topped up correctly.
2. Gear oil 201

– Remove bolts -2- and press in-line ATF filter to side.
Note
♦ Items marked -1- and -arrow- can be disregarded.

♦ The in-line ATF filter must be pressed to the side for access
to the filler and inspection plug for gear oil (MTF).
Note

left of the gearbox the tunnel cross member does not have to
be removed.


gearbox.
WARNING
Risk of eye injury.

– Unscrew filler and inspection plug -arrow- at side of gearbox

housing.
– Using hand pump for gear oil - VAS 6617- , fill up with gear oil
(MTF) until oil comes out at filler and inspection hole.
• Gear oil (MTF) specifications ⇒ Electronic parts catalogue
– Repeat the procedure, adding 50 ml of gear oil (MTF) every
15 seconds until the gearbox will not take any more oil.
Note
Make sure to wait the required amount of time so that the various
oil chambers in the gearbox are filled evenly.
• Gear oil level (MTF) must be up to bottom lip of filler and in‐
spection hole.
– Tighten plug.
⇒ “2.1 Exploded view - gear oil drain and inspection plugs”,
page 192
Note
The level does not need to be re-checked after this step.

2. Gear oil 203


– Screw in bolts -2-.
Tightening torques:
Note

left of the gearbox the tunnel cross member must be cleaned.
♦ Any gear oil (MTF) which has run into the casting pockets on
the tunnel cross member must be removed completely.
– Remove cloth on tunnel cross member.

– Clean tunnel cross member and remove any remaining gear
oil.
Applies only to vehicles with gearbox oil temperature sender 2 -

G754- -1-:
– After changing gear oil, perform “Guided Function” 02 - Re-
set temperature counter (G754) using vehicle diagnostic
tester ⇒ page 231 .
2.4 Removing and installing gearbox oil

temperature sender 2 - G754-
icing dual clutch gearbox; Rep. gr. 39 ; Gear oil .

3 Oil seals
⇒ “3.1 Renewing oil seal (left-side)”, page 205
⇒ “3.2 Renewing oil seal (right-side)”, page 205
3.1 Renewing oil seal (left-side)

• Gearbox removed
dual clutch gearbox; Rep. gr. 39 ; Oil seals; Renewing oil seal
(left-side) .
3.2 Renewing oil seal (right-side)

• Gearbox installed or removed
dual clutch gearbox; Rep. gr. 39 ; Oil seals; Renewing oil seal
(right-side) .
3. Oil seals 205

4 Differential
⇒ “4.1 Removing and installing flange shaft (left-side)”,
page 206
⇒ “4.2 Removing and installing flange shaft (right-side)”,
page 206
4.1 Removing and installing flange shaft

(left-side)
• Gearbox removed
dual clutch gearbox; Rep. gr. 39 ; Differential; Removing and in‐
stalling flange shaft (left-side) .
4.2 Removing and installing flange shaft

(right-side)
♦ Drift - VW 295-
♦ Multi-purpose tool - VW 771-
♦ Eye-head bolt - 3368-

♦ Sealing grease ⇒ Electronic parts catalogue

♦ Nut M10 (2x)
Removing
– Remove front right wheel.
– Remove cover -1- for drive shaft (right-side) from wheel hous‐
ing.

noise insulation .
4. Differential 207
– Remove bolts -arrows- and detach heat shield -1- (right-side).

(right-side).
– Unbolt drive shaft (right-side) from flange shaft on gearbox and
move drive shaft to rear.
gearbox.
– Screw eye-head bolt - 3368- into threaded hole in flange shaft
(right-side).
– Attach multi-purpose tool - VW 771- with -VW 771/13- to eye-
head bolt - 3368- and knock out flange shaft.
Installing
Note
Renew circlip for flange shaft (right-side).
– Clamp flange shaft in vice, using jaw protectors. Use new cir‐
clip -A- to press old circlip out of groove in flange shaft.
– Pack space between sealing lip and dust lip half full with seal‐
ing grease; for sealing grease refer to ⇒ Electronic parts
catalogue .
– Drive in flange shaft (right-side) with drift - VW 295- .
– Check gear oil level in final drive and top up as required
⇒ page 193 .

5 Centre differential
⇒ “5.1 Exploded view - centre differential housing”, page 209
⇒ “5.2 Removing and installing centre differential housing”, page
213
⇒ “5.3 Removing and installing rear flange shaft, oil seal and ball
bearing for rear flange shaft”, page 225
⇒ “5.4 Removing and installing rear splined shaft, oil seal and ball
bearing”, page 225
⇒ “5.5 Renewing oil seal for rear splined shaft”, page 225
⇒ “5.6 Pressing vibration damper onto rear splined shaft”,
page 226
⇒ “5.7 Removing and installing centre differential housing”, page
226
5.1 Exploded view - centre differential hous‐

ing
⇒ “5.1.1 Exploded view - centre differential housing - bolted prop‐
shaft”, page 209
⇒ “5.1.2 Exploded view - centre differential housing - propshaft
with splines on gearbox end”, page 211
5.1.1 Exploded view - centre differential hous‐

ing - bolted propshaft
The centre differential housing can also be removed and installed
with the gearbox installed in the vehicle ⇒ page 213 .
Note

♦ Repair work and tightening torques are described in Workshop
Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tron‐
ic)”.
5. Centre differential 209

1 - Bolt
❑ Aluminium bolts
❑ 11x
Rep. gr. 39 ; Centre dif‐
ferential; Exploded view
- centre differential
2 - Housing
❑ For centre differential
installing centre differ‐
ential housing - bolted
propshaft”, page 213
3 - Ball bearing
❑ For flange shaft (rear)
Centre differential; Ex‐
ploded view - centre dif‐
ferential
4 - Spacer sleeve
❑ Pressing out and in ⇒
Servicing dual clutch
ferential
5 - Bearing plate
❑ Installation position:
shoulder must engage
in recess in gearbox
housing
6 - Spacer sleeve
7 - Shim
8 - Ball bearing
9 - Centre differential
10 - Ball bearing
11 - Spring
12 - Shim
13 - Dished spring
❑ Installation position: convex side (which curves outwards) faces oil seal -item 17-
14 - Circlip
❑ For flange shaft (rear)
❑ Removing and installing ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differential; Exploded
view - centre differential
15 - Bolt
❑ Steel bolts
❑ 2x

❑ Tightening torque and sequence ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differential;
Exploded view - centre differential
16 - Damper weight
❑ Depending on version
17 - Oil seal
❑ Renewing ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differential; Exploded view - centre
differential
18 - Flange shaft (rear)
❑ Without vibration damper
19 - Flange shaft (rear)
❑ With vibration damper
20 - Bolt
❑ Tightening torque ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differential; Exploded view -
centre differential
5.1.2 Exploded view - centre differential hous‐

ing - propshaft with splines on gearbox
end
The centre differential housing can also be removed and installed
with the gearbox installed in the vehicle ⇒ page 213 .
Note

♦ Repair work and tightening torques are described in Workshop
Manual “Servicing 7-speed dual clutch gearbox 0B5 (S tron‐
ic)”.

1 - Bolt
❑ Tightening torque ⇒
Servicing dual clutch
ferential
2 - Bolt
❑ Aluminium bolts
❑ 11x
Rep. gr. 39 ; Centre dif‐
ferential; Exploded view
- centre differential
3 - Housing
installing centre differ‐
ential - vehicles with
propshaft with splines
on gearbox end”,
page 220
4 - Bearing plate
❑ Installation position:
shoulder must engage
in recess in gearbox
housing
5 - Centre differential
6 - Spring
7 - Assembly sleeve
❑ Does not have to be re-
installed
8 - Circlip
❑ For ball bearing for rear splined shaft
9 - Circlip
❑ For rear splined shaft
10 - Ball bearing
❑ For rear splined shaft
11 - Bolt
❑ Steel bolts
❑ 2x
❑ Tightening torque and sequence ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differential;
Exploded view - centre differential
12 - Damper weight
❑ Depending on version

13 - Oil seal
❑ Renewing ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differential; Exploded view - centre
differential
14 - Dust ring
❑ Renew if removed
15 - Rear splined shaft without vibration damper
16 - Rear splined shaft with vibration damper
❑ Pressing on vibration damper ⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differential; Exploded
5.2 Removing and installing centre differen‐

tial housing
⇒ “5.2.1 Removing and installing centre differential housing - bol‐
ted propshaft”, page 213
⇒ “5.2.2 Removing and installing centre differential - vehicles with
propshaft with splines on gearbox end”, page 220
5.2.1 Removing and installing centre differen‐

tial housing - bolted propshaft
♦ Gearbox support - 3282-

♦ Counterhold tool - T10172- with -T10172/5-
♦ For sealant, refer to ⇒ Electronic parts catalogue

Removing
– Remove noise insulation (rear) -2- ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
Caution
Risk of damage to flexible joint in front exhaust pipe.

♦ The flexible joint in the front exhaust pipe must not be bent
further than 10°.
– Unscrew bolts -arrows-, push clamp towards rear and tie up

front exhaust pipe to body.

Vehicles with twin exhaust system:
Caution
Risk of damage to flexible joint in front silencer.

♦ The flexible joint in the front silencer must not be bent fur‐
ther than 10°.
– Unbolt clamps -1- and -2-, push clamps towards rear and tie
up front silencers to body.

propshaft.

T10172/5- ).
– Tie propshaft up to underbody.

Caution
There is a risk of damage to the gearbox oil pan.

♦ Do not place gearbox down on the gearbox oil pan.
– Attach two flat support mountings -1- and -2- to gearbox sup‐
port - 3282- .
– Set up gearbox support - 3282- on engine and gearbox jack -
V.A.G 1383 A- .
– Support gearbox at bolted surface of gearbox oil pan as shown
in illustration, using rubber packing -3- on each side.
– Slightly lift gearbox with engine and gearbox jack - V.A.G 1383
A- .
WARNING
Risk of accident.
left unattended.


A- until gearbox oil pan is just above cross brace -A- but does
not make contact.
gearbox.
– Remove bolts -1 … 4- and carefully detach centre differential
housing; gear oil (MTF) will drain off.
Caution
Risk of damage to the centre differential.

♦ Pull the centre differential housing slowly and carefully to‐
wards the rear off the gearbox. The centre differential may
otherwise fall out of the gearbox.
♦ A centre differential which has fallen to the ground can no
longer be installed.

If bearing plate -1- remains behind in centre differential housing,

proceed as follows:
Caution
Risk of damage to the sealing surface of the centre differential

housing.
♦ Carefully tap the housing in several places with a hammer.
– Grip one of the side ribs on bearing plate -1- with pliers and
pull off in direction of -arrow A-.
– While doing so, carefully tap alternate sides of housing
-arrows B- with a rubber-headed hammer.
Installing
Tightening torques:
• See Workshop Manual “Servicing 7-speed dual clutch gear‐
box 0B5 (S tronic)” ⇒ Servicing dual clutch gearbox; Rep. gr.
39 ; Centre differential; Exploded view - centre differential
Note
Renew the bolts for the centre differential housing.
– Thoroughly clean both housing joint surfaces; they must be

free from oil and grease.
– Apply bead of sealant -arrow 1- evenly and not too thick on

housing joint surface; for sealant refer to ⇒ Electronic parts
catalogue .
– To avoid contact corrosion, apply a ring of sealant around each
bolt hole -arrow 2-.
– Lightly lubricate fitting surfaces for bearing plate with gear oil
(MTF).

– Check that spacer sleeve -2- and shim -1- are fitted on output
shaft.
– Lightly lubricate surfaces of both races on outside of bearing

plate with a small quantity of gear oil (MTF).
– Insert bearing plate.
• Installation position: shoulder of bearing plate -arrow A- must
engage in recess on gearbox housing -arrow B-.
– Fit centre differential -2- onto gearbox -1-.

– Insert spring -3- in centre differential.
– Apply a small quantity of grease to dished spring -5- and shim
(s) -4- and secure in place in centre differential housing -6-.
• Installation position of dished spring: convex side (which
curves outwards) faces rear flange shaft.
– Press centre differential housing fully onto gearbox housing,

keeping it centred, and hold in place.
– Tighten bolts for centre differential housing; see Workshop
⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differ‐
ential; Exploded view - centre differential .

– Install tunnel cross member and tighten ⇒ page 139 .
Note

– Secure propshaft to gearbox; refer to Workshop Manual “Rear

final drive 0BC” ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Exploded view - propshaft , or “Rear final drive 0BF and 0BE
- sport differential” ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Exploded view - propshaft .
– ⇒ “2.3 Draining and filling gear oil”, page 197 .
ers .
5.2.2 Removing and installing centre differen‐

tial - vehicles with propshaft with splines
on gearbox end
♦ Gearbox support - 3282-

♦ For sealant, refer to ⇒ Electronic parts catalogue

Removing
noise insulation .
Note

– Remove propshaft (version with splines on gearbox end); refer

to Workshop Manual “Rear final drive 0BC” ⇒ Rear final drive;
Rep. gr. 39 ; Propshaft; Removing and installing propshaft ,
or “Rear final drive 0BF and 0BE - sport differential” ⇒ Rear
final drive; Rep. gr. 39 ; Propshaft; Removing and installing
propshaft .
Caution
There is a risk of damage to the gearbox oil pan.

♦ Do not place gearbox down on the gearbox oil pan.
– Attach two flat support mountings -1- and -2- to gearbox sup‐
port - 3282- .
– Set up gearbox support - 3282- on engine and gearbox jack -
V.A.G 1383 A- .
– Support gearbox at bolted surface of gearbox oil pan as shown
in illustration, using rubber packing -3- on each side.
– Slightly lift gearbox with engine and gearbox jack - V.A.G 1383
A- .
WARNING
Risk of accident.
left unattended.

– Remove bolts -arrows- and detach air deflector -A-.

A- until gearbox oil pan is just above cross brace -A- but does
not make contact.

gearbox.
– Remove bolts -1 … 4- and carefully detach centre differential
housing; gear oil (MTF) will drain off.
Caution
Risk of damage to the centre differential.

♦ Pull the centre differential housing slowly and carefully to‐
wards the rear off the gearbox. The centre differential may
otherwise fall out of the gearbox.
♦ A centre differential which has fallen to the ground can no
longer be installed.
If bearing plate -1- remains behind in centre differential housing,

proceed as follows:
Caution
Risk of damage to the sealing surface of the centre differential

housing.
♦ Carefully tap the housing in several places with a hammer.
– Grip one of the side ribs on bearing plate -1- with pliers and
pull off in direction of -arrow A-.
– While doing so, carefully tap alternate sides of housing
-arrows B- with a rubber-headed hammer.
Installing
Tightening torques:
• See Workshop Manual “Servicing 7-speed dual clutch gear‐
box 0B5 (S tronic)” ⇒ Servicing dual clutch gearbox; Rep. gr.
39 ; Centre differential; Exploded view - centre differential
Note
Renew the bolts for the centre differential housing.
– Thoroughly clean both housing joint surfaces; they must be

free from oil and grease.

– Apply bead of sealant -arrow 1- evenly and not too thick on

housing joint surface; for sealant refer to ⇒ Electronic parts
catalogue .
– To avoid contact corrosion, apply a ring of sealant around each
bolt hole -arrow 2-.
– Lightly lubricate fitting surfaces for bearing plate with gear oil
(MTF).
– Lightly lubricate surfaces of both races on outside of bearing

plate with a small quantity of gear oil (MTF).
– Insert bearing plate.
• Installation position: shoulder of bearing plate -arrow A- must
engage in recess on gearbox housing -arrow B-.
– Fit centre differential -2- onto gearbox -1-.

– Fit assembly sleeve -4- on centre differential.
– Insert spring -3- in centre differential.

– Press centre differential housing fully onto gearbox housing,

keeping it centred, and hold in place.
– Tighten bolts for centre differential housing; see Workshop
⇒ Servicing dual clutch gearbox; Rep. gr. 39 ; Centre differ‐
ential; Exploded view - centre differential .
– Install tunnel cross member and tighten ⇒ page 139 .
Note


– ⇒ “2.3 Draining and filling gear oil”, page 197 .
ers .
5.3 Removing and installing rear flange

shaft, oil seal and ball bearing for rear
flange shaft
dual clutch gearbox; Rep. gr. 39 ; Centre differential .
5.4 Removing and installing rear splined

shaft, oil seal and ball bearing
5.5 Renewing oil seal for rear splined shaft

icing dual clutch gearbox; Rep. gr. 39 ; Centre differential; Re‐
newing oil seal for rear splined shaft .

5.6 Pressing vibration damper onto rear

splined shaft
5.7 Removing and installing centre differen‐

tial housing
dual clutch; Rep. gr. 39 ; Centre differential; Removing and in‐
stalling centre differential .

6 Gearbox control system

⇒ “6.1 Overview of fitting locations - gearbox control system”,
page 227
⇒ “6.2 Guided Functions for gearbox”, page 231
6.1 Overview of fitting locations - gearbox

control system
Diagnostic connection
♦ Fitting location: The diagnostic connection for the vehicle di‐
agnostic tester is located in the driver's footwell.
♦ Before servicing the gearbox, the cause of the fault should be
identified as exactly as possible using the vehicle diagnostic
tester via Guided Fault Finding , Vehicle Self-diagno-
sis and Test Instruments .
Mechatronic unit for dual clutch gearbox - J743- , valves, sensors

and gearbox input speed sender
♦ Fitting location: the mechatronic unit for dual clutch gearbox -
J743- is bolted to the bottom of the gearbox housing and
covered by the ATF oil pan.
Note
♦ The mechatronic unit incorporates the hydraulic control sys‐

tem, the electronic control unit and the sensors and actuators
as a complete synchronised unit.
♦ All components mentioned are tested via self-diagnosis.
⇒ “1.4 Removing and installing mechatronic unit”, page 22 .
6. Gearbox control system 227

Gear actuator module and temperature sender on mechatronic

unit - overview
1- Printed circuit 1
2- Gear actuator module
3- Gear selector movement sensor 1 - G487- for gear actuator
2–R
1-3
7-5
4-6
7- Clutch temperature sender - G509-
8- Gearbox input speed sender 3 - G641- for clutch input speed
10 - Electrohydraulic control unit
Printed circuit 1 and printed circuit 2 can be removed and installed
separately; for description of work, refer to Workshop Manual
icing dual clutch gearbox; Rep. gr. 34 ; Mechatronic unit; Explo‐
ded view - mechatronic unit .
Connectors and sensor modules on mechatronic unit

Electrical connectors on mechatronic unit:
1- Gearbox control unit to printed circuit 1
2- Gearbox control unit to printed circuit 2
4- Connector, sensor module to wiring harness
5- Gear sensor - G676-
6- Printed circuit 3 in sensor module
7- Gearbox input speed sender 1 - G632-
8- Gearbox input speed sender 2 - G612-
9- Wiring harness with wiring duct
10 - Gearbox control unit to vehicle wiring harness
11 - Gearbox control unit to sensor module
12 - Gearbox control unit
Components -4 to 8- are designated as the sensor module .

Sensor module , with integrated senders and sensors -G612- , -

G632- , -G676- and printed circuit 3
Sensor module -2- is installed in intermediate gearbox housing.
The following components are integrated in the sensor module :
♦ Gear sensor - G676-
♦ Gearbox input speed sender 1 - G632-
♦ Gearbox input speed sender 2 - G612-
♦ Printed circuit 3
– For removing and installing sensor module , refer to Workshop
⇒ Servicing dual clutch gearbox; Rep. gr. 34 ; Dismantling
and assembling gearbox .
Selector lever position display - Y6-

♦ Fitting location: The selector lever position display - Y6- is in‐
tegrated in the instrument cluster.
Note
If the selector lever position display is defective, the instrument

cluster must be renewed ⇒ Electrical system; Rep. gr. 90 ; Dash
panel insert; Removing and installing dash panel insert - KX2- .
Selector lever sensors control unit - J587-

♦ Fitting location: the selector lever sensors control unit - J587-
-item 2- is clipped onto the shift unit -arrows-.
⇒ “2.7.2 Removing and installing selector lever sensors control
unit J587 ”, page 40 .
Selector lever lock solenoid - N110-

♦ Fitting location: the selector lever lock solenoid - N110-
-item 1- is clipped onto the selector mechanism.
N110 ”, page 38 .

Gear selector position P switch - F305-

♦ Fitting location: the gear selector position P switch - F305-
consists of two reed contacts (-1- and - 2-) and is installed on
printed circuit -B- in selector lever lock solenoid - N110-
-item A-.
Note
Gear selector position P switch - F305- can only be renewed to‐

gether with selector lever lock solenoid - N110- .

N110 ”, page 38 .
Different types and fitting locations according to version
Gearbox oil temperature sender 2 - G754-

In conjunction with certain engine versions the 7-speed dual
clutch gearbox 0B5 (S tronic) has an additional gearbox oil tem‐
perature sender 2 - G754- , which monitors the temperature of
the gear oil (MTF) employed for the gear cluster.
♦ Fitting location: The gearbox oil temperature sender 2 - G754-
is screwed into the gearbox in the area behind the oil pan.
♦ Different types and fitting locations possible according to ver‐
sion; see Workshop Manual “Servicing 7-speed dual clutch
gearbox 0B5 (S tronic)” ⇒ Servicing dual clutch gearbox; Rep.
gr. 39 ; Gear oil .
Selector lever position display - Y26-

♦ Fitting location: the display unit for selector lever position -
Y26- -item 1- is clipped into the centre console.
⇒ “2.9 Removing and installing selector lever position display Y26
”, page 51 .

Kickdown switch - F8-

A specific value for the accelerator position sender - G79- and
accelerator position sender 2 - G185- is stored in the engine con‐
trol unit.
♦ Fitting location: the accelerator position senders are integrated
in the accelerator pedal module -arrow-.
Note
The accelerator pedal module must be renewed if one of the ac‐

celerator position senders is defective ⇒ Fuel supply system;
Rep. gr. 20 ; Accelerator mechanism; Removing and installing
accelerator pedal module with accelerator position sender -G79- /
-G185- .
6.2 Guided Functions for gearbox

Procedure:
• Vehicle diagnostic tester is connected.
– Using diagnostic tester in Guided Functions mode, select
02 - Gearbox electronics, functions and then select
the appropriate “Guided Function”.
Requirements:
• It is important to follow all the instructions given by the diag‐
nostic tester exactly in order to complete the “Guided Func‐
tion” successfully.
The appropriate “Guided Function” must be performed on the di‐
agnostic tester after the following operations:
1- Renewing shift unit: 02 - Basic setting (Rep. Gr.
34) ⇒ page 232
2- Repair work on selector lever cable, including adjustment of

selector lever cable: 02 - Basic setting (Rep. Gr.
34) ⇒ page 232
3- Renewing mechatronic unit for dual clutch gearbox - J743-

with automatic gearbox control unit - J217- : 02 - Replace
control unit/mechatronics (Rep. Gr. 34)
⇒ page 232
4- Renewing dual clutch, renewing automatic gearbox control
unit -J217- , gearbox repairs, renewing gearbox compo‐
nents: 02 - Basic setting (Rep. Gr. 34)
⇒ page 233
5- Changing gear oil on vehicles with gearbox oil temperature
sender 2 - G754- (Audi RS 5/RS 4): 02 - Reset temper-
ature counter (G754) (Rep.-Gr. 34) ⇒ page 233

1. Renewing shift unit
Note
⇒ “2.6 Removing and installing selector mechanism”, page 32
The following steps are necessary after performing this work:

– In Guided Functions mode, select 02 - Gearbox elec-
tronics, functions and then select “Guided Function” 02
- Basic setting (Rep.-Gr. 34) .
– Select basic setting Calibration of gear sensor -

G676- and follow instructions on diagnostic tester .
2. Performing repair work on selector lever cable and adjusting

selector lever cable
Note
⇒ “2.11 Checking and adjusting selector lever cable”, page 57

– Select basic setting Calibration of gear sensor -

G676- and follow instructions on diagnostic tester .
3. Renewing mechatronic unit for dual clutch gearbox - J743- with

automatic gearbox control unit - J217-
Note
⇒ “1.4 Removing and installing mechatronic unit”, page 22

- Replace control unit/mechatronics (Rep.-Gr. 34)
and follow instructions on diagnostic tester .

4. Renewing dual clutch
Note
Removing and installing dual clutch; refer to Workshop Manual

icing dual clutch gearbox; Rep. gr. 30 ; Clutch; Removing dual
clutch , and ⇒ Servicing dual clutch gearbox; Rep. gr. 30 ; Clutch;
Installing dual clutch .

– Select basic setting Adaption of clutch kiss points and

follow instructions on diagnostic tester .
5. Gear oil change (Audi RS 5/RS 4)

♦ For vehicles with gearbox oil temperature sender 2 - G754-
-1-, the gear oil (MTF) must be changed after a specified
change interval (specified number of km) ⇒ ELSA mainte‐
nance tables .
♦ On these vehicles the gearbox oil temperature is monitored
additionally by the gearbox oil temperature sender 2 - G754- .
If a high gearbox oil temperature is registered over a certain
period of time, an internal counter in the automatic gearbox
control unit - J217- is incremented. If the normal temperature
parameters are exceeded a specified number of times, an en‐
try is made in the event memory of the gearbox control unit,
and the gear oil (MTF) must also be changed.
In both cases, a “Guided Function” must be performed to reset
the internal counter in the automatic gearbox control unit - J217-
after a gear oil change.
Note
Always switch off ignition before unplugging connector at gearbox

oil temperature sender 2 - G754- . If the ignition is on, the gearbox
reverts to a backup programme. This increments the counter for
high temperature operation, and after 10 minutes an entry is re‐
corded in the event memory of the automatic gearbox control unit
- J217- .
Procedure:
- Reset temperature counter (G754) (Rep.-Gr. 34) .

7-Speed Dual Clutch Gearbox 0B5 (S Tronic)

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7-speed dual clutch gearbox 0B5 (S tronic)

Service Department. Technical Information

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.1 Gearbox identification

2.1 Safety precautions when working on ve‐

Accidents and injury can be caused if a gear is inadvertently

Observe the following precautions to avoid possible injury and/or

When disconnecting the battery there is a risk of serious dam‐

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

2 Rep. gr.00 - Technical data

2.2 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

2.3 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

2.4 Notes on tow-starting and towing

Risk of irreparable damage to gearbox.

It is not possible to start the engine by tow-starting, for instance

3.1 Rules for cleanliness

3.2 General notes

4 Rep. gr.00 - Technical data

3.3 General repair instructions

Environmental and waste disposal regulations for oil

⇒ “2.2 Checking gear oil level”, page 193 . Capacities

6 Rep. gr.00 - Technical data

♦ Lubricate bearings with gear oil (MTF) or ATF, depending on

The gearbox control unit (mechatronic unit) can be damaged

3.4 Contact corrosion

3.5 Safety functions of gearbox control unit

4.1 Allocation of gearbox to engine

♦ Period of gearbox manufacture ⇒ Electronic parts catalogue

Dual clutch gearbox 0B5 four-wheel drive

Dual clutch gearbox 0B5 four-wheel drive

8 Rep. gr.00 - Technical data

Dual clutch gearbox 0B5 four-wheel drive

Dual clutch gearbox 0B5 four-wheel drive

Dual clutch gearbox 0B5 four-wheel drive

Dual clutch gearbox 0B5 four-wheel drive

Dual clutch gearbox 0B5 four-wheel drive

10 Rep. gr.00 - Technical data

Dual clutch gearbox 0B5 four-wheel drive

4.2.1 ATF capacity

Risk of damage to gearbox

♦ ⇒ “7.2 Checking ATF level”, page 146

Risk of damage to gearbox

– Renew ATF filter (exchangeable filter) ⇒ page 180 .

4.2.2 Gear oil (MTF) capacity

12 Rep. gr.00 - Technical data

Capacities Dual clutch gearbox 0B5: gear

1.1 Exploded view - flywheel and dual clutch

14 Rep. gr.30 - Clutch

1.2 Removing and installing flywheel

All repair work and tightening torques are described in Workshop

Description of work sequence ⇒ Servicing dual clutch gearbox;

1.3 Removing dual clutch

All repair work and tightening torques are described in Workshop

Description of work sequence ⇒ Servicing dual clutch gearbox;

1.4 Installing dual clutch

All repair work and tightening torques are described in Workshop